Prestressing Manual

THE FREYSSINET PRESTRESSED CONCRETE CO. LTD.
6B, 6th Floor, Sterling Center, Dr. Annie Besant Road,

Worli, Mumbai – 400018, Maharashtra – India.
: +91 22 43229500, 24921129, 24921141
Fax: +91 22 24938461
INTRODUCTION
PRINCPLES OF PRESTRESSING
Prestressing is a method of inducing known permanent stresses in a structure or
member before the full or live load is applied. These stresses are induced by
tensioning the High Tensile Strands, wires or rods, and then anchored to the
member being Prestressed, by mechanical means.
The Prestressing counteracts the stresses, produced by subsequent loading on the

structures, thereby extending the range of stresses to which a structural member
can safely be subjected. This also improves the behavior of the material of which
the member or structure is composed. For Example; The Concrete which has
relatively a low Tensile strength, shall behave like a member having high tensile
strength, after Prestressing.
The High Tensile wires/strands, when bunched together are called Cables. These
cables are generally placed inside a cylindrical duct made out of either metallic or
HDPE material. The Anchorages, one of the main components of the Prestressing
activity, are used to anchor the H.T. Cable after inducing the Load. The whole
assembly of the Anchorage and the H.T. Cable is named as ‘TENDON’.
APPLICATION AND USE OF PRESTRESSING

In structural Member, where the span length is very high with low rises and low
structural height, the application of Reinforced Cement Concrete shall be virtually
impractical. In such a case, Prestressing is used to achieve a light weight, elegant
looking and much economical structure with high durability. Prestressing, therefore,
is widely used for long span beams and Bridges.
In building structure also, prestressing method is very effectively used to achieve

lighter beams and slabs; thus reducing their dead load considerably as compared to
R.C.C. Structures. Application of Prestressing in building construction also facilitates
a larger span between the columns, thus reduces the number of columns. This also
makes the structure more versatile for interior planning.
Prestressing is also very widely used in the construction of Mega Structures like
Containment Wall of Nuclear Reactors, LNG Storage Tanks, Cement Silos,
Chimneys, Dams and Rock Anchors etc.
SECTION - A
THE FREYSSINET PRESTRESSED CONCRETE COMPANY LTD. Page: 1

TYPE OF PRESTRESSING SYSTEMS
Prestressing System can be classified by two basic methods, as under:-
a. Pre-Tensioning
b. Post-Tensioning.
Pre-Tensioning - is a method where Prestressing Steels are pre-stressed, prior to

concreting, against two rigid abutments. This method is most widely used for mass
production of short span structures, where pre-stressing is also a prerequisite, such
as; Railway Sleepers, Electric Polls, Fencing Polls, Pre-Tensioned Slabs and
I-Section Bridge Girders etc.
In this system, a number of identical structural frames are placed in between the
two rigid abutments or reaction bolster. Prestressing Steel is then placed
longitudinally across these frames and abutments, in the required orientation, and
stressed. After achieving required elongation and stresses they are blocked at two
abutments and then concrete is poured in the frames with stressed steels in
position.
Post-Tensioning - is a method where Prestressing Steels are stressed after

concrete attains its preliminary strength. Two extreme ends of the structure are
considered as a reaction face, against which force is applied. Ducts are placed
inside the formwork alongwith reinforcement and the concreting is completed. After
achieving required concrete strength, a stipulated numbers of Prestressing Steel is
then inserted in each duct for stressing purpose. After achieving required elongation
and stresses they are blocked at two ends with the help of Anchor Plates and grip.
The broad classifications are given as under
PRESTRESSING SYSTEMS
PRE-TENSIONING POST-TENSIONING
WIRES STRAND BONDED UNBONDED

TENDONS TENDONS
MONO MULTI
STRESSING STRESSING
BARS
WIRES, BARS WIRES STRANDS

& &
STRANDS STRANDS
SECTION - A
THE FREYSSINET PRESTRESSED CONCRETE COMPANY LTD.
The FPCC Post-Tensioning systems have been successfully used throughout the
country since 1954. They are time tested and have earned a reputation for their
quality and reliability.
The FPCC Post-Tensioning system has been used in every sector of prestressed
concrete constructions. While primarily used for Rail or Road Bridges, now extended
it’s application in various other structures such as; Nuclear Reactors, Cement Silos,
Dams and buildings etc. FPCC Post-Tensioning is also used for Rock and Soil
Anchors and for lifting and shifting of heavy loads.
USERS OF THE MANUAL

This manual presents detailed technical information about various FPCC Systems,
and is intended as a working guide for Consulting Engineers, Government
Authorities, Clients and the Inspection Agencies, who are responsible for execution
and supervision at site.
We hope to give information to all those who have as yet little or no experience in
Prestressed concrete and who wish to acquire a wider knowledge of its details and
site usage.
FPCC SYSTEM OF PRESTRESSING

FPCC has developed a range of Anchorages, to cater to a wide range of Prestressing
tendons. The fundamental concept of Mono-Strand and Multi-Strand system
remains the same; regardless of Prestressing elements are used. i.e. - Wire/Strand,
Steel/Concrete Anchorages, No. of Wires/Strands in a tendon or method of
stressing.
The Prestressing cables, when fitted with their Anchorages, are called ‘TENDONS’.
They are made up of Wires / Strands grouped generally in a cylindrical duct made
out of metal strips or HDPE.
FPCC Anchorages, an important component of Tendon, cater to a wide range of

Prestressing forces starting from an U.T.S. of 18.75 MT to 700MT. Anchorages for
larger capacity tendons and for special purposes are also available on request.
The Tension members of the FPCC post-tensioning systems are made up of high
strength steel strands, either in the form of mono-strand or as multi-strand
tendons. The term “INTERNAL” and “EXTERNAL” tendons are used, according to the
position of the cables with respect to cross section of the structures.
SECTION - A
This Manual provides the details of the FPCC post-tensioning systems and contains
the most important information for design and construction. Details about the Pre-
tensioning system can be provided on special request.
Anchorages are categorised in two types, given as under:-

1. Mono-Group Anchorages
2. Slab Stress Anchorages
Multi-Strand Anchorages are recommended for Prestressing of concrete structures

where higher capacity of Prestressing forces are required; such as Bridges, Silos,
Dams and containment walls etc.
Slab Stress Anchorages are developed for using in flat concrete structure such as
buildings etc. where Prestressing forces are considerably low.
SECTION - A

PRESTRESSING MATERIALS
PRESTRESSING STEELS
Prestressing Steels are best known as the High Tensile Steel Wires, Strand or Bars
and are available in various sizes and configurations to impart a range of UTS.
A few of them are as listed below:
DIAMETER BREAKING
TYPES SHAPE
RANGE STRENGTH
Plain Round 2.5 mm. - 8
9.87 kN - 69 kN
Wire mm.
Indented Wire 4 mm. - 7 mm. 23 kN - 61 kN
Strands - 3Ply 3.0mm. x 3 Wire 38.25 kN
9.5mm. -
Strands - 7Ply 89 kN - 265 kN
15.7mm.
Threaded Bar 20 mm. - 40

173 kN - 691 kN
(McALLOY) mm.
High strength prestressing steels requires careful handling during transportation

and storage. They should neither be dragged on hard rough surface nor laid
unprotected on naked soil. It should be properly wrapped and covered with
tarpaulin etc. to prevent ingress of moisture and dirt in a humid or corrosive
atmosphere.
They should be stored at an elevated platform to prevent them from rising moisture
if any, from the humid / wet ground condition. The Storage area must also have an
adequate ventilation, to prevent condensation.
SECTION - B
ANCHORAGE SYSTEMS
Prestressing forces of the Tendons are transferred to the concrete structures
through Anchorages. Anchorage for the Post Tensioning system normally comprises
of a steel plates with a number of conical holes, the conical Grips and the Guide
(Trumpet). Trumpet or Guide is used to connect the ducts and provides a flat
surface for locating the Bearing Plate on it. As shown in the figure below:
PRESTRESSING ANCHORAGES
a. Guide - This is specially formed component made out of graded Cast
Iron, which generally gets embedded in the concrete and
used to distribute the tendon forces to the concrete.
b. Bearing Plate - This is cylindrical round shaped component made out of

forging of graded Alloy Steel. This plate contains a number
of tapered holes for wedging the Prestressing Steel with the
help of grips.
c. Grips & Circlips - This is a tapered shaped components made out of Alloy
Carbon Steel and subsequently hardened & tempered. These
grips are slitted in three equal parts to work like a split jaws
and contains serrations inside.
SECTION - B

FLAT ANCHORAGES
The components and the functions of the FLAT ANCHORAGES are similar to that of
Prestressing Anchorages, but they are specially designed in flat shape for use in
slab stress applications.
BLIND END ANCHORAGES:

A Blind End Anchors are used where the end of the Prestressing cable is buried in
concrete and or the location is in-accessible for stressing of the tendons. A typical
arrangement is as shown below. BLIND-END Anchorages are also available for
complete range.
SECTION - B
ANCHORAGE COUPLERS:
In the construction of continuous deck bridges, it is essential to extend Prestressing
cables as the construction proceeds. FPCC has a range of Multi Strand Anchorage
Couplers in configuration of 12, 19 and 27 strands, for strand diameter of ½”
(13mm.) & (0/6”) 15.2mm.
In COUPLER arrangement, the first stage of Stressing is carried out in the same
way as with the standard Anchorage, except that one COUPLER RING is placed
between the GUIDE and the BEARING PLATE. The coupler Ring contains the
required number of slotted lugs to accommodate SWAGED GRIPS fitted on the
strands for Second stage cable.
 






FREYS SINET
EXT RUDED G RIPS
15.2 mm.

FREYS SINET
EXT RUDED G RIPS
15.2 mm.







