@ SSIHISANS DIU MAE moe : : ey A: a : AS 1 g se : f | f 4 z { 5 | oy ee | i Th SS f g j 4 As tei AF U WYThe prestressing technology is emerging fost growing field in construction industry particularly for buildings, bridges, metro rail, flyovers, nuclear power plants, LNG tanks, cement plant etc. Dynamic Prestress a specialist agency in the field of prestressing, is accredited with on ISO 9001 certificatian & has state of the art facility for development, production and testing of related products ond equipments required for prestressing industry. Prestressing is a technique of construction in which internal stresses of a suitable magnitude & distribution ore introduced in @ member, so that the stresses resulting from external loads are counteracted to a desired degree. Pre-tensioning & Post-tensioning Pre-tensioning is a method of prestressing concrete in which the tendon is tensioned before the concrete is placed In case of Post-tensioning, the tendon is tensioned after the concrete has hardened. The presiressing force is imparted to the concrete by bearing & this, procedure can be applied to members either precast or castin-situ Prestressed concrete structures can be classified in a number of ways depending upon their features of design & constructions like a) _ Externally or Internally prestressed b) Bonded or Unbonded tendons ¢) Linear or Circular prestressing The various components used for post tensioning work involves use of Anchorages, H.TSirands, Sheathing Ducts, Multi and Single strand Hydraulic Jacks with Power packs, Grout pumps, Agitators, Grout caps, Destressing tools, etc. Dynamic has state of the art infrastructure facility for manufacturing all sizes of prestressing anchorages and equipments Dynamic is providing tailor made solutions for construction industry in the field of prestressing since last two decades. The company’s specialisation includes * Technically qualified engineers and technical supervisors having vost experience in the prestressing industry. Providing Services for installation and supervision Experienced team for quality control with in-house testing faci Providing equipments having low maintenance cost Providing Smaller gripping length of prestressing jacks, * Ability to develop equipments and devices as per site conditions. * Wide experience with clients like NHAI, RAILWAYS, MSRDC, NPCIL, PWD, etc. for all type of Structures & has completed variety of projects in several countries like INDIA, UAE, OMAN, SAUDI ARABIA, MONGOLIA, MAURITIUS etc.HLT. STRANDS & Duct HLT. Strands are available in various diameters such as 12.7mm (0.5"), 15.2mm(0.6"), and 15.7mm (0.62"). Properties of LRPC : AS PER INDIAN SPECIFICATION : IS 14268/1995 AS PER BRITISH SPECIFICATION BS 5896:1980 TABLE 1 TABLE 2 oe lenles | Sac “[_Telerence J. | 2 Ble &3| § |5b)eez| 825/258 g \Eal Gos |5 Elf se cles oa cos || & | es/SRE| SESe | be B [§ §| ic |Secionolle B/S 39 Slee 8c 20) © |2%) 8") SBas | Zoe ZA) mm | owos | 3) F55 sao |S = 8 mass 6 mm | mm | mm] kN KN _| Ko/km fmm] mm | _% [mm N KN _[kgikn 12.7|+0.66| 98.7] 183.7] 165.3 | 775 Wire}. |+0-40] +4% " 0.15 Super|'57| 2% |150]} 265 225 |1180] 15.2|+0.66| 140}260.7 | 234.6 | 1102 0.29 0.15 Dynamic Group donot manufacture H.T. Strands. The above mentioned datais for reference & can be checked with the manufacturers | Sheathing creates the necessary void in the structure in which the prestressing steel (strands/wires) is free to move during stressing. Metallic Sheathing is corrugated throughout ils length & is manufactured out of C.R.C.A. strip. The diameter ranges from 39mm to 130mm & strips thickness from 0.24mm to 0.7mm. strips are available in Bright Metal / Galvanized / Lead coated finish. (A) Metalic sheathing (Duct: — TBE 5 Following tests on sheathing pipes is carried out at our Nasik | Weeofduct eteereoree or shea to be used in design works as per IRC: 18-2000 iperrroaraa at 1.Transverse Loadtest 2. Tension load test Bright metal 0.0046 0.25 3. Water loss test 4. Workability test Ganariaa 0.0030 0.20 PE Sheathing (Duct) should conform the following specification | Leod coated p:0030) oe *FibBulletin-7_* NPC Specification No.PP/M/1721 # *IRC: 18-2000 * Addendum and Corrigendum IRS Slip No.6 *Railway Concrete Bridge Code 1997 Friction coefficient & wobble coefficient The friction coefficients (y) and wobble coefficient (k) can vary depending upon various factors including the nature and TABLE 4 | surface condition of the prestressing steel, the type, diameter and surface condition of the sheathing duct, and the Porameter ‘As per fib As per NPC Taelesormahsd (Units Bulletin 7 (2000) | Report PM/1721 The value of p and k given in the table 3.