STRESSING

I. Preparation for Stressinq Inspection

One of the most essential preparations for stressing
inspection is the calculation of theoretical elongations due
to jacking. Recommended practice is to calculate 80% of
theoretical elongation, and to compare field measurements
taken between 20% and 100% of jacking force. This should
eliminate the effect of dead end seating loss, cable slack,
and variation in the modulus of elasticity (E) of the strand
at lower stress ranges. This is not a hard and fast rule.
If variations are encountered or long cable lengths are to
be stressed, one can base comparisons on a calculated 70% or
75% of the theoretical elongation.
It is the responsibility of the Contractor to submit
elongation calculations as part of the working drawings.
Structure Design and the Structure Representative then check
the Contractor's calculations. Appendix D gives an
acceptable method of calculating elongations as well as
force factors.
Tendon elongations are calculated on the basis of an
assumed modulus of elasticity (E) - usually 27,500 ksi for
strand, The strand area is commonly assumed to be 0.153
square inches. The actual E and cross-sectional area (A)
will be shown on the-materials release tag for the
prestressing steel and the elongations should be re-

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calculated to be consistent with those figures, In other

words, actual E and A must be used to calculate elongations.
However, do not recheck the minimum required area (A) based
upon the actual values. Often packs of strand arrive with
varying E and A. In this case, it is best to separate the
strand so that all strand in a given tendon are the same.
However, if the variations are small, tracking the varying
strands in each tendon and using an average E and A is
acceptable. Appendix D gives examples of elongation
calculations.
Prior to stressing, it is also necessary to make
preparations for monitoring the jacking force. The Standard
Specifications (Section 50-1.08) require the Contractor to
have an accurate load cell or pressure gage on each jack and
that the jack/gage combination be accompanied by a certified
calibration chart. Recertification should be done at least
every 12 months. The Contractor's jack and gage are usually
monitored by State pressure cells during stressing. Up to
date information regarding jack calibration is available by
accessing the Structure Construction computer bulletin
board.
The Engineer in charge of field inspection of stressing
should be familiar with the calibration chart and pressure
cell prior to stressing. Appendix B gives instructions in
the use and care of the pressure cell and Bridge

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 Construction Records and Procedures Memo 160-3.0 gives
administrative instructions relevant to the pressure cell.

II . Field Inspection
The practice of stressing both simple span and some
continuous structures from one end only is allowed only when
shown on the contract plans or specifications. When two end
stressing is required, the Contractor must stress both ends

to Pjack either simultaneously or non-simultaneously and show

the actual method of stressing on the working drawings.
In order to minimize the possibility of undesirable
construction stresses, Standard Plan B8-5 states, " No more
than l/2 of the prestressing force in any girder may be
stressed before an equal force is stressed in the adjacent
girders. At no time during the stressing operations will
more than l/6 of the total prestress force be applied
eccentrically about the centerline of the structure."
However, please note that the l/6 factor is often modified
for railroad structures.
If compliance with these requirements is overly
difficult because of a particular tendon arrangement,
Structure Design should be consulted.
In order to efficiently monitor stressing operations, a
record in chart form must be kept for each tendon stressed.
Figure 6 is an example of such a chart. Note that some of
the information shown can be entered prior to stressing.

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Remember, that this form is a guide. You may desire to
custom design your own chart.
Each individual strand should be marked or painted at
both ends of the structure to measure elongation and check
for slippage. Tendons should be checked during and after
stressing for any strand slippage or dead end seating loss,
The area of l/2" prestressing strand typically varies
between 0.151 and 0.154 square inches. However, some strand
has been received with an area as small as 0.149 square
inches. Such small strand has presented problems with
proper seating of the wedges, Particular care should be
used when stressing any strand with an area below 0.151
square inches. With the Dywidag bar system, the elongation
can also be monitored by counting the turns of the anchor
nut during stressing.
An important requirement of prestressing inspection is
obtaining the anchor set shown on the plans. Anchor set is
the amount of strand movement at the time of force transfer
to the bridge. This is usually 3/8" for continuous
structures and per shop plans for simple spans. In
most prestress systems, elongation of the tendon occurs
within the jack itself. At 0.75 f's, the tendon elongates
approximately l/12" per foot of jack measured from the
anchorage to the pulling head. When measuring or computing
anchor set, do not include this jack elongation. Refer to

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 CALIFORNIA PRESTRESS MANUAL

Appendix D for calculating the effect that anchor set has on

tendon stress. For a complete jacking sequence including
anchor set, see Figure 7, which is provided by the VSL
Corporation.
It is the policy of Structure Construction that the
pressure cell be used at the start of stressing to verify
the Contractor's calibration chart and at least one
calibration curve be made per structure or frame, The
Structure Representative may require additional monitoring
as needed. Figures 8 and 9 are examples of completed forms
DS-C 86 and 86A for recording the Contractor's gage readings
versus pressure cell readings. These forms shall be
submitted upon completion to Structure Construction in
accordance with Bridge Construction Records and Procedures
Memo 3-1.0. See Appendix C for a complete inspection
checklist.