After the completion of first stage of prestressing and grouting, the strands fitted
with swaged grips are installed for second stage stressing. Swaged grips are
prepared with the help of a specially designed sleeves and locks, on an extrusion
press.
The strands are then deflected through a conical shaped trumpet called REDUCER
CONE, which also prevents ingress of concrete and slurry during casting of second
stage. This Reducer Cone provides a grout exit point, which should be placed at the
top location to prevent any air being trapped during grouting. Small end of the
Reducer cone is securely tapped to the duct of second stage.
SECTION - B
TENDON DUCTS (SHEATHING):
Sheathing is used to create a void in the concrete structure, through which the
stressing steels are inserted and remain free to stretch during stressing operation.
Sheathings are available in two types:
A) Metallic Ducts
B) H.D.P.E. Ducts
A. Metallic Ducts: Metallic Sheathing ducts are manufactured, by rolling CRCA

Steel Strips with a spiral corrugation throughout its length. These corrugations
provide better bonding with the Concrete from outside and the Cement Grout
from inside.
These spiral corrugations also work as a
helical thread and facilitate coupling of
two ducts by screwing another oversize
duct. This way a continuous length of
the duct can be formed. These ducts are
available in different diameters and
varying wall thickness to suit various
configurations of Tendons. Since these
ducts are made out of Steel and the
chances of corrosion is very high and
hence a lot of precautions are needed to
store them at work site. However coated
steel strips are some times used to
protect them for corrosion for a longer
period and enhance its service life.
However, the need for using a perfect
corrosion resisting material, has
introduced a non-metallic ducts in the construction work.
B. H.D.P.E. Ducts: Non-metallic ducts are made out of High Density Poly
Propylene (HDPE) or Poly-Propylene and have a number of advantages over
metallic ducts, such as-
I. They are highly corrosion resistant
II. They are effectively resistant to passage of chloride ions.
III. They are very poor for electrical conductivity.
IV. The duct materials has a high co-efficient of thermal expansion
(Typically - 140 x 10 -6 deg˚C)
V. It has a low Young’s Modulus (Nearly 800 N/mm2 )
VI. Can be sealed against ingress of contaminants.
VII. Can be pressure tested during construction to demonstrate integrity.
SECTION – B

TENDON SUPPORTS:
To ensure the adequate transfer of calculated forces to the structure, it is very
important that the tendon profile and the location of the duct, in ‘X’ & ‘Y’ directions
are maintained as shown in the drawing. For this purpose; the ducts needs to be
properly supported and secured at an intervals of 0.50 – 0.70 meter. The axis of
the duct is considered as the line of Center of Gravity of the tendon.
A B
W IRE
SHEATHINGS SHEATHINGS TIED
W ELDED
W ELDED CO VER C OVER
BLO CK BLO CK
TENDON SUPPORT
Examples shown above are two typical arrangements of Tendon Supports:

A. Standard Solution: The ducts are inserted through the Tendon Support.
B. Typical Arrangement for Pre-assembled tendons placed from above.
PROPER CARE TO BE TAKEN FOR INSTALLING TENDON SUPPORT:

1. In the case of lightly curved tendons or ducts, which are not supported by the
strands during concreting, the supports must be placed at shorter distance to
prevent uplift.
2. Tendon supports shall never be placed directly underneath the Guide Castings,
Duct Joints or Sleeve for Grout Vent.
3. Tendon Supports shall never be welded near ducts or already placed tendons.
SECTION – B

ANCHORAGE DIMENSIONS AND SETTING-OUT DETAILS
THE ANCHORAGES: The term Anchorage is referred to the assembly of three

components, used for pre-stressing purposes
They are namely –
a. GUIDE
b. BEARING PLATE &
c. GRIPS
GUIDE is used as a pocket former and is made out of S.G. Iron Casting; in the
shape of conical tubular form. It has a square flange with for notches at four
corners for securing it to the formwork. The GUIDE is fixed in the position prior to
concreting. The sheathing duct is then fitted on the smaller end of the tubular guide
with the help of waterproof adhesive tape or a heat shrink sleeve. The BEARING
PLATE with the GRIPS is mounted over it at the time of tensioning the tendons.
ANCHORAGE
a c e f Øg Øh i j k
TYPE
4 K 13 - 104 45 45 56 85 158 147 147 75
7 K 13 4 K 15 103 50 62 72 120 184 160 160 85
12 K 13 7 K 15 180 55 84 100 140 254 220 235 90
19 K 13 12 K 15 190 60 95 105 160 190 244 244 95
27 K 13 19 K 15 270 70 127 136 200 234 275 293 105
37 K 13 27 K 15 395 78 171 190 252 425 365 365 115
- 37 K 15 467 85 178 206 270 495 425 425 125
SECTION – C

Assumptions:
a. The minimum distances between anchorages “a” and the minimum distance “b”
from the nearest free edge are given for various concrete strength levels.
b. The minimum distance “a” must be combined with a distance between a’ > a in
the orthogonal direction to provide for each anchorage a rectangular distribution
area that satisfies the conditions aa’ ≥ 3b2.
c. M30 / M35 / M40 /.... are Characteristic Breaking Strength of Concrete Cube
after 28 days.
d. Nominal Breaking Strength: for Ø 15.2mm. Strand – 260.7 kN.
for Ø 12.7mm. Strand – 183.7 kN.
e. Recess dimension d’ (eg.220/270) are shown with basic Jack/Optional Jack.
f. All Dimensions shown here are in millimeters.

SECTION – C
REINFORCEMENT DETAILS OF THE ANCHORAGE ZONES
The reinforcement of the anchorage zones basically provides “Bursting

Reinforcements”, and applies to structures with a minimum number of bars such
that all the reinforcement in the End-Block Zone, to a depth 2b, corresponds to a
minimum steel percentage of 1% in each direction perpendicular to the Prestressing
axis.
This type of reinforcement must be adapted to particular cases whenever there is a

group of anchorages or a risk of cracking at the boundary of the End-Block zone;
independent small size reinforcement cages must then be replaced by continuous
reinforcement of equivalent cross-section. A selection guide is given in the table
below.
GRID TYPE REINFORCEMENT SPIRAL REINFORCEMENT

UNIT TYPE
Nb Dia b/2 s q q’ Nb Dia. D e f
7 K 13 4 K 15 6 10 80 100 350 260 6 10 200 50 300
12 K 13 7 K 15 6 12 100 120 420 312 6 12 280 50 300
19 K 13 12 K 15 6 14 120 150 500 374 6 14 360 60 360
27 K 13 19 K 15 6 16 150 170 570 426 6 16 440 65 390
37 K 13 27 K 15 2X6 14 180 210 560 434 7 18 540 70 490
55 K 13 37 K 15 2X6 16 200 240 640 496 8 20 640 70 560
SECTION – C
DETAILS OF THE BLIND END ANCHORAGES
When a Prestressing tendon can be stressed from one end only, a dead end
anchorage can be used at the other end. When the anchorage is accessible, a
manually blocked type jacking
anchorage (Type A or B) can
be used; the anchoring jaws
are driven in by sledge
hammer. If the Non-tensioned
end of the tendon is not
accessible during stressing, a
buried and fixed anchorage
must be provided and the
tendon is then put in place
before concreting.
In one type of Blind end

Anchors; the end of each
strand is provided with a
swaged sleeve. The swaged
sleeve ends are positioned on
a distribution plate and are
held in position with the help
of a spring or a retaining ring.
In another type of Blind end Anchors; the end of the strands is unwound in the
form of bulbs or flower and can be laid out in square or rectangular orientation.
UNIT TYPE e f g h l
4 K 13 350 70 150 170 800
4 K 15 390 90 190 210 950
7 K 13 370 70 170 190 1280
7 K 15 450 90 210 230 1300
12 K 13 350 190 310 270 1280
12 T 13 S 350 190 310 270 1280
12 K 15 430 230 390 330 1300
19 K 13 470 190 310 390 1280
19 K 15 570 230 390 470 1300
27 K 13 670 220 470 430 1280
27 K 15 810 260 570 510 1700
37 K 13 870 310 570 430 1680
37 K 15 1050 370 690 510 2000
55 K 13 1170 350 670 550 1980
SECTION – C
FLAT-SLAB PRESTRESSING
The F.P.C.C. Flat-slab
Prestressing System is used for
all types of slabs in buildings,
bridge decks and similar other
applications. FPCC Flat-Slab
Anchorages are available in the
range consists of 2, 3, 4 & 5
strands of 13mm. (0.5”) &
15mm. (0.6”) diameter, placed
in flat ducts, with respective
anchorages. Strands are
stressed and locked-off
individually. Tendon placement
and grouting procedures are
similar to those of multi-strand
systems.
Flat Slab Prestressing enables
deflections and cracks under service conditions to be kept under control. This
permits the use of a larger span with thinner slab, and can effect a substantial
reduction in construction cost and time due to reduction in material and labour cost.
Application of Flat-Slab prestressing also gives some important indirect savings on
foundations, column and beam sizes, walls and vertical services.
DUCT SIZE
TENDON
UNIT A B C D E F G X H
FORCE
TYPE (INNER)
kN mm. mm. mm. mm. mm. mm. mm. X mm.
2 S 13 367.40 145 78 80 165 95 90 40 X 20
3 S 13 551.10 165 88 82 185 100 95 60 X 20
4 S 13 734.80 192 96 88 215 105 98 70 X 20
5 S 13 918.50 220 110 88 240 110 110 90 X 20
2 S 15 521.40 160 85 82 180 100 95 45 X 25
3 S 15 782.10 192 96 85 215 120 100 70 X 25
4 S 15 1042.80 230 110 100 250 120 110 90 X 25
5 S 15 1303.50 280 170 100 300 125 110 100 X 25
Assumptions:
a. Nominal Breaking Strength: for Ø 12.7mm. Strand - 183.7 kN.
for Ø 15.2mm. Strand - 260.7 kN.
b. All Dimensions shown here are in millimeters
SECTION – C

STEEL CHARACTERISTICS
Prestressing steel stressed and embedded in concrete losses a part of its initial
tension, as times goes by. This loss is known as “stress relaxation”, and must be
taken care of in the design of prestressed structures. Any reduction in the amount
of relaxation losses will substantially improve the efficiency of the prestressed
tendons.
“Low Relaxation” steels give a relaxation loss not greater than 2.5% (after 1,000
hours, at 20oC / 68o F), when initially loaded at 70% of the specified minimum
breaking strength. Normal stress relieved steel exhibits, in comparison, losses of
around 7%.
The Introduction of Super Strand represents a significant development for the
prestressed concrete industry. It has higher breaking load than normal strand
without sacrificing any of the other mechanical properties. Higher strength strand
means an initial savings in material costs, and fewer strands in a prestressed
member results in a further savings due to lower handling cost.
SPECIFIED SPECIFIED
NOM. NOM. NOM.
BREAKING LOAD AT 1%
STANDARD GRADE SIZE DIA. SECTION WEIGHT
LOAD ELONGATION
2
mm. mm. Kg/m kN kips kN kips
1770 MPa ½” – T13 12.50 93.00 0.730 164 36.9 139 31.3
Euronorm 1860 MPa ½” – T13 12.50 93.00 0.730 173 38.9 147 33.1
138-6/79
Standard 1670 MPa 0.6” – T15 15.20 139.0 1.090 232 52.2 197 44.3
1770 MPa 0.6” – T15 15.20 139.0 1.090 246 55.3 209 47.0
Euronorm 1860 MPa ½” – T13 12.90 100.0 0.785 186 41.8 158 35.5
138-6/79
Super 1770 MPa 5/8” – T13 15.70 150.0 1.180 265 59.6 225 50.6
250 kpsi ½” – T13 12.70 92.90 0.730 160.1 36.0 144.2 32.4
A.S.T.M. A 270 kpsi ½” – T13 12.70 98.71 0.775 183.7 41.3 165.4 37.2
416/80 250 kpsi 0.6” – T15 15.24 139.35 1.094 240.2 54.0 216.3 48.6
250 kpsi 0.6” – T15 15.24 140.00 1.102 260.7 58.6 234.7 52.8
Example of Elongation Curves

