CLASSIFICATION OF PRESTRESSED CONCRETE MEMBERS

There are many ways of classifying prestressed concrete members based on the method of design, construction and application of prestresses. A. EXTERNAL AND INTERNALY PRESTRESSED MEMBERS In this type of prestressing the members can be prestressed by two ways: 1. External Prestressing: In this method the member is prestressed by external reaction offered by rigid abutments. In this instead of providing a tendon from which the prestress can be applied, the necessary prestressing force can be applied by compressing the member by ac!ing against abutments. " sliding surface may be provided underneath the beam. "fter the prestressing is over, the space between the end of the beam and the abutment may be pac!ed with concrete and the ac! recovered. This method is difficult to rely as prestress transferred to the member is li!ely to be lost due to any possible outward displacements of the abutments. "lso shrin!age and creep of concrete are li!ely to affect the initially applied prestress. Even slight vertical deformations of the supports will disturb the stresses seriously.

#. LINEAR OR CIRCULAR PRESTRESSING. The term circular prestressing is applied to prestressing circular structures li!e cylindrical tan!s, silos and pipes. In this case, the tendons are provided in the form of rings. $inear prestressing is a term applied to prestressing straight members li!e beams and slabs. C. PRE-TENSIONING AND POST TENSIONING 1. Pre-tensioned e !ers

In these, the tendons are tensioned even before casting the concrete. %ne end of the reinforcement (i.e. tendon& is secured to an abutment while the other end of the reinforcement is pulled by using a ac! and

this end is then fixed to another abutment. The concrete is now poured. "fter the concrete has cured and hardened, the ends of the reinforcement are released from the abatements. The reinforcement which tends to resume its original length will compress the concrete surrounding it by bond action. The prestress is thus transmitted to concrete entirely by the action of bond between the reinforcement and the surrounding concrete.

". tensioned e !er

PostIt is one in which the reinforcement is tensioned after the concrete has fully hardened. The beam is first cast leaving ducts for placing the tendons. The ducts are made in a number of ways ' by leaving corrugated steel tube in the concrete, by providing steel spirals, sheet metal tubing, rubber have or any other duct forming unit in the form wor!. (hen the concrete has hardened and developed its strength, the tendon is passed through the duct. %ne end is provided with an anchor and is fixed to one end of the member. )ow, the other end of the tendon is pulled by a ac! which is butting against the end of the member. The ac! simultaneously pulls the tendon al1d compresses the concrete. "fter the tendon is sub ected to the desired stress, the end of the tendon is also properly anchored to the concrete. To avoid crushing of concrete due to excessive bearing stress, a distribution plate is provided at each end.

SYSTEMS OF PRESTRESSING
" system of prestressing means the actual process adopted in ma!ing a prestressed beam. " system of prestressing involves the process of tensioning the tendons and securing them firmly to the concrete. *ome of the systems commonly followed are described below:

A. Pre-tensionin# s$ste
The simplest method of ma!ing a pre'tensioned member is to pull the tendon between abutments or bul!heads which are secured or anchored firmly against the ends of the stressing bed. The tendons are cut off at each end after the concrete hardens. )ow the prestress is transferred to the concrete. The bul!head at the ends and the bed should be designed to resist the prestress and the eccentricity. %OYER SYSTEM The +oyer system is usually adopted for the production of pre'tensioned members on a large scale. This method consists of first stretching the wires between two bul!heads at a large distance apart. The concrete is now poured so that a number of beams can be produced in one line, by providing suitable shuttering between them. "fter the concrete has hardened, the wires are released from the bul!heads. The wires between the different units in one line of beams will also be cut off. The prestress is transferred to the concrete through bond between the tendons and the concrete. There are similar systems based on the above principle. These systems are put to use for usually precast beams. Pre' tensioning system was widely used in earlier days but has since been replaced by post tensioning system. Pre' tensioning system is found uneconomical for large spans. In order to grip the pre' tensioned wires properly to the bul!head the devices shown are followed.

