PSC

PRE STRESSED CONCRETE STRUCTURES
SHAIK BADEMIYA
Structural Design Engineer
+91-99080 16786
Overview
What is PSC
Application of Prestressing
RCC & PSC
Stressing and Grouting Materials
Procedure
Comparison RCC & PSC
Observations
The need for PSC Structure
Is there a possibility to counteract the vertical forces ?

Prestressing helps in counteracting the vertical forces. How?
PRESTRESSED CONCRETE
It involves inducing high compressive forces to the structure/section so that

the load carrying capacity of the structure/section is enormously
increased and the external loads are counter acted to a desired extent
Earlier attempts
1) Force fitting of metal bands on wooden barrels
The metal bands around the barrel induce a state of initial hoop
compression to counteract the hoop tension caused by filling of liquid in
the barrels
Figure shows the wooden barrels
wounded with steel metal bands
Earlier attempts
2) Pre-tensioning of spokes in a bicycle wheel. The pre-tension is
applied in the spoke to such an extent that there will always be

a residual tension in the spoke
Fig: spokes of a bicycle wheel in pretension
Earlier attempts
The concept of Prestressed concrete is also not new. In 1886, a patent was
granted for tightening steel tie rods in concrete blocks. This is analogous to
modern day segmental constructions.
Early attempts were not very successful due to low strength of steel at
that time.
Since we cannot prestress at high stress level, the prestress losses
due to creep and shrinkage of concrete quickly reduce the effectiveness
of Prestressing.
Applications of PSC In Bridges
Superstructure
Girder
Slab
Applications of PSC In Bridges
Sub-structure
Precast
PSC piles
Precast PSC piers
Applications of PSC In Other structures
Buildings
Slab
Portal
frame
Railways
Sleepers
Difference between RCC & PSC
RCC
Concrete
is good in compression and Steel is good in Tension

Tensile strength of concrete is neglected.
The failure strain of concrete is so low that the reinforcement has to hold the
cracked sections together
When the concrete cracks the strains are transferred to steel
In order to avoid failure, the stress in the steel is to be limited
Steel acts as a tension flange in RCC structures

Steel plays passive role in RCC
Difference between RCC & PSC
PSC
Steel
is primarily used for inducing Prestressing forces

There is no need to limit the stress in steel in order to control the cracking of
concrete
The whole section will be under compression even under service condition
and so there is lesser possibility of developing a crack in PSC structure
Hogging can be observed in the structure after the prestress forces applied
Steel plays a active role in PSC
ADVANTAGES OF PSC
The cross section is fully used in case of Prestressed members

Dead loads are reduced considerably
Have high shear resistance when compared with RCC members
Low shrinkage
Low creep and permeability
Deflections are less and so more stiffer
More resistance to impact and vibration
Types of Prestressing
Types of Prestress
PRE-TENSION
INTERNAL
POST- TENSION
EXTERNAL
Prestressing system
Pre-Tensioning
Tendons
are stressed before the concreting is done

Tendons are stressed singly or in groups and are generally anchored to the
abutments by steel wedges
Bond is the main factor in transfer of stress to concrete
Ex : Hoyers Long line process
Generally employed in case of mass production
Pre-Tensioning
Pre-Tensioning
Casting of Railway sleepers
Curing of Railway sleepers after strands are cut
Prestressing Systems
Post-Tensioning
Tendons
are stressed after concrete achieving sufficient strength to withstand

the stresses
End bearing is the main factor for stress transfer
Space between the tendons are grouted 24hrs after stressing
Ex: Freyssinet System , Magnel System , Gifford Udall System
Used in case of long span bridges
Post-Tensioning
Concreting Done
Stressing
Grouting
Post-tensioning
First stage stressing
MATERIALS USED IN PSC
High strength concrete

HTS (High Tensile Steel ) strands
HDPE(High Density Polyethylene) Duct
In both RCC and PSC we use only two materials i.e. concrete and steel
but their structural behavior is quite different
Forms of Prestressing steel
Wires
Prestressing
wire is a single unit made of steel
Strands
Two,
three, seven wires are wound together to form
a prestressing strand
Forms of Prestressing steel
Tendon
A
group of strands or wires are wound to
form a prestressing tendon
Cable
A
group of tendons form a prestressing cable
Bars
A
tendon can be made of single steel bar.

The diameter of bar is much larger than that of wire
Post-tensioning materials
Wedges
Anchor cone
Bearing Plate
Stressing operation
Stressing Operation
Pre Tensioning/Post tensioning bed
Hydraulic Jacks
Hydraulic pump
LRPC strands Low Relaxation Prestressing Cables
Anchorages
Anchor
cone
Bearing plate
Wedges
Stressing equipment
Stressing jack
Bearing plate assembly
Stressing materials
Different types of HTS Strands

Corrugated HDPE Ducts
Grouting
Grouting Operation
Grout cap
Grout agitator
Grout pump
Cement bags
Admixture- Cebex 100
Ice cubes
Grouting Equipment
Grout pump
Grout Cap
Grout Agitator
RCC & PSC Comparison
Concrete calculation
Steel calculation
PSC material cost estimation
Time estimation
PSC & RCC Comparison

