1 Lecture 4: Post-Tensioning Systems and Devices: ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

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1 Lecture 4: Post-tensioning Systems and Devices

This section covers the following topics:
 Introduction
 Stages of Post-tensioning
 Advantages of Post-tensioning
 Disadvantages of Post-tensioning
 Devices
 Manufacturing of a Post-tensioned Bridge Girder
1.1 Introduction
Prestressing systems have developed over the years and various companies have patented their products.
Detailed information of the systems is given in the product catalogues and brochures published by
companies. There are general guidelines of prestressing in Section 12 of IS 1343: 1980. The information
given in this section is introductory in nature, with emphasis on the basic concepts of the systems.
The prestressing systems and devices are described for the two types of prestressing, pre-tensioning and
post-tensioning, separately. This section covers post-tensioning. In posttensioning, the tension is applied
to the tendons after hardening of the concrete. The stages of post-tensioning are described next.
1.2 Stages of Post-tensioning

In post-tensioning systems, the ducts for the tendons (or strands) are placed along with the
reinforcement before the casting of concrete. The tendons are placed in the ducts after the casting of
concrete. The duct prevents contact between concrete and the tendons during the tensioning operation.
Unlike pre-tensioning, the tendons are pulled with the reaction acting against the hardened concrete. If
the ducts are filled with grout, then it is known as bonded post-tensioning. The grout is a neat cement
paste or a sand-cement mortar containing suitable admixture. The grouting operation is discussed later
in the section.
In unbonded post-tensioning, as the name suggests, the ducts are never grouted and the tendon is held
in tension solely by the end anchorages. The following sketch shows a schematic representation of a
grouted post-tensioned member. The profile of the duct depends on the support conditions. For a simply
supported member, the duct has a sagging profile between the ends. For a continuous member, the duct
sags in the span and hogs over the support.
Figure 1: Post-tensioning
ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

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Among the following figures, the first photograph shows the placement of ducts in a box girder of a simply
supported bridge. The second photograph shows the end of the box girder after the post-tensioning of
some tendons.
Figure 2: Post-tensioning ducts in a box girder
Figure 3: Post-tensioning of a box girder

The various stages of the post-tensioning operation are summarized as follows.
1) Casting of concrete.
2) Placement of the tendons.
3) Placement of the anchorage block and jack.
4) Applying tension to the tendons.
5) Seating of the wedges.
6) Cutting of the tendons.

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The stages are shown schematically in the following figures. After anchoring a tendon at one end, the
tension is applied at the other end by a jack. The tensioning of tendons and pre-compression of concrete
occur simultaneously. A system of self-equilibrating forces develops after the stretching of the tendons.
Figure 4: Stages of post-tensioning (shown in elevation)

Advantages of Post-tensioning
The relative advantages of post-tensioning as compared to pre-tensioning are as follows.
• Post-tensioning is suitable for heavy cast-in-place members.
• The waiting period in the casting bed is less.
• The transfer of prestress is independent of transmission length.
1.3 Disadvantage of Post-tensioning

The relative disadvantage of post-tensioning as compared to pre-tensioning is the requirement of
anchorage device and grouting equipment.
1.4 Devices
The essential devices for post-tensioning are as follows.
1) Casting bed
2) Mould/Shuttering
3) Ducts
4) Anchoring devices
5) Jacks
6) Couplers (optional)
7) Grouting equipment (optional).

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1.4.1 Casting Bed, Mould and Ducts
The following figure shows the devices.
Figure 5: Casting bed, mould and duct
1.4.2 Anchoring Devices
In post-tensioned members the anchoring devices transfer the prestress to the concrete. The devices are
based on the following principles of anchoring the tendons.
1) Wedge action
2) Direct bearing
3) Looping the wires
1.4.2.1 Wedge action

The anchoring device based on wedge action consists of an anchorage block and wedges. The strands are
held by frictional grip of the wedges in the anchorage block. Some examples of systems based on the
wedge-action are Freyssinet, Gifford-Udall, Anderson and Magnel-Blaton anchorages. The following
figures show some patented anchoring devices.
Figure 6: Freyssinet “T” system anchorage cones

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Figure 7: Anchoring devices
Figure 8: Anchoring devices
1.4.2.2 Direct bearing

The rivet or bolt heads or button heads formed at the end of the wires directly bear against a block. The
B.B.R.V post-tensioning system and the Prescon system are based on this principle. The following figure
shows the anchoring by direct bearing.
Figure 9: Anchoring with button heads

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1.4.2.3 Looping the wires

The Baur-Leonhardt system, Leoba system and also the Dwidag single-bar anchorage system, work on this
principle where the wires are looped around the concrete. The wires are looped to make a bulb. The
following photo shows the anchorage by looping of the wires in a post-tensioned slab.
Figure 10: Anchorage by looping the wires in a slab
1.4.2.4 Sequence of Anchoring

The following figures show the sequence of stressing and anchoring the strands. The photo of an
anchoring device is also provided.

