Materials in Prestress

“
Objectives
Objectives

1. Determine various materials used in Prestressed Concrete and how and when to
apply during designing
 “
Introduction
Introduction

The primary material considerations for prestressed concrete structures are the
mechanical properties and durability of concrete, prestressed and non-prestressed
reinforcement, and anchorage devices
Introduction

The development of high-strength steel was essential to the development of

prestressed concrete. Without the ability to stretch the prestressing steel to offset
the time-dependent effects of concrete creep and shrinkage, prestressed concrete
is not practical.
Introduction

By the 1950s, steel manufacturing techniques had developed sufficiently that

stress-relieved steel wire with high strength and ductility was produced at a cost
that was economically suitable for use in producing prestressed concrete
structures.
Introduction

Since the inception of prestressed concrete, prestressing strand has further

advanced with the advent of low-relaxation prestressing strand, which is the most
commonly used prestressing steel in the world today
Introduction

Prior to about 1960, concrete was essentially composed of Portland cement, water,
and fine and coarse aggregates, which would produce modest strength gains with
time. It was quickly discovered that increased production rates for both cast-in-
place and precast concrete required higher compressive strength earlier in the
project.
Introduction

This was necessary so that the large prestressing force could be applied to the
member soon after casting to allow the next member to be produced.
Introduction

In the late 1960s, the first plasticizing admixtures became available. These
admixtures evolved into today’s high range water reducing (HRWR) admixtures.
Introduction

HRWR admixtures reduce the mixture viscosity allowing concrete mixtures to use
lower water-cementitious material ratio (w/cm) while maintaining the same
workability. The lower w/cm also improved the early strength gain.
Introduction

This combined with improved Portland cement production techniques led to

greatly improved production rates, which, in turn, has improved the economic
viability of prestressed concrete.
Introduction

More recent developments of admixture chemistry have resulted in flowable self-

consolidating concrete mixtures.
Introduction

SCC allows concrete placement into tighter form locations, reduces segregation,
and reduces the vibration effort and noise in a precast plant, which has improved
production rates, plant efficiency, and safety, while reducing energy consumption
 “
Concrete
Concrete

Concrete, particularly high-strength concrete, is a major constituent of all

prestressed elements. Hence, its strength and long-term endurance have to be
achieved through proper quality control and quality assurance at the productions
stage.
Reason why concrete is the most widely used material

▫ Concrete possesses excellent resistance to water

▫ Concrete can be formed into a variety of shapes and sizes
▫ Concrete is one of the cheapest and most readily available of materials
 “
Parameters Affecting Quality of Concrete
Parameters Affecting the Quality of Concrete

Strength and endurance are two major qualities that are particularly important in
prestressed concrete structures. Long-term detrimental effects can rapidly reduce
the prestressing forces and could result in unexpected failure.
Parameters Affecting the Quality of Concrete

Hence, measures have to be taken to ensure strict quality control and quality
assurance at the various stages of production and construction as well as
maintenance
 “
Properties of Hardened Concrete
Properties of Hardened Conrete

The mechanical properties of hardened concrete can be classified into two-

categories: Short-term or instantaneous properties, and long term properties.
 Short-Term Long-Term

1. Compression 1. Creep
2. Tension 2. Shrinkage
3. shear
 “
Compressive Strength
Compressive Strength

This is the most common and well-accepted measurement of concrete strength to

assess the performance of a given concrete mixture.
Compressive Strength

It is the ability of concrete to withstand loads that will decrease the size of concrete.
It is usually tested at 7 days and then again at 28 days. The seven-day test is done
to determine early strength gains.
Compressive Strength

Depending on the type of mix, the properties of aggregate and the time and quality
of curing, compressive strengths of concrete can be obtained up to 20,000 psi.
Commercial production of concrete with ordinary aggregates is usually in the range
4,000 psi to 12,000 psi, with the most common concrete strength in the 6,000 psi
range.
Compressive Strength

Prestressed concrete members have 2 compressive strength requirements:

1. f’ci = transfer strength is minimum strength required to resist the initial prestress
force to the member
2. F’c = specified compressive strength is used in calculating other serviceability
and strength conditions of the section
Compressive Strength

The transfer strength is usually specified at 16-18 hours after casting the
pretensioned members and 2-7 days for post-tensioned members.