Example of Relaxation Curves
SECTION – C

TABLE FOR STANDARD PRESTRESSING TENDONS
The ‘K’ Range of anchorages has been designed for use with all existing grades of
strand and in particular those possessing the highest performance characteristics,
such as those complying with the Euronorm Super Grade.
Engineers should of course refer to the specific manufacture’s characteristics (e.g. –

Nom. Breaking Strength, Cross-Sectional Area, Relaxation etc.) for the type of
strands specified for any particular structure.
For all anchorage systems listed, individual or groups of strands may be omitted to
optimize the system. However, it should be borne in mind that the tendons
containing maximum possible number of strands for any particular anchorage,
represents the most efficient use of that anchorage.
CABLE FORCES (in kN)
EURONORM 138 - 6/79 A.S.T.M. – A 416/80

STANDARD
Super Grade
Grade 1770 Grade 1860 Grade 250 K Grade 270 K
1860
UNITS 100% 80% 100% 80% 100% 80% 100% 80% 100% 80%
4 K 13 656 525 692 554 744 595 640 512 735 588
7 K 13 1148 918 1211 969 1302 1042 1121 897 1286 1029
12 K 13 1968 1574 2076 1661 2232 1786 1921 1537 2204 1764
19 K 13 3116 2493 3287 2630 3534 2827 3042 2434 3490 2792
27 K 13 4428 3542 4671 3737 5022 4018 4323 3458 4960 3968
37 K 13 6068 4854 6401 5121 6882 5506 5924 4739 6797 5438
55 K 13 9020 7216 9515 7612 10230 8184 8806 7045 10104 8083
Super Grade
Grade 1670 Grade 1770 Grade 250 K Grade 270 K
1770
4 K 15 928 742 984 787 1060 848 865 692 1043 834
7 K 15 1624 1299 1722 1378 1855 1484 1514 1211 1825 1460
12 K 15 2784 2227 2952 2362 3180 2544 2596 2077 3128 2502
19 K 15 4408 3526 4674 3739 5035 4028 4110 3288 4953 3962
27 K 15 6264 5011 6642 5314 7155 5724 5840 4672 7039 5631
37 K 15 8584 6867 9102 7282 9805 7844 8003 6402 9646 7717
SECTION – C

EQUIPMENT DIMENSION AND INSTALLATION DETAILS
K-RANGE JACKS
The FPCC is manufacturing a range of Jacking Units, to cover the entire range of
Prestressing Systems; with Mono-Strand and the Multi-Stressing System. The K-
Range Jacks are designated as Central Hole, Twin Cylinder Double Acting Hydraulic
Jacks. The Main Jacking Unit has a to-n-fro moving piston and is used as Stressing
Cylinder. Strands are being anchored at the rear end of the Piston with the help of
specially designed Anchor Plate and self releasing Conical Grips. Another Jacking
Unit located at the front end, is a hollow cylinder Single Acting Hydraulic Jack and is
used for blocking purposes. Depending on the tendon type and the available
spaces; a complete range of Jacks are available.
The table below can be referred for the selection of the Jack for Prestressing of
Cables:-
JACK
ANCHORAGE TYPE e f g h i j k l
TYPE
4 K 13 - 635 200 185 275 785 190 126 192
K 100
7 K 13 4 K 15 635 200 185 275 785 190 126 192
7 K 13 4 K 15 720 200 220 350 875 230 228 274
K 200
12 K 13 7 K 15 726 200 220 350 875 230 231 274
12 K 13 7 K 15 820 250 267 440 970 270 235 324
K 350
19 K 13 12 K 15 820 250 267 440 970 270 230 324
19 K 13 12 K 15 940 250 267 515 1090 310 230 410
K 500
27 K 13 19 K 15 933 250 267 515 1090 310 222 410
27 K 13 19 K 15 881 260 350 610 1030 360 142 478
K 700
37 K 13 27 K 15 973 260 350 610 1125 360 104 478
37 K 13 27 K 15 1062 220 400 710 1220 410 268 535
K 1000
55 K 13 37 K 15 1171 220 400 710 1320 410 279 535
SECTION – D

ELECTRICALLY OPERATED HIGH PRESSURE PUMP:
The FPCC Prestressing Jacks are being operated
using FPCC manufactured E.O.H.P. Pumps. Three
variants of these power packs are used to suit the
individual need of the various jacks.
The Pumping unit used in these power packs is of

Multi-Plunger, Axial Flow and Positive
Displacement type. They are suitably coupled with
a TEFC Electric Motor and are mounted on a
special designed Oil Tank.
The power pack also houses suitable D. C. Valve,

Check Valve, Relief Valve and Shut-off Valve etc.
mounted on a manifold for effective control of the
Hydraulic Jacks. Two distinguished Pressure
Gauges are also mounted on the front panel of the
power pack to read the Stressing and Blocking
Pressure; as the case may be.
Other than the EOHP, FPCC also manufactures Hand Operated High Pressure Pump
(HOHP).
The table below represents the suitability of various models of the power packs:
SALIENT FEATURES OF E.O.H.P. Power Pack
UNITS H.O.H.P. Pump
THE POWER PACK MK-I MK-II MK-III
Test Pressure (Max.) Kg.f/cm2 600 650 650 640
2
Working Pressure (Max.) Kg.f/cm 450 580 580 550
Ltr./min 0.20 (S/A)
Oil Delivery (Max.) 1.50 1.50 2.50
. 1.50 (D/A)
Oil Tank Capacity: Ltr. 25 60 -
Total- - Do - -
Ltr. 10 25 -
Useable
T.E.F.C. Electric Motor:
hp / KW 2.0 / 1.49 3.0 / 2.24 5.0 / 3.73 -
440 Volts, 3 ph, 1440 rpm
Dimensions - mm. 575 630 600
LENGTH
mm. 335 950 350
WIDTH
mm. 705 800 980
HEIGHT
Machine Weight: Dry kgs. 45.0 110.0 58.0
With Oil kgs. 66.0 162.0 -
4S13 - 5S13 4K13 - 12K13 19K13 - 27K13 4S13 - 5S13
Recommended Sizes
- 4S15 - 5S15 4K15 - 7K15 12K15 - 27K15 4S15 - 5S15
of Prestressing Cable
4K13 - 7K13 or Equivalent or Equivalent 4K13 - 7K13
JACK RECOMMENDATION - SC-2 & K100 K-100 & K-200 K-500 & K-700 SC-2 & K-100
Other than the Prestressing Jack & Power pack, FPCC also manufactures some other
Special Application Jacks and Pumps to suit customer’s specific needs, Such as - Heavy
Lifting Jacks, Lifting & Lowering Jacks, Side Shifting Jacks and Flat Jacks etc. A special
power pack is also available to operate these jacks.
SECTION – D

GROUTING SYSTEM:
F.P.C.C. also manufactures the complete machinery & system for Grouting purpose.
It comprises of Grout Mixer & Agitator and Grout Pump.
GROUT MIXER & AGITATOR:
It is a combination of two circular

formed drum units, where the first
drum is used as Cement Mixer and the
other drum is used as an Agitator for
the cement slurry. The first Drum
`MIXER’ is equipped with an
electrically driven rotary turbulating
blades at the center and churning
blades fixed on the inner wall of the
drum. In this drum Cement is mixed
with water. The Mixing Drum is
generally kept at a higher level than
that of Agitator Unit, such that mortar
can flow directly into the second tank,
the Agitator, placed just beneath the
mixing drum. Before flowing into the
Feed Drum (Agitator), the mortar is passed through a 2mm. mesh screen to
eliminate impurities and lumps etc. Cement mortar stored in the Feed Drum
(Agitator), is continuously stirred to avoid setting or segregation.
A Schematic Diagram of such an arrangement is shown above.
AGITATOR Model J-700:

Shaft Rotation : 120 rpm
Electric Power : 2 hp. / 440 volts/ 1440 rpm
Motor
Handling Weight : 38 kgs.
Overall Dimension: Length x Width x Height
125 x 25 x 48 mm.
SECTION – D

GROUT PUMP - Model J-600:
To fill the cement mortar inside the
cable duct, FPCC Manufactures, a very
compact electrically driven Pump Model:
J-600.
This is a reciprocating type, twin
cylinder, positive displacement pump.
The Salient features of this pump are:

Delivery : 1200 liters/hr. (Maximum)
Testing Pressure : 30 kg.f/cm2
Delivery Pressure : 25 kg.f/cm2 (Maximum)
Electric Power : 2 hp. /440 volts/1440 rpm Motor
Overall Dimension : Length x Width x Height in mm.
980 x 480 x 940
GROUT PUMP - Model P-2001:

FPCC has also developed a higher version of Grout Pump Model: P-2001, for grouting of
vertical cables in the cylindrical structures such as Cement Silos, Chimneys,
Containment wall of Nuclear Reactors etc.
A representative pictorial View is presented
here for Reference.
Flow Rate : 900 liters/hr. to
(Range) 3900 liters/hr.
Pressure : 10 - 40 kg.f/cm2
(Range)
Working Pressure : 30 bar (Maximum)
Power Supply : 7.5 hp/440 volts/3Ph.,
1440 rpm Elect. Motor
For Controls : Solenoid Valve, Limit
Switches, Pressure
Switch & Control
Circuits etc.
Overall Dimensions : Length x Width x Height in mm.
1460 x 1455 x 1540
SECTION – D

HAND OPERATED GROUT PUMP - Model HOGP:
For special application in shorter cables and small

structures, FPCC has a unique Hand Operated
Grout Pump. This pump is used where the
quantum of Grouting Mortar, to be pumped, is
relatively low and the cable cavity is small. Since
the pump is hand operated one and does not
require any electricity, it has a very wide
acceptance in the remote areas where the supply
of electricity is scares. A representative pictorial
View is presented here for Reference.
Flow Rate : 8.50 liters/minute
Delivery Pressure : 14 kg.f/cm2
Testing Pressure : 17.5 kg.f/cm2 (Maximum)
Overall Dimensions : Length x Width x Height in mm.
580 x 300 x 900
SECTION – D