& 4 may be adopted | Kipermetro) | Not specified 0.003 for calculating the friction losses. x 10-014 | 00-014 Se Na NE AS AN + Mark out tendon spacings and lay duct as per approved drawings + Proper taping of duct-duct coupler joint and also anchorages - duct joints. + Use de-coiler and safety goggles while uncoiling and cutting of srands. + Use sirand bullet while threading the sirand in the cable duct. + While concreting, the duct should be filled with H.1. Strands or dummy pipe. + Use rust preventive ol for pre-threaded strands for its protection till the date of stressing + The gripping length of strand should be cleaned before mounting the anchor plate and stressing jack. + The corroded or pitted strand shall not be used for stressing purpose. + The anchor cone (Tube Unit) is made of grey cast iron and hence is brite in nature. The concrete behind the anchor cone should be sound and compact. The anchor cone is meant for transferring the load only & in case of bad concrete behind the anchor or insufficient anti- burst reinforcement, the anchor cones likely. to get crushedUPA cata GUS 33 Dynamic post tensioning multi-strand anchorages includes entire range for all three types of strands viz - 12.7 mm (0.5"), 15.2 mm (0.6") and 15.7 mm (0.62") and the anchorages are widely approved and accepted for all types of Prestressed Concrete structures. SPACING OF ANCHORAGES & ANTI-BURST REINFORCEMENT MN" tume eee Sc Anchor |_UTS 80% of Duct Anchor Pocket Min. Edge Spacing Pocket PCDof Spiral Longth Spiral No. of Pitch of No Type (Tons) UTS Diameter Cone Size (Recess) Distance _Betwoen Depth Holes on Reinforce of Spiral Bar Turns Spiral Anchorages Anchorage mont OD Spiral Dai AxA ExE | F GH) KD] LtiMN/P 1, 40P13 | 75) 60 | 51 | 45 215 | 120 «220+» «105: «125 +~««150| sO. 166 O 2) 7orI3 [131/105 51 | 145 | 215 | 120 | 220 | 105 | 125 150 240 16 6 | 40 3[12pP13 [225] 180 | 75 | 190 | 240 | 148 | 260 | 120 | 165 | 190 | 480 | 16) 8 | @ | 4) 190PI3 | 356° 28590245 300|S«s198_~=S=S*C«CSCS*C«NZO| «00-2501 | —O 5|270P13 | 506 405 | 105 | 305 350295 = 485120 | 274 300 | 600 20 10 40 +The Technical details of stand anchorages with 31DP13 & more, shal be provided by our Mumbai office on request 7/40? 15.2 | 106] 85 51 145 [215 120 220 | 120 [ 125 [ 150 | 480 [16] 8 | 600) 8/70P152| 186 149 75 | 190 | 240 148 260+ *120'| 165 190 480 16 | 8 60 | 9/120P152| 319, 255 85 | 245 | 300 200 300 120) 200 250 540 16 9 60 10/19DP15.2/ 505/404 | 105 | 275 | 350 260 350 | 120 | 235 | 260 | 600 20 10 | 60 | 11/270P 15.2 718 674 | 120 | 350 | 392 340575130 | 285 350 | 720-20. «12 60 | 12/310? 15.2| 824 659 | 130 | 370 412 | 355 —620»«*140 | 295 370 | 720 20 «12 60 13/370P 15.2 984 787 | 140 | 400 | 440 380 | 675 140 | 320 400 | 840 20 14 | 60 14/43? 15.2/1143 914 | 150 | 435 | 485-400) 725|«140| 375435 | 960 20, 16 60 15/480? 15.2 1276 1021 | 160 | 435 | 485 | 420 | 770 | 150 | 375 | 435 | 1080/20) 18 | 60 16/550P 15.2 1462/1169 | 170 | 455 | 500430 | 820 | 160 | 390 | 480 | 1200 20 20 60 | '* The Technical details of other capacity anchorages for 15.7 mm strands shall be provided by our Mumbai office on request | 17, 70P 157 | 189] 151 | 75 | 190 | 240 | 148 | 260 | 120 | 165 | 190 | 540 | 16| 9 | 60 18/120P 15.7) 324 259 | 85 | 245 | 300 | 200 | 300 | 120 | 200 | 250 | 600 16, 9 | 60 19/190P 15.7 513 410 | 105 | 275 | 350 213 | 350 | 120 | 235 | 300 | 660 20 10 | 60 + Dimensions of Single Strand Anchorages and other flat anchorages can be provided on request. 20) 4513 | 75 | 60 | 60x20 | 170x75| 220x125 170 | 325 | 130 | - 270x110 300 | 10| 6 | 50 21, 5813 93. 