The specified compressive strength is typically specified at 28 days.

Compressive Strength

For prestressed plant operations, the transfer strength ranges between 2,500psi –
5,000 psi, and higher strengths are used regionally.

The corresponding design strength ranges from 4,500 – 10,000 psi.

Compressive Strength

Cast-in-place post-tensioned concrete specifies 28-day strengths between 4,000

psi and 8,000 psi.
Compressive Strength

Two methods are used to monitor and obtain transfer strength:

1. Accelerated curing
2. Cure time
Compressive Strength

Plant prestressed elements transfer the prestress at 16-18 hours to reuse the forms
on a 1-day cycle. To obtain these short cure times, the concrete mixture may use
TYPE III high early strength cement or may contain admixtures to accelerate initial
curing time, or can use steam or heat to further accelerate curing.
TYPE OF CEMENT DESCRIPTION

Suitable for all general uses such as pavement, sidewalks,

Type I and Type IA
buildings, bridges, tanks, water pipes, etc.

Used when the acid or sulphate content of the groundwater or

soil is higher than normal.
Type II and Type IIA
It generates heat of hydration at a slower rate than Type I

Used in large piers, heavy abutments, and retaining walls

Gain strength faster and develop more heat of hydration than
other cements.

May be used if you are in a hurry to strip forms and use them
Type III and IIIA
again.

Used when you need to put the concrete in service faster than
normal
TYPE OF CEMENT DESCRIPTION

Since this type has low heat hydration, it is used in massive

Type IV structures such as large dams where the temperature rise
during hardening may cause problems
This type is used where solids or groundwater have a high
sulphate or acid content.
Type V
Structure exposed to coal mine drainage should be considered
for type V
Compressive Strength

Concrete in cast-in-place slab construction is usually cured for 24-72 hours prior to
post-tensioning and admixtures may be used to accelerate strength gain.
Compressive Strength

The expanded use of chemical admixtures led to changes in long-term concrete

strength. Present –day mixtures can be fine-tuned to satisfy specified strengths with
little or no strength gain beyond 28 days. This practice results in little or no residual
strength beyond the specified strength
 Cement (per Sand Gravel (per Water (per Strength
Class Uses
bag) (per cu.m) cu.m) gal) (psi)

Prestress
AAA 1 1 2 6 4,500 and Post-
tensioned
Underwater
retaining
wall, shear
AA 1 1.5 3 6 4,000 wall, and
core
elevator,
core walls
Footing, pier,
columns,
A 1 2 4 6 3,500 girders,bea
ms, joist, and
slabs
 Cement (per Sand Gravel (per Water (per Strength
Class Uses
bag) (per cu.m) cu.m) gal) (psi)

Slabs on fill
and non-
B 1 2.5 5 6 3,000
bearing wall
or 4” CHB
Concrete
plant boxes
C 1 3 6 6 2,500
and parapet
walls
Plant boxes,
foot paths,
D 1 3.5 7 6 2,000 walkways
and lean
concrete
 Category Compressive Strength

Low-Strength Concrete <20 Mpa (<3,000 psi)

Moderate Strength Concrete 20-40 Mpa (3,000 – 6,000 psi)

High Strength Concrete >40Mpa (>6,000 psI)

 “
Tensile Strength
Tensile Strength

The tensile strength of concrete is relatively low. A good approximation for the
tensile strength is 10-20% of compressive strength. It is more difficult to measure
tensile strength than compressive strength because of gripping problems with
testing machines.
Tensile Strength