PRESTRESSING OPERATION
This chapter shall deal with the Handling and Installation of H.T. Strands, Stressing
Procedure and the Grouting Operations etc.
HANDLING & INSTALLATION OF H.T. STRANDS

The H.T. Strands are used as medium for inducing the stressing forces in the
structures and thus become the most important constituent of the Prestressing
Operation.
The strands are inserted or placed into the ducts, provided in the concrete
structures. Placement / Insertion of the strands can be done either prior to
concreting or after the concreting as well, but the insertion before the concreting is
more dependable and therefore, should be given more preference.
In this case, the ducts/sheathings must be tied firmly to the tendon supports or
reinforcement bars.
When the strands are inserted after concreting, necessary precaution should be
taken to prevent the sheathing duct, from getting clogged with cement slurry
during concreting. The most commonly used method is to insert a dummy pipe or
mandrel inside the duct and regularly agitate it during concreting procedure. This
prevents any settlement of cement slurry in the duct.
NECESSARY PRECAUTIONS – FOR INSTALLING DUCTS & STRANDS

1. Fix the Sheathing duct firmly on the smaller end of the Guide or trumpet
2. Test Certificate of the Prestressing Steel and Identification Label from the
Strand Coil should be kept in safe custody. These data sets are very important
and shall be used for Calculating the modified force and elongation at the time
of carrying out stressing operation. Strand data from the “Identification label”
and Tendon number, in which the strand has been used, should be recorded in
the Construction Book.
SECTION - E

3. Strand should be uncoiled in such a manner that it does not get twisted and
should not be laid or dragged on soiled or rough surfaces. A wooden palate
should ideally be erected in the yard for dragging & laying the strands after
de-coiling.
4. Strand should not be laid or dragged on soiled or rough surfaces. A wooden

palate should ideally be erected in the yard for dragging & laying the strands
after de-coiling.
5. Strands should be cut evenly by an abrasive cutter in desired length.
6. Strands ends should be ground smooth, to prevent any damage to the duct
during insertion by pushing. If required a suitable bullet end can also be
employed to have a smooth insertion.
7. When the strands are pulled into the tendon ducts together in bundle, special
care should be taken to prevent the damage to the duct or the strands. Roller
cradles can be used to carry the tendons on the rough ground.
8. In case of threading of strands after concreting, it is recommended to use a

De-Coiler and the Strand Pushing Machine for uncoiling and threading of
strands into the duct.
9. Before concreting, check the entire length of the ducts for any opening or
damages. Seal them firmly with the adhesive tape or any suitable sealant.
10. Both the ends of the duct should be closed after installation, and the strand
ends should be wrapped firmly with anti moisture wraps to prevent the ingress
of any foreign particles, cement slurry, concrete or moisture inside the duct.
They may damage the duct and the strands in long run.
11. Precaution should be taken to prevent the sheathing/ducts from getting

damaged due to the use of Needle vibrators during concrete. Damage or
puncture of Sheathing may cause a severe ingress of cement slurry into the
duct and will result in blocking the Strands up to certain length.
12. Clogging of strands inside the duct will cause an unequal elongation during
stressing and will obstruct the passage during grouting.
SECTION - E
STRESSING OPERATION
This chapter shall deal with the Stressing Operation of Cables with Multi-Strand
System. For Stressing Operations of Wires/Bars/Mono Strand, details can be
furnished on request.
PREPERATIONS FOR STRESSING OPERATION

Before starting with the actual Stressing Operations, certain preparations should be
made; some are required to be done prior to concreting. They are listed out as
below:-
Basic Requirements:
1. The Stressing Operation can be initiated, only after concrete attains it’s
strength (usually 60% to 80% of it’s ultimate strength in 28 days). This can be
ascertained by testing the cube strength of the concrete.
2. 3 or 4 sets of Cube Mould (Size: 150 x 150 x 150 mm) should be

poured/prepared alongwith the concreting of the main structure, to be
Stressed. Each set should consist of minimum 3 numbers of moulds.
3. Stressing drawing should be thoroughly studied to ascertain following

parameters, and if required, should be consulted with the Principal/Design
consultant.
i. Stressing Schedule - Minimum Stay period after concreting, Minimum
Concrete strength for Stressing, Sequence of Stressing for various
cables etc. should be obtained from the drawing.
ii. Anchorage/Cable Type – The configuration and type of the cables is also
shown in the drawing (i.e. No. of Strand x Dia. of Strand). A suitable
Guide/Trumpet and suitable size of Sheathing duct should be installed in
the structure at the time of fixing of reinforcement cage and before the
actual concreting is done.
iii. Assumptions – At the time of designing any structure, designer assumes
the standard values of certain parameters for deriving the designed
forces & elongations. These parameters are shown in the drawing as
Assumptions and are mainly known as Cross-Sectional Area of
Prestressing steel (Strand), Modulus of Elasticity of Prestressing Steel,
Friction & Wobble Coefficient of Duct and the Wedge Set etc.
SECTION - E
iv. Stressing Force - Stressing force to be applied on each cable. Different
cables may require to be stressed at different force level.
v. Elongation - Elongation to be achieved, in each cable? Different cable
may require to be stressed for different elongation.
vi. Type of Stressing - One End Stressing or Stressing from both the ends.
Local Conditions:
1. The Prestressing Engineer should physically check the access of the
Prestressing point, for personnel and equipments.
2. Jack Clearance from the structure, distance between two cables, Pocket
dimensions of the End block should be checked, with respect to the size and
dimensions of our equipment and accessories.
3. If required necessary platform for the personnel and equipment, and the
handling gantry for the equipment should be erected for easy and comfortable
access to the Stressing point.
4. Our equipments require electricity as a source of energy, hence availability of

electricity to be checked to operate our equipment and to illuminate the Job
site for night work.
5. Availability of potable water (calcium/sulfur/chlorine free) is also required to be

checked. This is a most essential commodity for carrying out the grouting
operation
Planning:
1. The Prestressing operation should be carried out by a Qualified Engineer. He
should be competent enough to calculate the required forces and elongation
during stressing and can take necessary decision instantly at the work site. He
should also be sufficiently able to lead the team of experienced and skilled
technicians and workforce.
2. Necessary planning should be made to carryout the stressing operation as per

the given schedule, by effectively utilizing the available work force and
machinery and a reduced downtime.
3. Each strand carries a different cross-sectional area and thus a different

Modulus of Elasticity. These data has already been obtained from the
“Identification Label” and the “Test Certificate” of the Prestressing steel
(strand) at the time of preparing the Cables.
SECTION - E

4. Designed Forces and Elongations, needs to be modified from the actual values
of the Prestressing steel (strand) being used. Necessary formulae for
calculating the same has been given in the subsequent chapter of “GENERAL
DESIGN & INFORMATION”.
5. Friction & Wobble Coefficient of Ducts are the standard data and does not
necessarily need any modifications in normal conditions. These values are
given in various approved certificates. Unless mentioned otherwise, they
remain constant irrespective of the different supplier or supplies.
6. WEDGE SET of the Anchorages and equipments are specified by the

manufacturer. Necessary correction should be applied, if differs from the
design assumptions.
Equipment & Accessories:
1. Make a thorough visual inspection of the equipments to ascertain, if they are

visibly not damaged, or having any of its parts truncated, dislocated or
damaged. Check for any visual leakages etc. in the hydraulic equipments.
2. Check the quality & quantity of all the accessories of the Hydraulic Jacks and
Accessories; such as Conversion Kits, Master Grips, Terminal Adaptors, Grip
releasing Agent etc., for it’s perfection.
3. Check the condition of Pressure Gauges, it’s fittings & connections etc. for
correctness. Obtain necessary Gauge Calibration Certificate from the
competent authority. The calibration certificates should not be older than 6
months or the 100 repetitive uses (whichever comes earlier)
4. It is recommended that sites should have Master Pressure Gauge or the

Pressure Gauge Calibrator to conduct, periodical calibration of the Pressure
Gauges.
5. Check the Hose pipes and it’s end fittings are intact and are connected
correctly with the pump & Jack.
6. Obtain Jack efficiency data from the Factory or the manufacturer/supplier of

the Jack. It should also be checked periodically at site level to update the
stressing record. The detail methodology for “Jack Efficiency Test” is given in
the subsequent chapter “GENERAL DESIGN & INFORMATION”.
7. Check the adequacy of handling equipments, in advance. They should not fail
while lifting, holding and positioning of the jack during stressing.
SECTION - E

Stressing Data & Records:
After complete setup and planning; Stressing operation should be carried out, as
described below:-
1. Check the concrete strength and if it attains 60% to 80% strength of its
prescribed value, Stressing operation may be started.
2. Apply necessary correction to the ‘Stressing Force’ and ‘Elongation’, with

respective available ‘Cross-sectional Area’ & ‘Modulus of Elasticity’ of
Prestressing steel, ‘Friction & Wobble Co-efficient’, if any, and the
recommended ‘Wedge Set’ for the equipment etc.
3. Stressing operation is monitored in two ways:
a. By Pressure Gauge Reading: Pressure gauge reading on the power

pack is translated into the force applied by the jack and ultimately
transferred to the anchorages through Prestressing Steel. The tendon
force can be calculated by multiplying the pressure gauge reading to the
‘Ram Area’ of the Jack. Ram area of the Prestressing Jack is generally
provided by the manufacturer.
b. By Elongation Method: Actual elongation can be compared with the

theoretical elongation of the Prestressing steel. It can be calculated with
respect to data available for the Prestressing steel used. Necessary
calculation detail is given in the subsequent chapter “GENERAL DESIGN &
INFORMATION”.
4. The Measurement of forces ‘By Elongation Method’ provides the measure of