75 | 70x20 204x75| 255x150 170 | 360 | 190 | - 270x110 300/10, 6 | 50 22 4515 10885 | 80x25 | 250x80/ 300x150 200 | 375 | 130 | - 270x110 300/10 6 | 50 23) 5815 133, 106 | 90x25 250x80| 300x150 200 400 | 130 = 270x110 400 | 10 | 8 | 50 | Notes (oll dimensions oe in mm |) The P& G dimensions ae based on ure of MAS grode of concrete. Incozeif grade of concrete difers hen the dimension moy be suitably altered by referingit teourtechnical deparment. The stressing sequence simportan & moy influence the concrete strength requirementat each phase ofsrssing, 2), Bursting reinforcement should perfect str, 35 mm from theinner surface of Anchor cane. 3). Incase ofigstobe used insted of pro oranfburt reinforcement for lat anchorages thon equivlen! steel oreo houldbe provided inthe fom of woligs spaced 80 mm oper 4). Slip due elastic shortening oF arinping length of ond and he slip de to wedge se, shouldbe seporotely considered. 5) Wedge eetinthe onchoroge durin ronsercovre or of prstes, Wedge sein he nor-sressing anchorages ond temporary Jack wedge occurs durin srestng ond causes on apparent inceose in extension bu no los ol prsies. ‘Thenormal wedge setin Dynamic system is 6mm. m. a sessing end ond 3mm. atnon sessing end 6), Theload or locking wedges shall beinthe range ol 1.57 t02.57 /Wedge. Thelocking pressure depends onthe rom ‘oreaofthe jock ond the ype of trond and hence the exact ood tobe applied shall be checked without echnical team 7) The internal or ofthe sheathing duct shell be abou! three times the orea ol he tendons or as pes ou" ndividuel 5 ‘echnical leaflet mode forthe specif structures of projec, 8), Theinteral diameter of dctis pected above, the exerna diameter shellbe approximately 5 me bigger. 9), Pocket dimensions are fornermel packe sizes, ary devition in histo be studied individual aking jack dimensionsinto account 10) The spacing, edge covers and grouping ofcables hal conform to relevant National codes of practice. ml 11) Length oftrand quoted in he dato gripping length of sessing jock ond is measured rom the face of he anchor cone tube uni). 12) The compaibty of Jock componenisfor range of anchorages & the detiled echnical inputs shalllbe mode cveilable on request tienea nd Dynamic provides Single Strand Coupler and Multi Strand Coupler for Pre-Tensioning ‘and Pos-Tensioning works respecively The coupler is a mechanical device used for structures buil in sections; in cases when the cost of scaffolding & forms for a complete structure becomes expensive. Certain cables are stressed & anchored at partial length & later extended using couplers. The execution work of continuous spans using multi strand coupler is « bit different from the regular mult sirand anchorages and hence special precautions needs to be token. As the couplers are embedded in the concrete there is likelihood of strands getting corroded in the anchorage zone dve to the extensive exposure fo slury ond water. The sirands if excessively corroded will loose the grip of wedges ‘and during the stressing activity of the next stage, the strands may slip from the other end. It is therefore mandatory and absolutely essential to complete the concreting in shortest possible time and protect the strands and coupler when installed at site. The Multi Strand Couplers are of two different types namely pre-locked spring loaded wedge coupler (Iype-A] and swadge type of strand couplers (Type ~ 8) + The strand coupler (Type-A) consist of anchor plate with active anchorage at the center of anchor plate and pre locked spring loaded wedges at the periphery. The whole assembly is protected by tube which is seated on the bearing plate. The other end of the couplers connected to the sheathing of the next phase. + The swadge types of coupler (Type ~ 8} constitutes of peripheral strands, swadged and positioned in the grove provided on the bearing plate & the active ‘anchorage at the centre. The whole assembly is protected by a tube which is seated on the concrete with a rubber gasket. Stage Stressing is essential when prestressing is to be applied in stages to the concrete as per (design requirement) or if the stroke of jack is insufficient. For prestressing in two or more stages, multi use live wedges are recommended to be used instead of single use live wedges. For detail procedure of prestressing in stages, you may contact our technical office. Dynamic provides special type anchor plate for restressing in order to compensate for the loss of prestress of ungrouted tendon. The resiressing of cables is done using tailor made jacks & shimming foot. The