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Figure 11: Sequence of anchoring
Figure 12: Final form of an anchoring device
1.4.3 Jacks
The working of a jack and measuring the load were discussed in Section 1.3, “Pretensioning Systems and
Devices”. The following figure shows an extruded sketch of the anchoring devices.
Figure 13: Jacking and anchoring with wedges

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1.4.4 Couplers
The couplers are used to connect strands or bars. They are located at the junction of the members, for
example at or near columns in post-tensioned slabs, on piers in posttensioned bridge decks.
The couplers are tested to transmit the full capacity of the strands or bars. A few types of couplers are
shown.
Figure 14: Coupler for strands
Figure 15: Couplers for strands

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1.4.5 Grouting
Grouting can be defined as the filling of duct, with a material that provides an anticorrosive alkaline
environment to the prestressing steel and also a strong bond between the tendon and the surrounding
grout. The major part of grout comprises of water and cement, with a water-to-cement ratio of about 0.5,
together with some water-reducing admixtures, expansion agent and pozzolans.
The following figure shows a grouting equipment, where the ingredients are mixed and the grout is
pumped.
Figure 116: Grouting equipment
1.5 Manufacturing of Post-tensioned Bridge Girders

The following photographs show some steps in the manufacturing of a post-tensioned I girder for a bridge.
The first photo shows the fabricated steel reinforcement with the ducts for the tendons placed inside.
Note the parabolic profiles of the duct for the simply supported girder. After the concrete is cast and
cured to gain sufficient strength, the tendons are passed through the ducts, as shown in the second photo.
The tendons are anchored at one end and stretched at the other end by a hydraulic jack. This can be
observed from the third photo.
(a) Fabrication of reinforcement

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(b) Placement of tendons
(c) Stretching and anchoring of tendons
Figure 127: Manufacturing of a post-tensioned bridge I-girder
The following photos show the construction of post-tensioned box girders for a bridge. The first photo
shows the fabricated steel reinforcement with the ducts for the tendons placed inside. The top flange will
be constructed later. The second photo shows the formwork in the pre-casting yard. The formwork for
the inner sides of the webs and the flanges is yet to be placed. In the third photo a girder is being post-
tensioned after adequate curing. The next photo shows a crane on a barge that transports a girder to the
bridge site. The completed bridge can be seen in the last photo.

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(a) Reinforcement cage for box girder (b) Formwork for box girder
(c) Post-tensioning of box girder (d) Transporting of box girder
(e) Completed bridge

Figure 18: Manufacturing of post-tensioned bridge box girders

1 Lecture 4: Post-Tensioning Systems and Devices: ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

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1 Lecture 4: Post-tensioning Systems and Devices

1.2 Stages of Post-tensioning

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

Figure 2: Post-tensioning ducts in a box girder

Figure 3: Post-tensioning of a box girder

2) Placement of the tendons.

3) Placement of the anchorage block and jack.

4) Applying tension to the tendons.

5) Seating of the wedges.

6) Cutting of the tendons.

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

Figure 4: Stages of post-tensioning (shown in elevation)

• Post-tensioning is suitable for heavy cast-in-place members.

• The waiting period in the casting bed is less.

• The transfer of prestress is independent of transmission length.

1.3 Disadvantage of Post-tensioning

7) Grouting equipment (optional).

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

1.4.1 Casting Bed, Mould and Ducts

The following figure shows the devices.

Figure 5: Casting bed, mould and duct

1.4.2 Anchoring Devices

3) Looping the wires

1.4.2.1 Wedge action

Figure 6: Freyssinet “T” system anchorage cones

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

Figure 7: Anchoring devices

Figure 8: Anchoring devices

1.4.2.2 Direct bearing

Figure 9: Anchoring with button heads

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

1.4.2.3 Looping the wires

Figure 10: Anchorage by looping the wires in a slab

1.4.2.4 Sequence of Anchoring

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

Figure 11: Sequence of anchoring

Figure 12: Final form of an anchoring device

Figure 13: Jacking and anchoring with wedges

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

Figure 14: Coupler for strands

Figure 15: Couplers for strands

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

Figure 116: Grouting equipment

1.5 Manufacturing of Post-tensioned Bridge Girders

(a) Fabrication of reinforcement

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

(b) Placement of tendons

(c) Stretching and anchoring of tendons

Figure 127: Manufacturing of a post-tensioned bridge I-girder

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

(c) Post-tensioning of box girder (d) Transporting of box girder

(e) Completed bridge

ECE 411 Design of Concrete Structures II Dr. Moonis Zaheer

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