Lecture 2 Materials and Methods 2

MATERIALS FOR
PRESTRESSED
CONCRETE
OUTLINE
High strength concrete High tensile steel

• Higher strength is necessary for
prestressed concrete for following
reasons:
HIGH • Anchorages for prestressing steel
always designed on the basis of
STRENGTH high strength concrete.
CONCRETE • High strength concrete offers
high resistance in tension and
shear ,as well as bond and
bearing.
• High strength concrete is lees
liable to the shrinkage cracks.
• It also has a higher modulus of
elasticity and smaller creep
HIGH strain ,resulting in smaller loss of
STRENGTH prestress.
CONCRETE • By using high strength concrete
the c/s area required for
member will be reduced
resulting less dead weight
moment.
• Cold working: rolling the bars
through a series of dyes.
• Stress relieving: heating the strand
to about 350°C and cooling slowly.
HIGH Improves plastic deformation of
STRENGTH steel
STEEL • Strain tempering for low relaxation:
heating the strand to about 350°C
while it is under tension .Improves
the stress-strain behaviour of steel .
Also the relaxation is reduced.
PROPERTIES OF PRESTRESSING
STEEL
High Adequate
Bendability
Strength Ductility
Low Minimum
High Bond
Relaxation Corrosion
SYSTEMS OF
PRESTRESSING
Systems in pre-
tensioning
OUTLINE
Systems in
post-tensioning
• As system of prestressing
involves the process of
tensioning the tendons and
SYSTEMS OF securing them firmly to the
concrete.
PRESTRESSING
Pre- tensioning
• Hoyer long line system
Magnel
Freyssinet
balton
system
system
Gifford - P.S.C mono

Udall system wire system
POST-
TENSIONING
Lee-mc-call Electrical
system prestressing
Chemical
prestressing
The Hoyer system is usually
adopted for the production of
pre –tensioned members on a
large scale.
HOYER It consists of stretching wires

between two abutments at a
LONG LINE large distance apart.
SYSTEM
With this Hoyers process,
several members can be
produced along one line, by
providing suitable shuttering.
HOYER LONG • After concrete has hardened ,the wires are
released from abutment
LINE SYSTEM • The prestress is transferred to the concrete
through bond between the tendons and the
concrete
Freyssinet system was first to
be introduced among the
post –tensioning systems.
Anchor element consisting in

FREYSSINET two parts, cylindrical piece
SYSTEM with tapered hole (sleeve)and
a cone(wedge).
The cylindrical piece is a

helically reinforced concrete
unit cast with M60 concrete.
• The tapered hole in the cylindrical piece is
lined with closely wound helix of 2.5mmǿ
steel wires of strength of 200𝑁/𝑚𝑚2 is that it
should be stronger than the wires pulled
FREYSSINET through the cone.
SYSTEM • The cone is made with M100 concrete
• A small tube is inserted inside the cone to

facilitate grouting.
• The surface of the cone is grooved with
grooves depending on the number of
wires to be stretched.
• As the wires are stretched and stressed
FREYSSINET ,released, cone slips in to the sleeves.
• The space between the wires will be filled
SYSTEM with the grout.
• This provides additional restraint against
the slipping of the tendons.
• Normally Freyssinet system is used for
pulling 5mm wires 12 to18Nos.
• The wires are arranged with four wires per
layer.
• The wires in the same layer and the wires in

adjacent layers are separated with a
MAGNEL clearance of 4mm spacers.
BALTON • The wires are anchored by wedging two

SYSTEM at a time in to sandwich plates.
• The sandwich plates are about 25mm thick

and are provided with two wedge-shaped
grooves on its two faces.
• The wires are taken two in each groove
and tightened.
• Then a steel wedge is driven between the

tightened wires to anchor them against
MAGNEL the plate.
BALTON • A complete anchorage unit may consists

SYSTEM of one to eight sandwich plates.
• Each plate can anchor eight wires.
• Two wires are tensioned at a time

MAGNEL BALTON SYSTEM
• Gifford Udall system is another wedge system.
• Small wedge is slit in to 2 units and the cut

pieces have teeth on the inner face.
GIFFORD
UDALL SYSTEM • The wires are stressed and anchored one by
one in a separate cylinder using small wedging
(METHOD-1) grips.
• Theses wedge grips are called Udall grips.

Gifford Udall System(method-2)
• Tube anchorage consists of a bearing plate, anchor
wedges and anchor grips.
• Anchor plate may be square or circular and have 8 or 12

tapered holes to accommodate the individual prestressing
wires.
• These wires are locked into the tapered holes by means of

anchor wedges.
• In addition, grout entry hole is also provided in
the bearing plate for grouting.
GIFFORD • Anchor wedges are split cone wedges carrying

wires on its flat surface.
UDALL SYSTEM
• There is a tube unit which is a fabricated steel
component incorporating a thrust plate, a steel
tube with a surrounding helix.
• This method is used to prestress steel bars.
• The diameter of the bar is between 12 and

LEE MC CALL 28mm. bars provided with threads at the
SYSTEM ends are inserted in the performed ducts.
• After stretching the bars to the required

length, they are tightened using nuts
against bearing plates provided at the end
sections of the member
• Wires are tensioned individually
• The anchorage consists of a single piece

collect sleeve wedging in a conical hole
P.S.C
MONOWIRE • A steel truncated guide leads each wire
SYSTEM from the cable to the anchorage point
along a gentle curvature
• In addition to the guide a central block is

also provided to anchor the central wires.
• in this method, reinforcing bars is coated with
thermoplastic material such as sulphur or low
melting alloy and buried in the concrete.
• After the concrete is set, electric current of low

voltage but high amperage is passed through
the bar.
ELECTRICAL
• Electric current heats the bar and the bar
PRESTRESSING elongates. Bars provided with threads at the
other end are tightened against heavy
washers, after required elongation is obtained.
• When the bar cools, prestress develops and the

bond is restored by resolidification of the
coating.
• Chemical prestressing is done using
expanding cement. Prestressing can be
applied embedding steel in concrete
made of expanding cement.
• Steel is elongated by the expansion of the

concrete and thus gets prestressed.
• Steel in turn produces compressive stress in

concrete.
CHEMICAL
PRESTRESSING

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MATERIALS FOR

High strength concrete High tensile steel

Gifford - P.S.C mono

HOYER It consists of stretching wires

Anchor element consisting in

The cylindrical piece is a

SYSTEM • The cone is made with M100 concrete

• A small tube is inserted inside the cone to

• The wires in the same layer and the wires in

BALTON • The wires are anchored by wedging two

• The sandwich plates are about 25mm thick

• Then a steel wedge is driven between the

BALTON • A complete anchorage unit may consists

• Each plate can anchor eight wires.

• Two wires are tensioned at a time

• Small wedge is slit in to 2 units and the cut

• Theses wedge grips are called Udall grips.

• Anchor plate may be square or circular and have 8 or 12

• These wires are locked into the tapered holes by means of

GIFFORD • Anchor wedges are split cone wedges carrying

• The diameter of the bar is between 12 and

• After stretching the bars to the required

• The anchorage consists of a single piece

• In addition to the guide a central block is

• After the concrete is set, electric current of low

• When the bar cools, prestress develops and the

• Steel is elongated by the expansion of the

• Steel in turn produces compressive stress in

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