Commonly used methods for tensile strength:

1. Split Cylinder Test
2. Flexural Beam Test
 Third Point Loading Center Loading Method

Flexural Strength Requirement Flexural Strength Requirement

• 3.80 Mpa (550 psi) • 4.5 Mpa (650 psi)
Tensile Strength

Neither the split cylinder nor modulus of rupture (flexural) test is typically
conducted to determine the tensile strength for design purposes. Rather the tensile
strength is derived from the specified compressive strength by correlating the
cylinder compressive stress with the tensile results from a variety of concrete
mixtures
Tensile Strength

The modulus of rupture is used to classify prestressed concrete members.

▫ uncracked (Class U), if the maximum tensile stress is less than the modulus of
rupture

▫ Cracked (Class C), if tensile stress is greater than 12 𝑓′𝑐 or a transitional

element.
▫ Class T, if the stresses are between these two limits.
 “
Modulus of Elasticity
Modulus of Elasticity

The modulus of elasticity of concrete is based on the initial slope of the stress-strain
curve of 6in x 12in cylinders loaded in compression.
Unit Weight of Concrete Modulus of Elasticity

90 – 165 pcf 33𝑤 1.5 𝑓 ′ 𝑐

Normal weight (145 pcf) 57,000 𝑓 ′ 𝑐

Where: w = is the density of concrete in pcf

Modulus of Elasticity

For concrete having compressive strength 6,000 psi to 12,000 psi (42-85 MPa), the
expression for modulus of elasticity are:

𝑊 1.5
𝐸𝑐 𝑝𝑠𝑖 = [40,000 𝑓 ′ 𝑐 + 106 ]( )
145

𝑊 1.5
𝐸𝑐 𝑀𝑝𝑎 = [3.32 𝑓 ′ 𝑐 + 6895]( )
2320
Modulus of Elasticity

It is highly crucial to define modulus of elasticity of concrete in the design of

concrete structures. Linear analysis of elements, which is based on the theory of
elasticity, is used to satisfy requirements of both ultimate and serviceability limit
state for instance in the case of prestressed concrete that demonstrate uncracked
section up to the failure.
Modulus of Elasticity

In addition, to compute deflections which are required to be limited under the

serviceability requirements in all structures
Modulus of Elasticity

Finally, knowledge of modulus of elasticity of high strength concrete is very

important in avoiding excessive deformation providing satisfactory serviceability
and avoiding the most cost-effective designs.
 “
Creep
Creep

Creep, or lateral material flow, is the increase in strain with time due to a sustained
load.
▫ The initial deformation due to load is the elastic strain,
▫ while additional strain due to the same sustained load is the creep strain.
Creep

Basically, long term pressure or stress on concrete can make it change shape. This
deformation usually occurs in the direction the force is being applied.

Creep does not necessarily cause concrete to fail or break apart. When a load is
applied to concrete, it experiences an instantaneous elastic strain which develops
into creep strain if the load is sustained.
 Creep

In this figure, it illustrates the increase in

creep strain with time. Creep cannot be
observed directly and can be determined
only by deducting the elastic strain and
shrinkage strain from the total deformation.
 Creep

An example of a relative numerical values of

strain due to the foregoing three factors.

These relative values illustrate that stress-

strain relationships for short-term loading
lose their significance and long-term
loadings become dominant in their effect on
the behavior of a structure.
Factors Affecting Creep

▫ Aggregates
▫ Mix Proportions
▫ Age of Concrete
Influence of Aggregates

Aggregate undergoes very little creep. It is really the paste which is responsible for
the creep. However, the aggregate influences the creep of concrete through a
restraining effect on the magnitude of creep. The paste which is creeping under
load is restrained by aggregate which do not creep.
Influence of Aggregates

The stronger the aggregate the more is the restraining effect and hence the less is
the magnitude of creep. An increase from 65 to 75 % of volumetric content of the
aggregate will decrease the creep by 10 %.
Influence of Aggregates