multiuse barrels & wedges alongwith monostrand jacks of stroke upto one metre length are provided by us for the production of pretensioned girders. The Jacks, Barrels & Wedges are available for 0.5”, 0.6"8.0.62" strands. ‘Barrelg® Wedads (Grips) Dynamic provides two types dead end anchorages a! the non - stressing end of the girder. Tis anchorages are portcularly 3 Useful for single end stressing os per the design ond for the cases where less gaps available in between the girders orif one of the end of girders not accessible opi] ie +The Bulb type of dead end anchorages (Type C) are suitable Tab Type Dead End Anchorager for lot post tension slab with less numbers of strands and low | | Sr No.| Ancharages. | 3 c capacity anchorages. The bulb portion and the bonding mom. mm min a 70 —s0 —| 600 length of strand is embedded in the concrete. i se 12 = we + The Spring loaded plate: of dead end anchore (Ty 3 4815. 270. 50 750° ring loaded plate typeof dead end anchorages (ype | [3 F355 zo} 30} 7a D) are suitable for entire range of 4 to 55 strands and have been extensively used for several metro rail projects PSLOe CR BL aSSTCCaTNVNg JACK THREADING SEQUENCE FOR PRESTRESSING OPERATION CHARACTERISTICS OF DYNAMIC STRESSING JACKS Jack Capacity) Overall | Outer dia, Ram Area _| Min.Gripping| Max. | Lock off| Cylinder| Weight Model tons | Length | of Main For For Length of | Travel| Length | dia for Cylinder | Stress | Lock | Strand to cut Lock (tons) | (mm) | (mm) | (em2) | (em2) (mm) | (mm){ (mm) | (mm) | (kgs) D-20 22 735 106 42.2 - 350 200 175 70 27.5 DP-20 22 | 450 | 100 | 333 F 125 | 200/ 75 | 65 18 DP-30, | 30 450 | 118 48.5, 14 125 200| 75 76 26 €G-12/200 | 140_|_675 | 285 |341.05| 5252 | 600 | 200| 298 | 200 | 175 €G-18/150 | 200 [7610 | 345 | 482.4 | 66 560 |155| 300 | 240 | 200 'cG-18/200 | 200 | 715 | 345 | 482.4 | 66 620 2102315 | 240 | 255 CG-20/200 300 745 400 641.5 | 116.8 650 210 315 270 280 CG-30/100 350 500 380 563.72 - 350 100 210 300 270 CG-40/200 400 735 492 |1058.94| 173.3 660 210 290 328 ‘490 ‘CG-50/200 500 745 525 1196.2} 178 680 210 305 346 584 CG-50/200 Modified 500 735, 494 1045.4 | 173.3 660 210 290 328 480 CG-50/100 | 500 | - 494 (1045.4 [= = a) a = ca-50/300 | 500 | 750 | 494 |1045.4|173.3 | 850 | 300 210 | 328 | 550 CG-120/200| 1200 | dimensional details of CG120/200 & CG160/400 jacks shall be provided on request CG-160/400) 1600 ASSEN All prestressed cable should be layed in smooth curve ond supported at a spacing not exceeding one meter. If necessary reinforcement bars shall be bent or shifted locally to avoid clashing with prestressed cables and bursting reinforcement. The revised extension shall be recalculated ot ste in case of variations in the design values ond octual volues of : a) Strand ore, b) Modules of elasticity ¢) Gripping length. Revised modified extensions shall be used for calculations. Similarly the revised pressure shall be modified aking into account the actual jack efficiency v/s design efficiency considered in the GFC drawing. SAFETY PRECAUTIONS WHILE STRESSING Very large forces are introduced in the tendons during stressing and the equipment is under heavy hydraulic pressure, thus careful working can avoid accidents. The following precautions ore essential - + Only trained and experienced personnel, under the guidance of Dynamic technical taf, should perform stressing, + Theequipment, especialy the high pressure hoses and the adapters must be in perfect condition. Damaged hoses must be replaced immediately Protection caps mus always be placed over unused connections (electric as wel as hydraulic) + Jock should never be handled by hoses. Stressing should be done occording to specified data, The allowed maximum pressure shovld never be exceeded + During stressing, nobody should stand behind or underneath the jack, since failure of strand con cause fatal accidents + Forstressing close to trafic areas, the jack must be secured by ropes or chain hoist + Allbors, wires and strands should be stored carefully Ensure that they are net damaged in any way and should be checked forrust ond corrosion before they ore used. + Care should be token while handling high tensile steel strand as they may Whip back’ with force, fot securely bound. + Donot permit welding near high tensile