Concrete

Pre-tension Presented by: Posttension

What is Prestressed Concreted?

A pre-stressed concrete structure is different from a conventional reinforced concrete structure due to the application of an initial load on the structure prior to its use. Steel reinforcement introduce in combination with concrete as reinforce concrete were ideal to become a very strong and cheap building construal members

PRESTRESSED CONCRETE

PRINCIPLE
Using high tensile strength steel alloys producing

permanent pre-compression in areas subjected to Tension A portion of tensile stress is counteracted thereby reducing the cross-sectional area of the steel reinforcement

The factors in chosen Prestressed Concreted

LONG SPAN

VERSATILITY DESIGN RAPID CONSTRUCTION

TO CONSERVE HEAVY LOAD MAINTANANCE FEE & SERVICES SPACE

FIRE RESISTANT

TWO METHODS OF

PRESTRESSED

CONCRETE

PRE-TENSIONED
HARPING/STRINGING

POST TENSIONED
BONDED POST-TENSION CONCRETE UNBONDED POST-TENSION CONCRETE

PRE-TENSIONING

The tendons of the reinforcement are stressed and anchored at the mould before the concrete is poured Tendon are release from the abutment and the pre stress is transferred into the concrete member.

PRE-TENSIONING

Pre-tension drawing detail.

POST TENSIONING
It is one in which the reinforcement is tensioned after the concrete has fully hardened.
A post-tensioning tendon is made up of one or more

pieces of pre-stressing steel, coated with a protective coating, and housed inside of a duct or sheathing. A tendon will have anchors on each end to transmit the forces into the structure. Long tendons may also have intermediate anchors along their length. The pre-stressing steel can be a high strength steel strand (typical in horizontal applications) or a high strength steel bar (typical in vertical applications).

Typical post tensioning system

POST TENSIONING Materials & Components

Steel Wire Strand

Anchor Head And Wedges

Standard Couplers

POST TENSIONING Material & Component

Steel Mould

Ducting

POST TENSIONING Machines

MOBILE CRANE

GROUTING MACHINE

HYDRAULIC STRESSING PUMP

HYDRAULIC JACK

POST-TENSIONING
BONDED & UNBONDED
BONDED
The

UNBONDED
Each

concrete is cast around a plastic, steel or aluminium curved duct, to follow the area where otherwise tension would occur in the concrete element.

individual tendons is coated with a grease (generally lithium based) and covered by a plastic sheating formed in an extrusion process.

USUAL PROBLEM AND FAILURE

PRESTRESSED CONCRETE
PRESTRESSING COMPONENT
Wire, strands and Tendons Failure Tendons Extension Grouting and Ducts Corrosion

CONCRETE AND REINFORCEMENT

Concrete Cracking Concrete Spalling Honeycombing Concrete Cover

USUAL PROBLEM AND FAILURE

PRESTRESSED CONCRETE
PROBLEMS DURING CONSTRUCTION
Failures Due To Design Construction Procedures Structural Behavior Problem

PROBLEMS AFTER OPENING

Durability Rehabilitation and Meditation

SITE LAYOUT

PROJECT DETAIL

SUPERSTRUCTURE PENANG BRIDGE.

PRESTRESSED
Post tension Segmental Box Girders CONCRETE The precast segmental box girder is designed as a continuous single twin box of 14.08m width,4.0m length and 3.20m depth structure with match cast joints, multiple shear keys and prestressing tendons.

This type of box-girder was selected because of its size that does not require extensive casting facilities, special heavy lifting equipment and storage as compared to a precast full-length box girder.

Total 7 types of Segmental Box Girder are designed for each span.
Total 8,092 nos of segmental box girder are constructed along the bridge.

Typical Cross section of SBG

Width 10-16m Width 10-16m

16m is enough for three lane highway. 4.0m length and 3.20m depth structure with match cast joints, multiple shear keys and prestressing tendons.

Segmental Box Girder

CASTING SEQUENCE

Tying rebar and ducting to in dedicated reinforcement jig

Placement of reinforcement cage in the SBG mould

Final inspection before concreting

CASTING SEQUENCE contd

Concreting the SBG

Completed SBG transported to yard

SBG storage yard

Launching of SBG using Span by Span Method

Installation of duct and anchor head

Stressing SBG process has been

done on site.
Setting

the Hydraulic Jack with good position to SBG tendons.

Lifting Cable

Hydraulic Jack

Stressing SBG process has been

supervised by Engineer.

Tendon stress is controlled by Hydraulic Pump.

Hydraulic Pump

Hydraulic Jack

Finally, Grouting the SBG

Grouting Machines & High pressure of pump are used to grouting the SBG completely.

Application of Epoxy as the Glue for the connection of SBG

SUPERSTRUCTURE PENANG BRIDGE.

POST TENSION BEAM AND SLAB DE

The cable stayed bridge utilizes post tensioned concrete beam-and-slab decks.
Typical beam height: 2.8m

Deck slab thickness: 28cm

Post tension slab deck at stayed cable Penang Bridge II

Post tension Beam structure

Prestessing in progress.

Marked the strand before stressing

Install the anchor

Post tension Beam structure

Prestessing in
progress.

Setting the Hydraulic Jack

Install the wedges

Prepare to be stressed

Post tension Beam structure

Prestessing in progress.

Set up the Hydraulic Pump

Record the result of stressing

Pre-stressed Beam launching

progress Pre-stressed beams and deck slabs have also been
launched for the superstructure of bridge at the Mainland (Batu Kawan & Batu Maung)

The launching of Pre-stressed

Beam

References
(Encik Aminudin Ali, Prestressed Concrete: 2013) (Matt Carter, 2nd International Seminar on Design & Construction of Second Penang Bridge: 2008) (Dato Prof Ir Dr. Ismail, Sustainable Bridge Asia Construction Practices, 2009) (Dr. Bijan O. Aalami, Unbonded and bonded PostTensioning System:1994) (Modjeski & Master, Inc, Prestressed Concrete Girder Superstructure Bridge Design:2003)