The modulus of elasticity of aggregate is one of the important factors influencing

creep. It can be easily imagined that the higher the modulus of elasticity the less is
the creep. Light weight aggregate shows substantially higher creep than normal
weight aggregate.
Influence of Mix Proportions

The amount of paste content and its quality is one of the most important factors
influencing creep. A poorer paste structure undergoes higher creep. Therefore, it
can be said that creep increases with increase in water/cement ratio.
Influence of Mix Proportions

In other words, it can also be said that creep is inversely proportional to the strength
of concrete. Broadly speaking, all other factors which are affecting the
water/cement ratio are also affecting the creep.
Influence of Age

Age at which a concrete member is loaded will have a predominant effect on the
magnitude of creep. The rate of creep rapidly decreases with time. The time taken
by a concrete structure to attain creep is 5 years.
Effects of Creep on Concrete

▫ In reinforced concrete beams, creep increases the deflection with time and may
be a critical consideration in design.
▫ In eccentrically loaded columns, creep increases the deflection and can load to
buckling.
▫ Creep property of concrete will be useful in all concrete structures to reduce
internal stresses due to non-uniform load or restrained shrinkage.
▫ Loss of prestress due to creep of concrete in prestressed concrete structures
 “
Shrinkage
Shrinkage

Shrinkage is an inherent property of concrete. The shrinkage in concrete can be

defined as the volume changes observed in concrete due to the loss of moisture at
different stages due to different reasons.
Shrinkage

Basically, there are two types of shrinkage:

▫ Plastic Shrinkage
▫ Drying Shrinkage
 Plastic Shrinkage

Occurs during the first few hours of placing

fresh concrete in the forms. Exposed
surfaces such as floor slabs are more easily
affected by exposure to dry air because of
their large surface area.

In such cases, moisture evaporates faster

from the concrete surface than its replace
by the bleed water from the lower layers of
concrete elements
 Prevention of Plastic
Shrinkage

1. The escape of water from the surface

can be prevented by covering the
surface with help of polyethylene
sheeting. Prevention of water
evaporation will prevent plastic
shrinkage.

2. Proper vibration of concrete

 Drying Shrinkage

Occurs after concrete has already attained

its final set and a good portion of the
chemical hydration process in the cement
gel has been accomplished.

It is the decrease in the volume of concrete

element when it loses moisture by
evaporation.

Swelling – opposite of shrinkage; volume

increase due to water absorption.
 “
Opposite of Shrinkage?
 Swelling

opposite of shrinkage; volume increase due

to water absorption.
Shrinkage

Shrinkage and swelling represent water movement out of or into the gel structure
of a concrete specimen due to the difference in humidity or saturation levels
between the specimen and the surrounding irrespective of the external load.
 “
Shrinkage is not a completely a reversible
process, why is it?
Shrinkage

Shrinkage is not a completely reversible process. If a concrete is saturated after

having fully shrunk, it will not expand to its original volume
Shrinkage

Shrinkage and swelling represent water movement out of or into the gel structure
of a concrete specimen due to the difference in humidity or saturation levels
between the specimen and the surrounding irrespective of the external load.
Factors Affecting Shrinkage

▫ Aggregate
▫ Water/Cement Ratio
▫ Size of Concrete Element
▫ Ambient Conditions
▫ Amount of Reinforcement
▫ Admixtures
▫ Type of Cement
Influence of Aggregate

The aggregate acts to restrain the shrinkage of cement paste; hence, concretes
with high aggregate content are less vulnerable to shrinkage. Those with high
modulus of elasticity or with rough surfaces are more resistant to shrinkage process.
Influence of Water/Cement Ratio

The higher W/C ratio, the higher the shrinkage effects.