the average forces throughout the length of the Tendon, whereas the Pressure
Gauge Method provides the measure of forces in the tendon at Anchorages.
At the Stressing Ends:
1. If the Prestressing steel (Strands) are laid prior to concreting, Try to move the
strands to & fro, individually or in group, to ascertain, the cable is free from
any incursions or clogging. If the cable is found to be free, we can proceed
with the stressing operation. Otherwise some efforts are required to make the
cables free and stress able.
2. Pull the projected length of the strands outside the cable opening, up to a
length equals to the “Strand Gripping Length of the Prestressing Jack” +
“Double of the Elongation required”. Thoroughly clean them with some fluid
cleaner and make them free from corrosion, dust and any short of inhibitions
etc.
SECTION - E
3. Repeat the above procedure from the other end of the cable too.
4. Push the extra length of the strands, inside the cable and adjust the projected
length of the strands equal to the prescribed “Strand Gripping Length” for the
Jack in use. Repeat this procedure from other end of the cable too.
5. Check the Taper holes of the ‘Bearing Plates’, and if necessary, remove rust
and clean them. Please consider unpacking and placing of ‘Bearing Plates’ and
‘Grips’ only shortly before the stressing. This will prevent the ‘Bearing Plate’
holes and ‘Grips’ from getting exposed to atmosphere as little as possible.
They should be free from rust and corrosion, until fully stressed.
6. Thread the ‘Bearing Plate’ over the strands and rotate it for 5 to 6 times in
clockwise direction and then reverse the rotation in anti-clockwise direction for
equal number of times. By doing this a considerable length of strand inside the
cable gets freed from entanglement.
7. Install the ‘Grips’ over the strands and push them into the taper holes of
‘Bearing Plate’ with the help of a pipe. ‘Grips’ should be pressed into the
‘Bearing Plates’ simultaneously from both the ends of the tendons, till it gets
fixed on the surface of the ‘Guide Cone’.
Set-up and Equipment Connections:
1. Check for the Oil level in the reservoir of the power pack. Top up if necessary
with required quantity of ENKLO-68 (Hindustan Petroleum) Hydraulic Oil.
2. Connect the Jack with high-pressure hose pipes to the hydraulic power pack.
Check the connectors/couplers for the leakage, if any. Secure them firmly and
keep them as clean and dry as possible. Leaking couplers attract more dust &
dirt and can easily get inhibited in the hydraulic system through oil.
3. Check the hose pipes also and ensure that they are also clean dry and dirt
free.
4. Check the Pressure gauges are connected properly and the end connections
are leak-free, clean and dry. Leaking joints shall reflect a continuous pressure
drop and will create hindrance in the stressing operation.
It is recommended that the pressure gauges fitted on the power pack are
properly calibrated with Master gauges or Dead Weight Calibrator and an
authentic calibration certificate is there in the possession of the engineer.
SECTION - E
6. After connecting all the Hoses, bleed the air from the hydraulic system. For
this close the hydraulic circuit and idle run the Jack for full extension and
retraction. Repeat this for 3 to 4 cycles.
This way any air bubble present in the hydraulic circuit/system shall escape
and will prevent any short of partial pressure drop and jerky or rattled
movement of the piston.
Mounting of Jack & Conversion Kit:

1. Insert the ‘Bearing Ring’ over the ‘Bearing Plate’ at both ends of the Tendon
and press to fully to sit properly over the ‘Guide Ring’.
2. Insert the ‘Pressure Plate’ as per the orientation of the Bearing Plate Hole.
3. Jack should be suspended through a ‘Jack Handling Gantry’ with the help of a
‘Chain Pulley Block’. The arrangement should be such that it gives a full
flexibility of movement to the Jack in both transverse & longitudinal direction.
In small projects, a rigid twin Runway beam structure could be erected at the
end of bridge girder, for easy maneuvering of the Jack.
4. Insert the bunch of the Prestressing steel (strands) in the central hole of the
jack and push it down towards the ‘Bearing Ring’ and ‘Anchorage’. Axis of the
Jack should coincide with axis of the tendon.
Raise, lower or tilt the jack, as required, the face of the jack should be
perfectly seating over the face of the ‘Bearing Ring’.
5. Insert the ‘Rear Anchor Plate’ on the strands as per the orientation of the
Tendon and then firmly locate it over the back seat of the Jack Piston.
6. Sprinkle ‘Molylube Spray’ or apply any other ‘Grip Releasing Agent’ on to the
external surface of all the ‘Master Grips’ and inside the taper hole of the ‘Rear
Anchor Plate’ as well.
Grip Releasing Agent works as a lubrication between the metals and prevent,
metal to metal locking of the ‘Master Grips’ with ‘Anchor Plate’. While applying
these agents, be careful not to apply or spray them on the serration /thread
portion of the Master Grip.
7. Insert the 3 piece ‘Master Grips’ over the strands coming out of the back side
of the ‘Rear Anchor Plate’ holes. Push ‘Master Grips’ into the taper holes of
‘Rear Anchor Plate’ with the help of a pipe, to sit tightly inside the Anchor
plate.
SECTION - E

8. Check all the connection of jack with power pack, giving flexibility to hose
pipes for movement of jacks at the time of stressing
9. It is important that supporting chains or hooks should be slackened off as soon

as the jack starts carrying load. Similarly they should also be ready to support
the jack again while retracting.
10. Now the system is ready for STRESSING OPERATION.
11. The Operating Instructions for the Equipment and Accessories should be kept
handy and available at the working site during stressing.
STRESSING DATA & RECORDS

Before starting Stressing Operations, following Data/Record should be available
with the Engineer.
1. Tendon Identifications No.
2. Stressing Sequence
3. Length of the Tendon (from Anchorage end to Anchorage end)
4. Design Elongation of the Tendon - ( lz )
5. Elastic Shortening of the Concrete - ( lb )
6. Wedge Set at Anchorage - ( ls )
7. Elongation of the Prestressing Steel - ( le )
Within the length of Stressing Jack
(From Bearing Plate Grip to Master Grip)
8. Total Calculated Elongation lo = ( lz + lb + ls + le )
9. Specified Stressing Force - (P)
10. Specified Cross-Sectional Area of Prestressing Steel
11. Specified Modulus of Elasticity of Prestressing Steel
12. Actual Cross-Sectional Area of Prestressing Steel
13. Actual Modulus of Elasticity of Prestressing Steel = ( Ea )
14. Ram Area of the Stressing Jack
15. Pressure Gauge Calibration Report
16. Jack Efficiency Report
17. Elongation & Stressing Force to be modified/estimated on the basis of the
Actual Jack Efficiency of the jack, Actual Cross-Sectional Area & Actual Modulus
of Elasticity of The Prestressing Steel under use.
SECTION - E

APPLICATION OF PRESTRESSING FORCES AND ELONGATION
Any load applied must cause an extension. Since there must be some slack in the
tendon, it is very difficult to establish the datum from which elongation should be
measured.
To overcome this Problem - Two methods are being followed::::
First Method:
A Nominal force ‘µp’, sufficient to get the Jack tightened, is applied to the tendon. It
is assumed that jack gets tightened only when the slackness is removed. This level
is then assumed as the datum for extension measurement. For all practical
purposes a nominal load of 40-50 kg.f/cm2 is normally considered as datum level.
Remaining forces are then applied in regular succession up to the desired level.
Record corresponding extension at successive applied forces and plot the recorded
values on a stress/Strain diagram. This is done by plotting a graph with the Gauge
Reading (Force) at abscissas and elongation as ordinates. On extra-polation, the
plotted curve intersects at Y-axis, and thus defines as the effective elongation
during slackness or initial tensioning. This elongation during initial tensioning should
be added to the measured elongation to arrive at the actual elongation. A
representative curve and data sheet is given in the document section.
Second Method:
In this method, a force equal to P/3 is applied to the tendon to establish the datum,
and the extension is measured between the ‘Force P/3’ and the ‘Force P’.
The measured extension is thus corresponds to ‘Force 2/3 P’ and the full extension
at ‘Force P’ can be calculated by formulae of proportion. Here it is assumed that
grip set is proportional to the applied force.
In this method, measured elongation should agree with calculated elongation within
± 15% for individual tendons, and ± 5% for all tendons. These assumptions are
based on the theory that the calculations are done with actual modulus of elasticity
and actual cross-sectional area of strand under use. Further, the Co-efficient of
Friction and the Wobble Co-efficient are considered at an average value, and may
vary slightly from project to project.
SECTION - F
This method is very effectively used for two stages stressing where the required
tendon elongation is more than the stroke length of the jack
Methodology:
Go to 1/3 rd of the designed Load, Operate the blocking Jack and block the Live
‘Grips’ in ‘Bearing Plate’ and retract the jack. No elongation Reading is required to
be taken at this stage. This forms the datum and slackness is totally removed.
Reset the Jack and go back to 1/3rd Load again and measure the Ram Extension.
Now go to Full Load and note the Ram Extension. Block the Grips and return to
1/3rd Load. Note the reduction in elongation.
This reduction in elongation represents the ‘Wedge Set’ and ‘Elastic Shortening of
Strand’ for 2/3 rd Load. Proportionately the value of ‘Wedge Set’ & ‘Elastic
Shortening’ for 1/3rd Load can also be added to get actual ‘Wedge Set’ and ‘Elastic
Shortening’.
SOME TYPICAL EXAMPLE FOR TWO END STRESSING: Are Given below-
i. SINGLE STAGE STRESSING – When Extension is less than 200mm, in
each jack at each end.
Ist. JACK – At One End IInd. JACK – At Other End
rd
* Go to 1/3 Load (1/3 P) Go to 1/3rd Load ( 1/3 P)
* Extension - Need not be recorded Extension - Need not be recorded
* Block the Grips and Retract the Jack Block the Grips and Retract the Jack
rd
* Go to 1/3 Load (1/3 P) again & Go to 1/3rd Load (1/3 P) again &
Measure Elongation - Say 38 mm. Measure Elongation - Say 43 mm.
* Go to Full Load (P) Go to Full Load (P)

* Extension Measured = 165 – 38 Extension Measured = 176 – 43

= 127 mm. = 133 mm.
* Multiply the Measured Extn. by 1.5 (3/2) Multiply the Measured Extn. by 1.5 (3/2)
... 127 x 1.5 = 190.5 mm. ... 133 x 1.5 = 199.5 mm.
* Total Elongation would be: 190.5 + 199.5 = 390.0 mm.