Design Details
Comparative statement between PSC & RCC I Girder

length of girder =
Description
PSC Girder
25.573 m
PSC Girder
Quantity
rate
1 Concrete quantity
22.3508 cu.m
2 Additional steel
reinforcement in RCC
girder
3 Cable strands psc girder 40 nos
Savings/exc
ess
RCC Girder
Quantity
4500
130
100579
rate
27.2866 cu.m
4300
117332
16753
3231.00
55 kg/m3
177705
0
177705
-146544
47915
146544
S.No PSC Girders

1
2
Casting bed is required for 7 days

Uncracked section design- so
highly durable, and less
maintenance
Bending Moment due to
Self weight of Girder

1472
1674*
Self weight of Deck slab
1569
1569
shuttering load
245
SIDL
1279
1279
Live Load
2927
2927
*- Due to increase in cross section
The BM are taken from DN 705, vide Page no 11
For the same BM design for RCC Girder sheets are attache
Additional steel Quantity

In PSC Girder
(-)8x 25.573x3.14x10^2/4x7850/10^6
Comparison
RCC Girder
-126.06977
RCC girders
Casting bed is required for 14 days
RCC section is cracked one and may
require periodical surface painting, being
near to seashore
In RCC Girder( design steel at bottom face is 22 nos of 32

8x26x3.14x.032^2/4x7850
1312.5099
8x24x3.14x.032^2/4x7851
1211.5476
6x22x3.14x.032^2/4x7852
832.9390
32
Slab hogging
I GIRDER CASTING AT SITE
SHAIK BADEMIYA
Structural Design Engineer
+91-99080 16786
Procedure Casting of Girder
Understanding the drawing

The
first and foremost thing in any construction activity is to understand

deeply the working drawings related to that particular structure/section.
Identifying different silent features present in the drawings and have to be
ready with them
Identifying the grade of steel and concrete to be used for that structure
Preparation of Bar Bending Schedule
Constructing reinforcement cage as per BBS and drawing.
Step by step process of casting girder
Reinforcement cage preparation

Alignment of end shuttering plate
Spiral reinforcement
Shuttering on one side
Cable profiling
Shuttering complete with shutter vibrators and dummy pipes
Concreting
Casting bed prepartion
Reinforcement cage
Profiling & Shuttering
Casting of I Girder
Concrete cubes for strength assessment
Stressing & Grouting
Stressing and Grouting
Girder erection
Pre requisites
For starting the Prestressing operation we need to careful about some

design principles
Concrete
strength achieved
What type of stressing i.e. one end stressing or two end stressing
How many cables are present and at what time each cable is to be stressed
Ready with the values of modified elongation and modified pressure that to
be achieved
Stressing
Requirements
Strength
of concrete
Design elongation
Design Force
Order of Stressing
No. of strands in respective cable
HTS strand test report
Stressing Calculations
Revised Elongation (mm)
Theo. Elongation X Theo. 'E' Value X Theo. 'A' Value

Actual 'E' Value X Actual 'A' Value
=
-5 % Value:
Modified Gauge Pressure (kg/cm2) :
+5 % Value:
Jacking Force (Ton) X 1000
Ram Area X Jack Efficiency
-5 % Value:
+5 % Value:
HTS Test report
Grouting
Ice cubes
Cement bags
Admixture Cebex 100
Thermometer
Spiral reinforcement

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PRE STRESSED CONCRETE STRUCTURES

The need for PSC Structure

Is there a possibility to counteract the vertical forces ?

It involves inducing high compressive forces to the structure/section so that

applied in the spoke to such an extent that there will always be

Fig: spokes of a bicycle wheel in pretension

Applications of PSC In Bridges

Applications of PSC In Bridges

Applications of PSC In Other structures

Difference between RCC & PSC

is good in compression and Steel is good in Tension

Steel acts as a tension flange in RCC structures

Difference between RCC & PSC

is primarily used for inducing Prestressing forces

The cross section is fully used in case of Prestressed members

are stressed before the concreting is done

Casting of Railway sleepers

Curing of Railway sleepers after strands are cut

are stressed after concrete achieving sufficient strength to withstand

First stage stressing

MATERIALS USED IN PSC

High strength concrete

Forms of Prestressing steel

wire is a single unit made of steel

three, seven wires are wound together to form

Forms of Prestressing steel

group of strands or wires are wound to

form a prestressing tendon

group of tendons form a prestressing cable

tendon can be made of single steel bar.

Bearing plate assembly

Different types of HTS Strands

RCC & PSC Comparison

PSC & RCC Comparison

Comparative statement between PSC & RCC I Girder

S.No PSC Girders

Casting bed is required for 7 days

Bending Moment due to

Self weight of Girder

Additional steel Quantity

In RCC Girder( design steel at bottom face is 22 nos of 32

I GIRDER CASTING AT SITE

Procedure Casting of Girder

Understanding the drawing

first and foremost thing in any construction activity is to understand

Step by step process of casting girder

Reinforcement cage preparation

Casting bed prepartion

Profiling & Shuttering

Concrete cubes for strength assessment

Stressing & Grouting

Stressing and Grouting

For starting the Prestressing operation we need to careful about some

Theo. Elongation X Theo. 'E' Value X Theo. 'A' Value

HTS Test report

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