Prstressingstel. A drop of molten metal f applied to the strand, will change its mechanical properties and promote the possiblities of premature file. (6) Hogging ofthe girder during stressing operation should be observed & recorded. =Post-tensioned cables are grouted to provide protection against corrosion. The grout encases the alkaline environment and prevents corrosion, it also develops bond between the prestress steel and surrounding concrete. Grouting should be done by water displacement method. The double acting reciprocating type Dynamic Grout Pump are widely used for grouting cable ducts & pressure grouting of rock anchors and dam. The pump is operated at working pressure of 5 kg/cm’ and has a discharge of 25 litres /minute. It operates on 3 phase electric supply and has 3 HP motor of 1440 rpm. The pump, weighs 200 kgs. and the area of piston is 19.64 cm2. The standard grout agitator used for making « homogenous grout mix of water, cement and admixture weighs 138 kgs. The agitator hos 3 HP motor and the capacity, (of mixing unitis 100 litres of cement grout. Dynamic has used high discharge capacity positive displacement type grout pump having minimum outlet pressure of 10.5 kg/cm’ for continuous span bridges of length 120 meters and more. Dynamic grout caps are advantageously used for speedy grouting. The grout cap is fixed by four allen key bolts and the air nuts keptin upward position + Protective glasses must be worn during grouting operation. + Do not start the pump while valves are in closed position as it may cause damage tothe pressure gauge. + Place the grout tank preferably at the same level as that of grout pump + Incose of a longer stoppage (> 5 min)of grouting operation, ensure that the grout does not set in the pump, ifnecessary empty the grout and flush pump with water. The high concrete stresses in the anchorage zone requires the compliance of specific conditions like the spacing of anchorages, minimum edge distance to the nearest conerete surface, strength of the concrete at the time of stressing, placing of primary anti-burst reinforcement in front of the anchorage & additional stirrups required to bind the edge & corner concrete into the mass of the end block. Perfectly compacted concrete in the anchorage zone is a must. The anti-burst reinforcement cannot make Up for local concrete defects. Precast end block can be used in case of ‘I’ girders or ‘Box’ girders. Transverse cables shall be avoided in the end zone portion While placing the anchor cone in the end zone, care should be taken that the ttachments must be strong enough to resist knocks & vibration and also the impact of the wet concrete dumped on it. The connection of the sheath with anchorage must bbe done with proper care to ensure that anchorage alignment is as per drawing & the connection is watertight (additional Heat Shrink tape if required should be used to ensure leak proof joint) The steel parts of anchorages must not be exposed to rusting while storing at site. When the anchorages are stored for more than 15 days, they should be keptin closed godown along with H.T. Strand. VPI (Vapour Phase inhibitor)bag shall be kept in godown fo prevent corrosion of Metallic Duct & H.T. Strands. For long exposure of anchor plate & anchor cones to rain & moisture at the construction site, the exposed parts & holes should be oiled and later cleaned before use. The live wedges should also be cleaned before installing in the anchor plate. After tensioning & grouting is completed, the exposed anchorage end & strands shall be cleaned & coated with epoxy bonding paint. The pocket portion shall be filled with compact concrete /mortar of approved grade.Void Formers Neopresne Bearings POT-PTFE Bearings Segmental Construction DMRC, Delhi. Dynamic Prestress Webiste : www.dynamieprestress.com Al Mawaleh Interchange OMAN - MUSCAT OFFICE 72, Mahavir Centre, Sector-17,, Vashi Navi Mumbai - 400 705,- INDIA. Tel: +91-22-27892628 /2789-1310, Fax 2 491-22-27891186 E-mail : dynamicmumbai @ gmail.com I 7 ihal i Incrementally Launched Deck on the River Yamuna PRODUCTION UNIT ‘Nasik, MIDC Satpur, Maharashtra, INDIA. Tel : +91-253-2351411/ 6601628 Fax _ :491-253-6607856 E-mail : [email protected] ‘hs ecument the propery yaa Pcs & matt pd, pincer ee hw ten dd et