* If the Losses due to Blocking (Wedge Set) have not been considered in design load, then
subtract the same from both the ends, from above Elongation.
SECTION - F

ii. TWO STAGE STRESSING – When Extension is more than 200mm, in
each jack at each end.
Ist. JACK – At One End IInd. JACK – At Other End
* Go up to 1/3rd Load (1/3 P) Go up to 1/3rd Load ( 1/3 P)
* Extension - Need not be recorded Extension - Need not be recorded
* Go up to 1/3rd Load (1/3 P) & Go up to 1/3rd Load (1/3 P) &
* Go up to 2/3rd Load (2/3 P) & Go up to 2/3rd Load (2/3 P) &
* Extn. Measured (Ist. Stage)= 183 – 40 Extn. Measured (Ist. Stage)= 195 – 47
= 143 mm. = 148 mm.
* Go back to 2/3rd Load (2/3 P) & Go back to 2/3rd Load (2/3 P) &
* Go up to Full Load (P) Go to Full Load (P)
* Extn. Measured (IInd. Stage)= 170 – 23 Extn. Measured (IInd. Stage)= 177 – 32
= 147 mm. = 145 mm.
* Total Extension Measured= 143 + 147 Total Extension Measured= 148+ 145
= 290 mm. = 293 mm.
* Multiply the Measured Extn. by 1.5 (3/2) Multiply the Measured Extn. by 1.5 (3/2)
... 290 x 1.5 = 435 mm. ... 293 x 1.5 = 439.5 mm.
* Total Elongation would be: 435.0 + 439.5 = 874.5 mm.
Block the Grips and Retract the Jack Block the Grips and Retract the Jack
* If the Losses due to Blocking (Wedge Set) have not been considered in design load, then
subtract the same from both the ends, from above Elongation.
SECTION - F

COMMON IRREGULARITIES DURING STRESSING & THEIR CORRECTIONS
During Stressing Operation, we normally observe that targeted extension are met
at the designated level of force/pressure, but some time, some common
irregularities in the tendon or the abnormal behaviours of the equipment arises in
between; and forces us to stop the work. These irregularities, needs to be
diagnosed and corrected properly.
Some of these irregularities and their corrective measures are described below:-
A. Desired Force is achieved but the Extension is very Low.
PROBABLE CAUSES CORRECTIVE MEASURES

1. Stroke Length of the Piston has Temporarily block the Grips and, Retract
reached to the final stage. the Piston and start with new stroke.
2. Faulty Pressure Gauge Calibrate the Pressure Gauge or connect
a Master Gauge in Pressure Line.
3. Error in computing the Stressing Notify the Design Engineer, correct error
Values: Incorrect assumptions or error and recalculate stressing values.
in calculations
4. Cross-Section Area of Prestressing Notify the Design Engineer, and
Steel is larger than assumed. (i.e. recalculate the Elongation value.
Strand Dia. is Ø15.7 instead of Ø15.2
or Ø12.9 instead of Ø12.5 mm.
5. Tendon is clogged due to ingress of Repeatedly overstress the tendon up to
cement slurry in the duct. 80% of UTS and Relax. This may break
the loose slurry, if any, and can free the
tendon.
6. Higher friction in the Sheathing/Duct. Repeatedly overstress the tendon up to
This may be caused due to rust, dents, 80% of UTS and Relax. This may relieve
depression or the deviation angle the tendon. If not, then notify the
larger than assumed designer.
7. Higher friction in the Stressing Jack Check for free travel for the Jack Piston.
If tight, notify the jack manufacturer.
8. Higher friction in the Stressing Jack Check for abnormal strand deviation, if
due to deviation of strand, inside the any, inside the Jack. Take Corrective
jack. action
NOTE:
1. In the case of (5) & (6), overstressing limit should not exceed 80% of the UTS,
or the 90% of the Yield Stress of the Strand, as specified in the FIP regulations.
2. During Overstressing Procedure, Don’t put ‘Grips’ in the ‘Bearing Plate’.
Fix up the Jack over the cable and travel out the Piston for at least 100-150mm.
before fixing ‘Rear Anchor Plate’ and ‘Master Grips’. Load should be applied
directly thr’u. Rear Anchor Plate.
SECTION - F

B. Elongation achieved but the Gauge Pressure is very Low.
PROBABLE CAUSES CORRECTIVE MEASURES

1. Some of the Master Grips are Missing De-stress the tendon, check the Master
or slipping grips and replace the defective ones.
2. Faulty Pressure Gauge Calibrate the Pressure Gauge or connect

a Master Gauge in Pressure Line.
3. Error in computing the Stressing Notify the Design Engineer, correct error
Values: Incorrect assumptions or error and recalculate stressing values.
in calculations
4. Cross-Section Area of Prestressing Notify the Design Engineer, and
Steel is smaller than assumed. (i.e. recalculate the Elongation value.
Strand Dia. is Ø15.2 instead of Ø15.7
or Ø12.5 instead of Ø12.9 mm.
5. Anchorage is yielding: Insufficient Essential Judgement by the Engineer
concrete strength or honeycombs in may stop mishap. Stop Stressing and
the concrete in Anchorage zone. repair the Anchorage Zone.
6. Some strands may be slipping at the Replace the faulty Anchors, Couplers or
Dead End Anchor, or the Coupler Joint Splices etc., if possible. Otherwise notify
or the Tendon Splice etc. the engineer to check the design for
reserves.
7. Smaller friction in the Sheathing or Notify the Design Engineer to review and
duct. recalculate the Elongation value.
8. Frictional Losses in the Jack are Check the Jack efficiency and re-evaluate
considerably less than assumed. the frictional losses. And make necessary
correction in applicable forces.
C. WEDGE SET:
Wedge Set is a term used to denote the losses/gains caused due to setting of
the ‘Grips’, during transfer of forces.
Setting of Grips in the Dead End Anchorage and in the Master Grips of
Stressing Jack causes an apparent increase in extension, but does not lose any
Prestressing force. Whereas the setting of Grips in the Bearing Plate certainly
causes a loss of Prestressing Force, during transfer of forces from Jack to the
anchorage.
Average values of such Wedge set, in normal conditions are as under:-
a) For Master Grips - 7 to 8 mm.
b) For Live Grips - 5 to 6 mm.
SECTION - F
METHODOLOGY FOR JACK EFFICIENCY TEST
OBJECTIVE: To check the Efficiency () of the system, at work site, comprising
of 2 (two) Prestressing Jacks & 2 (two) Power Packs.
EQUIPMENT: i) Two Prestressing Jacks with distinctive Identification Nos.

USED ii) Two Power Packs suitable to operate above jacks, with
distinctive Identification Nos.
iii) Two Pressure Gauges for STRESS line of above Power packs,
with distinctive Identification Nos.
PROCESS:
Calibrate the Pressure gauges on Dead Weight Pressure Gauge Tester, and connect
them on to the STRESS line of the two Power packs (under test).
Place both the Prestressing Jacks (under test) facing each other in horizontal
condition as shown in Drg. No. - A4: FPCC: MISC: 012 & A4: FPCC: MISC: 013 with
a Reaction Ring in between so that the concentricity of both the Jacks could be
maintained.
Connect the Stressing Cylinder of both the jacks to the respective Power packs with
two set of hose pipes. Ensure that the STRESS port of the Jack is connected to the
STRESS port of the Power pack and the RETURN port of the jack is connected to the
RETURN port of the Power Pack.
Operate both the jacks independently with their respective Power packs for full
extension and retraction, at no load. Repeat this procedure for couple of times to
perform the Air Bleeding operation. After completing the Air Bleeding operation,
extend the Ram of both the jacks by about 100 mm. and tighten the Shut-Off
Valves of both the Power packs to close the hydraulic circuit of both the system.
Insert requisite number of strands (Maximum Capacity of the Jack-Under Test)

through the center hole across the two jacks and lock them with the help of Master
Grips at Rear Anchor Block located at the rear end of the jacks.
SECTION - F
Now the system is ready for starting the calibration process. One unit of Jack and
Power Pack is made ÀCTIVE UNIT’ and the other one is made `PASSIVE UNIT’,
and vise versa.
Load is applied to the ÀCTIVE UNIT’ in small intervals and the pressure gauge
reading is noted. Since both the jacks are connected to each other with the help of
strands, load of ÀCTIVE UNIT’ shall be transferred to the `PASSIVE UNIT’, through
the strands; and hence the pressure gauge of the `PASSIVE UNIT’ will also start
indicating pressure.
Theoretically, the load indicated in the `PASSIVE UNIT’ should be equal to the load
applied on the ÀCTIVE UNIT’, but practically, due to some losses in the system,
caused by the friction or other transmission hindrances, the load indicated in the
`PASSIVE UNIT’ is always less than the ÀCTIVE UNIT’, and this variation in the
load is known as `LOSS OF EFFICIENCY’.
Now apply the pressure to the ÀCTIVE UNIT’ upto 75% of the total cable Load, in
10 intervals, in succession of 50 kg.f/cm². Note down the pressure indicated on the
`PASSIVE UNIT’ and calculate the EFFICIENCY LOSS at each intervals of First
Stage.
In the Second Stage, Process is reversed. The ÀCTIVE UNIT’ is now kept (idle)
closed and made a `PASSIVE UNIT’ and where the pressure is applied to the other
unit. Note down the pressure readings of both the UNITS (reversed) and calculate
the EFFICIENCY LOSS at each intervals of the Second Stage, as described in Para 8.
The average `LOSS OF EFFICIENCY’ is then calculated from the data of the both the
stages, which is denoted as the ÀVERAGE EFFICIENCY LOSS’ of the system.
Deduct this Efficiency Loss from the Ultimate value of 100%, shall compute as Net
Jack Efficiency ()
Refer the standard format, on next page, for calculating the efficiency of the
system.
SECTION - F
EFFICIENCY TEST ON PRESTRESSING JACK
TEST REPORT No. :_________________ DATE :______________
TYPE OF JACK : Multipull Prestressing Jack
MODEL : `FPCC’ K-500 MODEL JACK
JACK Sl. No. : K 500 - 94:X1X1

(Under Test) K 500 - 94:X2X2
POWER PACK Sl. No. : MK-III / 94:Y1Y1

(Under Test) MK-III / 94:Y2Y2
PRESSURE GAUGE No. : AA/BBBB for Powerpack No. - MK-III / 94:Y1Y1

(Under Test) CC/DDDD for Powerpack No. - MK-III / 94:Y2Y2
STRESSING RAM AREA : 765.70 cm2 (As shown in the attached Drawing)
ACTIVE PASSIVE ACTIVE PASSIVE
Sl. Jack No. 94:X1X1 Jack No. 94:X2X2 % Jack No. 94:X2X2 Jack No. 94:X1X1 %
No. Pump No. 94:Y1Y1 Pump No. 94:Y2Y2 LOSS Pump No. 94:Y2Y2 Pump No. 94:Y1Y1 LOSS
Gage No. AA/BBBB Gage No. CC/DDDD Gage No. CC/DDDD Gage No. AA/BBBB
Pressure Applied Pressure Observed Pressure Applied Pressure Observed
1. 50 kg.f/cm2 50 kg.f/cm2
2. 100 kg.f/cm2 100 kg.f/cm2
3. 150 kg.f/cm2 150 kg.f/cm2
2
4. 200 kg.f/cm 200 kg.f/cm2
5. 250 kg.f/cm2 250 kg.f/cm2
6. 300 kg.f/cm2 300 kg.f/cm2
7. 350 kg.f/cm2 350 kg.f/cm2
2
8. 400 kg.f/cm 400 kg.f/cm2
9. 450 kg.f/cm2 450 kg.f/cm2
10. 500 kg.f/cm2 500 kg.f/cm2
Avg. Efficiency Loss in STAGE – I Avg. Efficiency Loss in STAGE – II
( Efficiency Loss in STAGE – I ) + ( Efficiency Loss in STAGE – II )