Influence of Size of Concrete Element

Both the rate and the total magnitude of shrinkage decrease with an increase in the
volume of the concrete element. However, the duration of shrinkage is longer for
large members since more time is needed for drying to reach internal regions.
Influence of Medium Ambient Conditions

The relative humidity of the medium greatly affects the magnitude of shrinkage; the
rate of shrinkage is lower at high states of relative humidity. The environment
temperature is another factor, in that shrinkage becomes stabilized at low
temperatures.
Influence of Amount of Reinforcement

Reinforced concrete shrinks less than plain concrete, the relative difference is a
function of the reinforcement percentage.
Admixtures

This effect varies depending on the type of admixture. An accelerator such as

calcium chloride, used to accelerate hardening and setting of concrete, increases
the shrinkage. Pozzolans can also increase the drying shrinkage.
Influence of Type of Cement

Rapid-hardening cement shrinks somewhat more than other types, while shrinkage-
compensating cement, minimizes or eliminates shrinkage cracking if used with
restraining reinforcement
 “
Non-Prestressing Reinforcement
Non-Prestressing Reinforcement

Steel reinforcement for concrete consists of bars, wires, and welded wire fabric, all
of which are manufactured in accordance with the ASTM standards. The most
important properties of reinforcing steel are:
1. Young’s Modulus, Es
2. Yield Stress, Fy
3. Ultimate Strength , fu
4. Steel grade designation
5. Size or diameter of the bar or wire
To increase the bond between concrete and
steel, projections call deformations are
rolled onto the bar surface.

Deformed bars has indentations pressed

into the wire or bar to serve as deformations.
Except for wires used in spiral reinforcement
in columns.
 “
Prestressing Reinforcement
Prestressing Reinforcements

Because of high creep and shrinkage losses in concrete, effective prestressing can
be achieved by using very high-strength steels in range of 270,000 psi or more
(1,862 Mpa, or higher).

Such high-stressed steels are able to counterbalance these losses in the

surrounding concrete and have adequate leftover stress levels to sustain the
required prestressing force.
Prestressing Reinforcements

The magnitude of normal prestress losses can be expected to be in the range of

35,000 to 60,000 psi (241 to 414 Mpa). The initial prestress would thus have to be
very high, on the order of 180,000 psi to 220,000 psi (1,241 to 1,517 Mpa)
Prestressing Reinforcements

From the aforementioned magnitude of prestress losses, it can be inferred that

normal steels with yield strengths of 60,000 psi would have little prestressing left
after losses, obviating the need for using very high-strength steels for prestressing
concrete members.
Prestressing Reinforcements

From the aforementioned magnitude of prestress losses, it can be inferred that

normal steels with yield strengths of 60,000 psi would have little prestressing left
after losses, obviating the need for using very high-strength steels for prestressing
concrete members.
 “
Stress Relieved and Low Relaxation Wires
and Strands
 Stress Relieving

Consist of heating the steel to a temperature

below the critical range to relieve stresses
resulting from cold working, shearing, or gas
cutting. It is not intended to alter the
microstructure or mechanical properties
significantly. It is also a process for making
material softer.
 Stress Relieving

It is a controlled time-temperature heat

treatment process. It consists of heating the
wire for a short period of time to
temperatures 500F to1000F; the time and
temperature are varied to remove the
residual stresses without destroying the
fibrous grain structure.

The process produces a wire with increased

elastic limit ad ductility as-drawn wire.
Steel Relaxation

When a high tensile steel wire is stretched and maintained at a constant strain, the
initial force in the wire does not remain constant but decrease with time. The
decrease of stress in steel at constant strained is termed as relaxation of steel

This should not be confused with creep, which is a constant state of stress with an
increasing amount of strain.
Steel Relaxation

Creep is a change in strain while relaxation is a loss in steel stress.

Wires and Strands

▫ Stress-relieved wires are cold-drawn single wires conforming to ASTM

Standard A421

▫ Stress-relieved strands conform to ASTM Standard A416