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 CALIFORNIA PRESTRESS MANUAL

DEPARTMENT OF TRANSPORTATION JOB STAMP

PRESTRESS CALIBRATION 04 - SC1 - 85 - 3.0/5.3

MONITORING SHEET 04 - 123454
Wide River Bridge
DS-C86 wp50

DATE: 08 - 31 - 90 STR. REPRESENTATIVE: Joe Bridge

NAME OF SYSTEM: VSL INSPECTOR(S): I. Girder, T. Beam, I. M. Lost

JACK NUMBER: 6 - 1O - 43
GAGE NUMBER: 6 - 1O - 43 B
FOR l/2" 270 KSI STRAND ABSOLUTE MAX..Pj=31 Kip/Strand X #Strands/Tendon: = 31 Kips X 48 = 1488 K
FOR 0.6'" 270 KSI STRAND ABSOLUTE MAX..Pj=44 Kip/Strand X #Strands$Tendon: = 31 Kips X =
CONTRACT REQUIRED . . . . . . . . . . . . . . . . . . . . . P j = 1488 K

Theoretical Maximum Gage Pressure:-........= Pj = 1488 K = 8308 psi

Ram Area 179.1 in.2

Maximum Gage Pressure From Latest Contractors Calibration: 8750 psi

Strain Gage Indicator CHC 13686
Electro Hydraulic Cell Number: 18 Numerical Display Setting: 1094 , Actual Gage Factor: O-72
Measurable Elongation = 80% Total theoretical ELongation: 28.5"

Gage Load from Load from Remarks

Reading Indicator Calibration Chart

1680 297 300 20% P,

2000 352 350

3000 523 520

4000 692 690

5000 855 855

6000 1025 1025

7000 1198 1195

8000 1365 1360

8720 1488 1480 Meas E long = 29"

FIGURE 8 SAMPLE FORM DS-C86

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FIGURE 9 DS-C86A

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 CALIFORNIA PRESTRESS MANUAL

III. Overstressinq of Prestressinq Steel

Technically, prestressing wire and strand develop high
strength and excellent creep characteristics through cold
drawing. During this cold drawing process the grain
structure is elongated and aligned into a condition
resulting in specific physical and mechanical properties.
The three stress-strain curves shown in Figure 10 show
a l/4" cold drawn, stress relieved prestressing wire tendon
that had been stressed to 83% of the minimum ultimate
strength of the wire.
Note the great difference in the stress-strain
relationship between Sample #1 and Samples #2 and #3,
keeping in mind that all three samples came from the same
tendon. The illustrated variations in physical properties
of wire stressed above the proportional limit is one reason
that the Standard Specifications do not permit stressing
beyond 75% of the specified minimum ultimate strength.
Due to the possibility of wires or strands being of
unequal length within a tendon, some of the wire or strands
could be stressed to their yield strength, even when the
tendon is not overstressed. Therefore, when the jacking
force exceeds the 75% limitation, some of the wire or
strands in the tendon may be seriously overstressed. This
condition is demonstrated by the stress-strain curve for
Sample #1 in Figure 10.

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 When steel such as prestressing wire or strand is
stressed beyond its elastic limit or yield strength, some of
its physical characteristics change. The most significant
changes are in the modulus of elasticity (E) and the creep
rate. If these properties are changed by permanently
overstressing, the significance of elongation measurements
is questionable. Remember, if it appears that the 75% limit
is being exceeded - - stop!
The effect of permanent overstressing on physical
properties of strand has been demonstrated by laboratory
tests in a 100 ft. pretensioning bed as follows:
Initial Jacking Initial percent Residual Stress Percent Stress
Force of Ultimate @ 72 hrs Losses @ 72 hrs
34 kips 82.3 26 kips 23.5
28 kips 67.8 27 kips 3.6

This example indicates that strand when kept in an

overstressed condition (greater than 0.75 f's) results in a
significant reduction of prestressing force due to the
change in creep properties of the strand. This is one
reason why the maximum anchor stress may not exceed 70% of
the ultimate strength of the steel, and the jacking force
must not be exceeded.

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CALIFORNIA PRESTRESS MANUAL

FIGURE 10

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IV . Elongation
The measured elongation should substantially agree with
the calculated elongation. Since the last edition of the
California Prestress Manual, the friction coefficent has
been reduced to 0.20 and the wobble correction has been
eliminated. However, due to variations in friction factor,
elongations tend to run higher than calculated, often by 5%
to 10%. This is acceptable as long as the variations are
understood and explained; but deviations between elongations
of similar tendons of the same bridge should not vary more
than 4% +/-. Remember, each case must be carefully examined
to assure compliance with the working force required.
The following are possible reasons for elongations not
being within the calculated range:
1. Incorrect number of strands placed in the tendons,
2. Excessive wobble of ducts increases friction and
decreases elongation.
3. Unusually smooth duct placement decreases friction and
increases elongation.
4. Even, layered strand placement reduces friction and
increases elongation, particularly when strand are
'pushed' into the duct.
5. A change in jack efficiency is not detected by a
pressure cell. This may cause faulty readings.

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6. Elongation calculations may be wrong due to the

following:
a. Incorrect Modulus of elasticity (E) or area of
strand (A).
b l Incorrect or varying tendon lengths due to skew or
sharp radii.
c. Differing coefficient of friction between girders
on sharply curved structures.
d l Different tendon paths in a girder.
7. Incorrect method of measuring elongations.
8 l Slippage of strand during stressing, especially if the
strand area is small (below 0.151 sq. in.).
9. Gage damaged or indicator not zeroed.
The cause of any inconsistent elongations among the
tendons of a structure must be determined as soon as
possible. Do not cut off excess strand until the problem is
resolved. In the event it is necessary to detension a
tendon, stressing contractors must have suitable equipment
available for this purpose as required by the TransLab
approval procedure.
As a general policy, strand should not be cut off until
all tendons in the structure are fully stressed.

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