Avg. Loss of Efficiency =
2
() Net Jack Efficiency = 100% - (Avg. Loss of Efficiency) =
TESTED BY WITNESSED BY APPROVED BY
Sd. Sd. Sd.
SECTION – F
Schematic Layout for ‘Jack Efficiency Test’ is shown here

SECTION – F
GENERAL DESIGN DATA & INFORMATIONS
The data provided in this chapter are in compliance with FIP-CEB code for concrete
structures. For more precise and thorough calculations, the user must refer to the
information bulletins issued by COMITE EURO-INTERNATIONAL DU-BETON and their
appendices or national design codes.
Determination of the final Prestressing force in a tendon must allow for the losses of
tension resulting from the following factors:-
 Losses occurred due to friction of the tendon in its duct
 Losses occurred due to instantaneous deformation of the concrete; resulting
out of non-simultaneous tensioning of several tendons (elastic loss).
 Losses occurred due to Anchorage pull-in.
 Losses occurred due to deferred concrete shrinkage.
 Losses occurred due to creep failure of concrete.
 Losses occurred due to relaxation of Prestressing steel.
In most cases, simply mark the losses at time ‘to’ (start of tensioning) and ‘t∞’ (long
term). But in some particular case of construction, where partial prestressing is
induced initially and the final prestressing is done in phases, consideration must be
given to losses at a given time‘t’.
Appendix (e) of the FIP-CEB code gives instructions for calculation.
1. Losses due to Friction in Duct:

At a point on the tendon distance (x) from the Jacking anchorage, the stress in
the prestressing steel is given by COOLEY’s Law:
- µ ( + Kx)
X = o . e
Where: o - Stress at point of anchorage (x = 0)
µ - Coefficient of Friction of tendon in duct (in Radian-1)
 - Sum of angular deviations over the distance (x) (in Radian)
K - Unwanted angle of deviation from the theoretical profile, expressed

per unit of length (in Radian/meter)
X - Distance from Anchorage to calculation point (in meter)
SECTION – G

Following is a table for µ in the absence of the information relating to the
particular project or to the regulations purposes.
Values of µ (in Radian-1)
Range of Recommended Values
Type of Duct Standard Dry Non- Corroded
values Lubricated Strands
Strands
Passage through
0.40 - 0.60 0.50 -
concrete holes
Non Galvanised
0.20 - 0.30 0.25 0.23
Rigid Pipe
Non Galvanised
0.18 - 0.26 0.22 0.20
Flexible Sheathing
Galvanised Rigid
0.16 - 0.24 0.20 0.18
Pipe
Galvanised Flexible
0.14 - 0.22 0.18 0.16
Sheathing
Greased &
0.05 – 0.15 0.09 0.05
Wrapped Tubing
Wobble coefficient (K) basically depends on the accuracy with which the
theoretical profile is achieved. The accuracy is directly proportional to the
rigidity of the ducts and the simplicity of the tendon profile. The average value
of K can generally be taken as 0.01 rad/m. This figure must be adapted to the
diameter of the ducts, to the distance between their supports and
workmanship.
2. Losses due to Instantaneous Concrete Deformation:

A tendon that is already stressed and anchored in the concrete is affected by
the elastic shortening of the concrete due to the later stressing of other
tendons. The resultant loss in prestressing forces in such cases is very little
and is difficult to calculate. It can be compared to a uniform loss corresponding
to the fraction (n-1)/2n of the total instantaneous deformation of the concrete.
Following formulae give the loss of stress in the prestressing steel:
n-1 ci
∆і = Es. єci єci =
2n Eci
Where: n - Number of tensioning Stages.
єci - Instantaneous strain of concrete due to the total prestressing
forces
Es - Modulus of elasticity of steel (Average Value is 195x109.Pa)
ci - Permanent prestressing force in concrete estimated at centre of
gravity of prestressing tendons (in Pascal).
Eci - Instantaneous longitudinal modulus of elasticity of concrete at
the age, when stressed (in Pascal).
SECTION – G

3. Losses due to Anchorage Pull-in:
During blocking operation of Strands into the anchorages, the jaws move an
average distance (є) given in the table below.
Type of Without Hydraulic With Hydraulic

Anchorage Units Blocking System Blocking System
T 13 7 mm. 5 mm.
T 15 8 mm. 6 mm.
On account of the loss of elongation, the

stress in the tendon at the anchorage drops
from 0 to 1.
Due to reverse friction effects, the length of
tendon affected by this loss is limited to the
distance (a)
It can be assumed in most cases that the loss
due to friction is linear. On this assumption,
the under mentioned formula gives the
distance (a).
Є.Es ∆
a =  ∆ = 2a
∆ 
Where: a - Maximum distance of effect of the anchorage pull-in (in meter).

є - Anchorage pull-in (in meter).
Es - Modulus of elasticity of steel (in Pascal)
∆ - Loss of Prestress by friction over the distance (in Pascal).
4. Losses due to Creep and concrete shrinkage:

It is difficult to resolve this problem precisely and in most cases, approximate
solutions are acceptable. Assuming that deformation and stress are directly
proportional, the formulae below indicate the loss of stress in the steel.
c∞
∆c+s = Es (Є c∞ + Є s∞) Є s∞ = ∞
Ec28
SECTION – G

Where: Є c∞ - Concrete strain due to Creep.
Є s∞ - Concrete strain due to shrinkage.
c∞ - Permanent compression stress in concrete at center of
gravity of the Prestressing Tendons (in Pascal).
∞ - Coefficient of Creep.
Ec28 - Deferred longitudinal modulus of deformation of concrete
at 28 days (in Pascal).
Characteristic Strength of
12 16 20 25 30 35 40 45 50
concrete at 28 days, fck (MPa)
Longitudinal Deformation
26 27.5 29 30.5 32 33.5 35 36 37
Modulus, Ec28 (103 MPa)
U = Perimeter in contact with Humid Atmosphere Dry Atmosphere

Atmosphere (m) Outside Inside
Ac = Section of Concrete (m2) (Rel. Hum. 75%) (Rel. Hum. 55%)
2Ac = Artificial Dimension of the Small Large Small Large

U Structure <0.2 m >0.6 m <0.2 m >0.6 m
COEFFICIENT OF CREEP: ∞
Age of concrete when loaded:
Young (3 – 7 days) 2.7 2.1 3.8 2.9

Middle (7 -60 days) 2.2 1.9 3.0 2.5
Old (> 60 days) 1.4 1.7 1.7 2.0
SHRINKAGE: Єs∞
10-3 10 -3 10-3 10-3
Age of concrete at time to when

effect of shrinkage is considered:
Young (1 – 7 days) 0.26 0.21 0.43 0.31
Middle (7 -60 days) 0.23 0.21 0.32 0.30
Old (> 60 days) 0.16 0.20 0.19 0.28
5. Losses due to Relaxation in Prestressing Steel:

Relaxation is the loss of tension in highly tensioned steel that is maintained at
constant length.
The suppliers give figures for relaxation of the strand (see page 16) after 1000
hours, for 60%, 70% and 80% of the characteristic breaking load. It is
possible to interpolate intermediate values proportionately, with acceptable
accuracy
SECTION – G
The Table below gives a few average figures for relaxation ()of prestressing
strands after 1000 hours:
Values of 
Fraction of Initial Tension 60% 70% 80%
Non Stabilised Strand (%) 4.5 8 12
Stabilised Strands (%) 1 2 4.5
In order to take account of the interaction of losses due to shrinkage and creep
of the concrete and relaxation of steel, a reducing coefficient is simply applied
to the losses due to relaxation alone.
The under mentioned formulae indicates the loss of stress in steel, in simplified
form:
∆c+s
∆ r = o.  1 – 2 --------
o
Where: ∆ r - Effective loss due to relaxation (in Pascal).
o - Initial tension of prestressing tendons at the relevant
point (in Pascal).
 - Nominal relaxation (%)
∆ c+s - Stress losses due to creep and shrinkage already
calculated (in Pascal).
It is possible to approach the problem of interaction between shrinkage, creep

and relaxation more precisely. The reader may refer to the appendix of the
FIP-CEB Code, but the above simplified formula is on the safe side.
The loss at time (t) greater than 1000hours can be calculated from the
following formula:

t
∆r (t) = ∆r (1000th). -------
1000
Where:  - 0.20, failing precise information.
NOTE: Based on the above formulae, some typical calculations are shown, as
example, in the subsequent pages.
SECTION – G
EXAMPLE OF CALCULATIONS:
Assuming a rectangular Beam of size 0.40m X 1.20m, length 34 meters, was
prestressed by 5 parabolic tendons through the beam, from one end to the other.
Parameters:
Angular deviation at anchorages = 9° = 0.157 radian.
Initial stresses = 1330 MPa
Characteristic Concrete Strength fck= 35 MPa
Permanent compression at the Prestressing Level c = 10.5 MPa
1. LOSSES DUE TO FRICTION:

Calculation for the mid-span cross-section at x = 17m., Oil lubricated strand
was used with Non-Galvanised flexible sheathing.
= 0.20 rad.-1 and K = 0.01 rad/m
17 = 1330. e- 0.20 (0.157 + 0.01 x 17)
= 1246 MPa
2. LOSSES DUE TO INSTANTANEOUS DEFORMATION:

Calculation for the mid-span cross-section at x = 17m., Oil lubricated strand
was used with Non-Galvanised flexible sheathing.
Es = 195 x 10 9 Pa
Eci = 33.5 x 109 Pa
10.5
єci = ----- 10 -3 = 0.31 x 10 -3
33.5
5-1
∆r = 195 x 10 9 -------- 0.31 = 2.5 MPa
2x5
3. LOSSES DUE TO ACHORAGE PULL-IN:

Anchorage Pull-in є = 6 mm.
 = 17 - 0 = 1330 – 1246 = 84 MPa
Distance at which loss is nil:
6 x 10-3 x 195 x 109

a= ---------------------- X 17 a = 15.40 meter
84 x 10 6
Initial pressure at mid-span is unaffected by the anchorage pull-in.