B. Post-tensionin# s$ste
The basic principle in all post'tensioning systems is to introduce prestresses in the concrete member cast previously by tightening the tendons accommodated in the ducts which are formed while casting the beam. "s the tendons are pulled using a ac! against the end of the concrete member, the desired prestressing force is obtained. "fter the wires are pulled, they are anchored in their stretched position against the end of the concrete member by a suitable wedging device. The various systems followed differ in the arrangement of wires, in the process of ac!ing and in the anchorage devices. In order to ensure the correct prestress in the reinforcement, it is preferable to measure the load applied by the ac! as well as the conse,uent extension of the reinforcement. Extension measurements give an idea as to how much of the steel is being properly stretched. -or instance the sides of the ducts may obstruct the stretching of the reinforcement particularly at the end remote from the ac! and this part of the reinforcement may not receive the full tension. This defect is liable to occur when curved cables are provided %n the other hand. it may be possible that the extension might have ta!en place due to a certain part of the tendon being overstressed. -or this reason, it is necessary to measure the prestressing force applied. Excessive bearing stresses will be produced at the ends of the members due to the anchoring devices which bear against the concrete. In this part of the member it will be necessary to provide additional reinforcement to prevent local splitting and failure by shear.

S&it'!i(it$ o) t*e s$ste

Pre'tensioning and post tensioning are the only practically adopted methods of ma!ing prestressed concrete members. It is worthy to note that these methods have their own applications in practice. In pre'tensioning, the compressive force in concrete is due to the bond between concrete and the steel wires, which are !ept stretched between buttresses. This method is economically adopted in mass production in

factories which ma!e concrete products of limited si/e. This is so because, handling as well a transporting large products are highly expensive and may be practically impossible, if thee members are too large. The length of a prestressed concrete product that can be economically made by this method may not exceed 01 m. Even this length involves considerable difficulty in transport. In post tensioning, the prestressing wires are stretched after the hardening of concrete. This can be done by many ways li!e the following: (a) The cables may be accommodated inside sheaths before placing of the concrete. (b) The beam is cast with longitudinal holes so that the cables may be placed in them after the concrete is hardened. (c) "n I 'beam may first be made and cables may now be placed on each side of the web after the concrete is hardened. These methods can be adopted in sites or on the ground, and later hoisted into position. -or instance, if timber is costly or scarce it may be economical to ma!e the member on the ground in steel moulds. " number of systems are available each protected by patent rights. These systems are adapted for linear prestressing and with some modification for circular prestressing also. *ome of the commonly followed systems of post tensioning are described below.

S$ste s o) +ost- tensionin# A. T%E FREYSS(NET SYSTEM

The -reyssinet system was the first to be introduced among the post tensioning systems. +igh tension steel wires 2 3un to 4 mm diameter about 10 in number are arranged to form a group into a cable with a spiral spring inside. The spiral spring provides the means for a proper clearance between the wires and thus provides a channel which can be cement grouted. It further assists to transfer the reaction to concrete. The whole thing is enclosed in thin metal steel.

The anchorage consists of a cylinder of ordinary good ,uality concrete and is provided with corrugations on the outside. It has a central conical hole and is provided with heavy hoop reinforcement. These cylinders are !ept in the proper position and the conical plugs are pushed into the conical holes after cables are tightened. The central hole passing axially through the plug permits cement grout to be in ected through it. In this way the space between the wires will be filled with the grout. This provides additional restraint against the slipping of the tendons. "dvantage of the system (i) *ecuring the wires is not expensive. (ii) The desired stretching force is obtained ,uic!ly. (iii) The plugs may be left in the concrete and they do not pro ect beyond the ends of the member. 5isadvantage of the system (i) "ll the wires of a cable are stretched together. +ence the stresses in the wires may not be exactly the same. (ii) The greatest stretching force applied to a cable is from 021 KN to 211 kN. This may not be sufficient. (iii) The ac!s used are heavy and expensive. B. T%E MAGNEL BLATON SYSTEM In this system a cable of rectangular section is provided, which contains layers of wires 2 mm to 8mm diameter. The wires are arranged with four wires per layer 6up to sixteen layers deep for a cable of sixty four wires&. The wires in the same layer and the wires in ad acent layers are separated with a clearance of 4mm.The geometric pattern of the wires is maintained in the same form throughout the length of the cable by providing grills or spacers at regular intervals. The grills do not offer any appreciable frictional resistance to the wires which can be moved relative to each other during the tensioning process.