Loss at Anchorage 0 = 2 x 15.4 x 84/17 = 152 MPa
SECTION – G
4. LOSSES DUE TO CREEP & SHRINKAGE:
Tensioning after 28 days of concreting

Humid Outside atmosphere
Cross-Section of Beam: A c = 0.4 x 1.2 = 0.48 m2
Perimeter in contact: u = 3.2 m
Coefficient: 2A/u = 0.3

Interpolation between 0.2 and 0.6 for the values ∞, Є s∞
 (0.2) = 2.20
  (0.6) = 1.90
  (0.3) = 2.13
 Є s (0.2) = 0.230 x 10-3

Є s (0.6) = 0.210 x 10-3
Є s (0.3) = 0.225 x 10-3
10.5 x 10 6
Є s∞ = ------------- x 2.13 = 0.67 x 10 -3 Pa
33.5 x 109
c+s = 195 x 109 (0.67 x 10-3 + 0.225 x 10-3)

c+s = 174.5 MPa
5. LOSSES DUE TO RELAXATION OF PRESTRESSING STEEL:

Nominal Stress k = 1770MPa
Initial Stresses x = 0
 0 = 75% of  k = 1330 MPa
Initial Stresses x = 17
 17 = 70% of  k = 1240 MPa
Stabilised strands relaxation at 1000 hrs. = 2%
174.5
 r (1000h) = 1246 x0.02 (1 – 2 x -------)
1246
r (1000h) = 18 MPa
Loss at 10 5 hours (about 12 Years)
0.2
105
 r (105 h) = 18 x ----- = 45 MPa
10 3
6. FINAL STRESSES AT MIDSPAN:
17.∞ = (1246 - 2.5 – 174.5 – 45) MPa = 1024 MPa
SECTION – G
CHECKLIST FOR INSPECTION OF POST-TENSIONING OPERATION
AT MATERIAL MANUFACTURING STAGE:
For BONDED TENDONS For UN-BONDED TENDONS
Are the Anchor Plate (Bearing Plate) Are the Grips of Dead End Anchorage;
properly machined, cleaned and seating evenly and adequately on the
protected from corrosion? Anchor Plate?
Are the Grips free from Corrosion? Are Is excessive sheathing/duct stripped &
the Back relief provided uniformly? trimmed at Dead End (Fix) Anchorage?
Are the Grips of uniform length and Is the plastic sheathing of sufficient
serrations of consistent quality? and uniform thickness?
Are the ducts manufactured from Is the quality & texture of the filling
quality steel strip and specified strip grease is consistent?
thickness?
Are the Seam Joints intact, watertight Is the grease applied evenly all over
& uniform? and packed?
Does the bare prestressing steels Does the strand appear to be new and
appear to be new and are free from free from corrosion, when sheathing &
corrosion? grease are removed?
Are they adequately protected in Are the Anchors properly machined

store? with smooth Taper Holes for Grips?
Are the Anchors properly machined Are the Grips of uniform length and
with smooth Taper Holes for Grips? serrations of consistent quality?
- Are the Grips free from Corrosion?

Are the Back relief provided
uniformly?
Are all Test Reports and Certificate Are all Test Reports and Certificate
available for the Prestressing Steel available for the Prestressing Steel
and all the components of Anchorage, and all the components of Anchorage,
as required by the specification as required by the specification
SECTION – H
AT TENDON INSTALLATION STAGE:
Are the high & low points of the Are the high & low points of the
Sheathing duct at the correct Tendons, at the correct elevation?
elevation?
Are duct profiles smooth and correctly Are the tendon profiles smooth and
shaped (parabolic, circular or straight) correctly shaped (parabolic, circular or
between reference points? straight) between reference points?
Are all duct joints properly matched Do the tendons have excessive
and sealed with adhesive tape? horizontal wobble?
Are there any holes in the entire Are there any holes in the entire
length of the duct, and if so, have they length of the sheathing, and if so,
been repaired to prevent concrete have they been repaired?
ingress?
Are there any kinks in the entire Does the chairs or Support-bar
length of the duct, which may prevent system are adequate and confirm to
the installation of prestressing steel? the design requirement?
Is the Cable Supports are adequately Are the Stressing Anchors secured
tied to prevent displacement or and fastened with the appropriate
floating of the duct during concreting? pocket former?
Are the Guides firmly secured and Is bursting reinforcement installed

fastened with the End Block behind the anchorages are adequate
shuttering? and satisfying the design requirement?
Is bursting reinforcement installed -

behind the anchorages are adequate
and satisfying the design requirement?
Has the method of concrete placement Has the method of concrete

been reviewed as to its effect on duct placement been reviewed as to its
stability during placement? effect on duct stability during
placement?
Has the conventional steels placement Has the conventional steels placement
been reviewed? been reviewed?
SECTION – H

AT TENDON STRESSING STAGE:
Are the Bearing Plates holes & Grips, Are the Stressing Anchors holes &
free from rust dirt and grease? Grips, free from rust dirt and foreign
If not, clean them. particle? If not, clean them.
Has the elongation datum been Has a consistent dimension been used,
marked for the initial and final as the elongation datum mark on the
reading? Are they logically and clearly strand?
located?
Is the stressing equipments well Is the stressing equipments well

maintained, and are all the calibration maintained, and are all the calibration
charts & reports available? charts & reports available?
Is the Operating Technician, trained Are the tendons stressed slowly

and careful enough about the enough to allow the strands to
equipment and consistent from tendon overcome as much friction as possible
to tendons? prior to locking?
Are the Bearing Plate and Grips Are Grips seated evenly, properly
seating properly after stressing? under pressure?
After elongation approval, is the After elongation approval, is the

tendon tails properly cut well inside tendon tails properly cleaned and
and cleaned to fix Grout Cap for greased well inside & secured with
grouting? Grout Cap?
Are the stressing pockets properly -

cleaned and prepared to allow good
grout bond during and after patching?
SECTION – H
SAFETY PRECAUTION DURING POST-TENSIONING OPERATION
During Prestressing operation, a huge forces are been induced into the tendons by
the Jacking Equipments. These jacking equipments are working under tremendous
hydraulic pressure, and thus a careful and competent workmanship can avoid
accidents and damage to the equipment.
Some essential precautions are being listed here, to be adhered to:
 Stressing operation should be carried out by the trained and experienced

personnel, under a competent engineer or supervisor.
 The equipments, especially the high pressure hose pipes, and the end
fittings should be in perfect conditions. Damaged hose pipes must be
replaced immediately. Any lack of decision in this regard may cause a serious
accident.
 Protection caps must be placed over the Hose pipes nipples and the end
fittings of the equipments. Always avoid putting the gausses or cotton waste
into the nipple hole, as this may cause a severe ingress of dust & dirt into the
hydraulic system.
 Jacking equipments and power-packs shall never be lifted, using hose pipes
as a lifting devise.
 Stressing shall be done according to the specified data provided by the

designer. In no case the pressure should be exceeded beyond 5% of the
allowable limit.
 During stressing, nobody should be allowed to stand behind or underneath

the Jacking unit, since failure of a tendon can cause a sever injuries or even
death.
 In the stressing site; which are close to public traffic areas, A strong
protective shield should be erected and the jack must be secured by ropes or
chain pulley block to prevent failed strands from shooting out.
SECTION – H
 The Prestressing steel (i.e. bars, wires or strands) should be stored carefully
to ensure that they are not damaged in any way and should be checked for
rust or corrosion before use.
 Care should be taken while handling and unwinding of prestressing steel

coils, as they may ‘whip-back’ with force, if not securely bound.
 All the technicians should wear hand gloves and other safety harnesses while
working at overhanging/raised stressing platform. Technicians are prone to
fall down from a height in such cases.
 Ensure that unauthorized people should not gather in and around Stressing
Site as sight seeing location. Erect a safety warning sign around.
 Wear safety helmets at site during stressing operation.
 Do not permit welding operation near H.T. Prestressing steel. Molten sparks
arises from welding, if falls on the tendons, will change its mechanical
properties and promotes the possibilities of premature failure. The damages
caused by inadvertent heating, from welding, may not be detectable by
visual inspection.
 Do not use Acetylene gas Torch heating apparatus to cut or trim the strand
before stressing. Only abrasive cutting wheels should be used.
 Prestressing steel should not be used for providing earthing to the electrically
operated equipments. An electric spark, when jumps through the
prestressing steel, may effect or alter the molecular structure and a loss of
strength may occur.
 Lightening conductors should be routed clear of tendons and the Anchorages

etc.
SECTION – H

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THE FREYSSINET PRESTRESSED CONCRETE CO. LTD.

6B, 6th Floor, Sterling Center, Dr. Annie Besant Road,

The Prestressing counteracts the stresses, produced by subsequent loading on the

APPLICATION AND USE OF PRESTRESSING

In building structure also, prestressing method is very effectively used to achieve

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Pre-Tensioning - is a method where Prestressing Steels are pre-stressed, prior to

Post-Tensioning - is a method where Prestressing Steels are stressed after

WIRES STRAND BONDED UNBONDED

WIRES, BARS WIRES STRANDS

USERS OF THE MANUAL

FPCC SYSTEM OF PRESTRESSING

FPCC Anchorages, an important component of Tendon, cater to a wide range of

Anchorages are categorised in two types, given as under:-

Multi-Strand Anchorages are recommended for Prestressing of concrete structures

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A few of them are as listed below:

Indented Wire 4 mm. - 7 mm. 23 kN - 61 kN

Strands - 3Ply 3.0mm. x 3 Wire 38.25 kN

Threaded Bar 20 mm. - 40

High strength prestressing steels requires careful handling during transportation

b. Bearing Plate - This is cylindrical round shaped component made out of

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BLIND END ANCHORAGES:

A. Metallic Ducts: Metallic Sheathing ducts are manufactured, by rolling CRCA

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Examples shown above are two typical arrangements of Tendon Supports:

PROPER CARE TO BE TAKEN FOR INSTALLING TENDON SUPPORT:

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THE ANCHORAGES: The term Anchorage is referred to the assembly of three

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The reinforcement of the anchorage zones basically provides “Bursting

This type of reinforcement must be adapted to particular cases whenever there is a

GRID TYPE REINFORCEMENT SPIRAL REINFORCEMENT

7 K 13 4 K 15 6 10 80 100 350 260 6 10 200 50 300

12 K 13 7 K 15 6 12 100 120 420 312 6 12 280 50 300

19 K 13 12 K 15 6 14 120 150 500 374 6 14 360 60 360

27 K 13 19 K 15 6 16 150 170 570 426 6 16 440 65 390

37 K 13 27 K 15 2X6 14 180 210 560 434 7 18 540 70 490

55 K 13 37 K 15 2X6 16 200 240 640 496 8 20 640 70 560

In one type of Blind end

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Example of Elongation Curves

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Engineers should of course refer to the specific manufacture’s characteristics (e.g. –

CABLE FORCES (in kN)

EURONORM 138 - 6/79 A.S.T.M. – A 416/80

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The Pumping unit used in these power packs is of

The power pack also houses suitable D. C. Valve,

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GROUT MIXER & AGITATOR:

It is a combination of two circular

AGITATOR Model J-700:

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The Salient features of this pump are:

GROUT PUMP - Model P-2001:

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