The wires are anchored by wedging, two at a time into sandwich plates. The sandwich plates are about 02 mm thic! and are provided with two wedge'shaped grooves on its two faces. The wires are ta!en two in each groove and tightened. Then a steel wedge is driven between the tightened wires to anchor them against the plate. " complete anchorage unit may consist of one to eight sandwich plates, the number of wires depending on the number of wires in the cable. Each plate can anchor eight wires. The various sandwich plates forming a unit are arranged one above the other against a distribution plate. The wires are tightened by ac!ing two wires at a time.

GIFFORD UDALL SYSTEM

This method offers the following three methods of prestressing: First et*od This is earliest of the three methods of this system. In this method the wires are stressed and anchored one by one in a separate cylinder using small wedging grips called udall grips. Each grip consists of two'half cones. The bearing plate bears against a thrust ring which is cast into the concrete. The duct end is encircled by a helix. "nchorages are supplied to suit cables of 0, 7, 8 and 10 wires. Se,ond et*od

In this method, the wires are anchored by wedges which fit directly into tapered recesses made in the bearing plate. The bearing plate bears against a tube unit containing the tube unit and the helix. This tube unit is cast into the concrete. "nchorages are supplied for cables of 4 to 10 wires. This arrangement is compact and minimi/es the congestion of the steel wires in anchor bloc!. T*ird et*od In this method a tendon of 04 mm diameter +. T. type is used. This needs a duct of only 71 mm diameter. This tendon is stronger than 8 mm wires. The anchoring is done by 91 mm diameter grip with a three segments interloc!ing wedge. This method uses a barrel which bears directly against a tube unit which is cast into concrete.

P.S.C. MONO-IRE SYSTEM

In this system also the wires are tensioned individually. The anchorage consists of a single piece collet sleeve wedging in a concial hole. " steel truncated guide leads each wire from the cable to the anchorage point along a gentle curvature. In addition to the guide a central bloc! is also provided to anchor the central wires.

Monowire System

C.C.L. STANDARD SYSTEM

This is anchor system where the wires are tensioned individually. As many wires as may be required (not exceeding 12) are used in a circular cable. The size of the duct de ends on the number of wires ! "# mm diameter for $ wire!cables and %# mm diameter for 12!wire cables. At intervals of &## mm s acers are rovided to 'ee the wires se arated and to revent the outer wires from touching the sheathing. This not only reduces the friction but also allows satisfactory grouting. A s ecial (.(.). anchor gri is used to anchor each wire se arately. The anchor gri consists of steel wedges which fit over the wire and are accommodated in a steel barrel having a ta ered hole.

The barrels are 2# mm diameter arid 2% mm long. The wedges are made either in two ieces or " segments held together by a steel circli to form unit. These units bear against a drilled anchor late through which the wires are assed. The anchor late bears against a thrust ring which is cast into the concrete. The thrust ring is of mild steel & mm thic' and is made rectangular with a central rectangular hole. To revent local bursting effect a helix is rovided behind the thrust ring. A vertical mesh is also rovided behind the helix. The bearing late is 1$ mm thic' and has * mm diameter holes rovided at a s acing of 2% mm centers is arallel rows to accommodate the wires.

LEE-MCCALL SYSTEM
This is a system in which high tensile alloy steel bars (silicomanganese steel) are used as the restressing tendons. These bars are rovided in 22 mm, 2% mm, 2$ mm and +# mm diameter and in lengths u to 2# metres. The anchoring of the bars is done by screwing s ecial threaded nuts. The nuts bear against a distribution late rovided at the end of the beam.

ELECTRICAL PRESTRESSING
This is a method of ost tensioning without the use of ,ac's. According to the method introduced by Bi11ner and Carlson, steel bars are rovided with a coating of su- hur. before they are embedded in concrete. After the hardening of concrete electric current of low voltage and high am erage is used to heat the bars to a tem erature of 1/## (. As the bars ex and longitudinally. the nuts on the ro,ecting ends are tightened against heavy washers. As the tem erature falls. the restress is develo ed in the bars and the bond is again restored by the resolidification of the sul hur coating.

PREFIX BEAM
This is yet another method of restressing beams. A steel ,oist is tem orarily sub,ected to bending and the bottom flange of the ,oist is encased in concrete. After the concrete has hardened. the load roducing the bending of the beam is removed. As the ,oist recovers bac' to its initial osition the concrete gets com ressed. Though this is also a wor'able method of restressing it may!be noted that the ,oist rovides a much smaller tensile resistance than the high tension steel wires.