VSL Technical Report - PT External
VSL Technical Report - PT External
VSL Technical Report - PT External
Contents
Preface.................................................................................................. 1
1. Introduction ............................................................................................ 2
1.1. Historical developments ....................................................................... 2
1.2. Areas of application today ..................................................................... 4
1.3. Types and components of external tendons ........................................ 5
General ................................................................................... 5
Prestressing steel ..................................................................... 5
Tendon anchorages .................................................................. 5
Corrosion protection systems ................................................... 6
Saddles at points of deviation .................................................. 7
1.4. Future developments .................................................................................. 7
Copyright 1992 by VSL INTERNATIONAL LTD., Switzerland - All rights reserved - Printed in Hong Kong.
EXTERNAL POST-TENSIONING
Preface
The purpose of this report is to discuss the principles and applications of external
post-tensioning and to present the VSL External Tendons. It should assist engineers in
making decisions regarding both design and construction. This document does not
represent a complete manual for detailed design and practical construction of structures
with external tendons. In this respect the reader is referred to the relevant technical
literature (see bibliography in Chapter 7). Furthermore, it must be mentioned that the
emphasis is clearly on the applications for bridges. Where appropriate, however,
reference is also made to other applications such as in buildings and circular structures.
There are many similarities between external tendons, stay tables and permanent
prestressed ground anchors. In fact, regarding many aspects there is hardly any
difference. Reference is therefore made to the report on VSL Stay Cables for Cable-
Stayed Bridges [1] and the VSL documentation on ground anchors (e.g. [2]).
The VSL Organizations will be pleased to assist and advise you on questions relating
to the use of external post-tensioning. The authors hope that the present report will help
in stimulating new and creative ideas. The VSL Representative in your country or VSL
INTERNATIONAL LTD., Berne, Switzerland, will be glad to provide you with further
information on the subject.
Authors
H.U. Aeberhard, Civil Engineer ETH
1
EXTERNAL POST-TENSIONING
1. Introduction
1.1. Historical developments In 1934, Dischinger was granted his (25.20 - 69.00 - 23.40 m), external
patent DRP 727,429 (Fig. 1). It contains tendons consisting of smooth bars with a
The idea of actively compressing the innovative idea of post-tensioning yield strength of 520 N/mm² and a diame-
structural elements with a high tensile reinforced concrete girders with external ter of 70 mm were used [6]. Due to World
material such as steel is very old. tendons. For the determination of the War II and its aftermath, the originally
Everyone is familiar with timber barrels magnitude of prestressing, he proposed planned restressing operations were not
and timber wheels stressed together by the concept of concordant prestressing, performed until 1962, together with other
steel hoops. In ancient Egypt, the same which later became known as the “load- repair work [7]. In 1983, the original bar
technique was used for shipbuilding. balancing” method. Dischinger’s main tendons were again stressed [8]. Today,
In the history of modern engineering, concern was the long-term deformation the bridge has been in service for more
Farber may first be mentioned. He was due to the time-dependent, visco-elastic than 50 years. Some years ago the
granted German patent DRP 557,331 in behaviour of the concrete. He was aware German Democratic Republic listed this
1927. In essence, this patent describes a of the pioneering work of Freyssinet and remarkable structure as one of its
prestressing system in which bond with his classical experiments, carried out in technical monuments.
the surrounding concrete structure is the years 1926 to 1929. While Freyssinet In the late thirties and early forties,
prevented by covering the prestressing clearly recognized the nature of concrete Dischinger designed other road and
steel with a bond-breaker such as with regard to creep and shrinkage [4], it railway bridges with spans of up to 150 m.
paraffin. It is not known whether Farber’s was Dischinger who first proposed a valid The construction of the Warthe Bridge in
idea was actually applied in practice [3]. mathematical model in 1939 [5]. Thus, in Posen (today Posnan, Poland) with spans
the absence of a sound theory in the mid- of 55.35 - 80.50 - 55.35 m was stopped
thirties, it was quite logical for Dischinger because of the war. The external ten-
to opt for external post-tensioning. He dons, consisting of steel ropes 65 mm,
wished to retain the possibility of were already on site. They were, how-
restressing the tendons should undesir- ever, more urgently needed as external
able deflections occur. Furthermore, tendons for post-tensioning the heavy
Dischinger specifically mentioned in his reinforced concrete trusses carrying trav-
publications the longer life of such eling cranes in a large steel mill [9].
tendons resulting from the reduced Dischinger also conceived composite
influence of fatigue loadings and the bridges with external post-tensioning [10].
system-inherent possibility of replacing Based on Freyssinet’s ideas, Wayss &
tendons, even under traffic, should this be Freytag AG designed and constructed in
required. 1938 the bridge over the Dortmund-
In the years 1936 and 1937, these Hannover Autobahn in Oelde, FRG,
ideas were applied in practice for the now where for the first time high tensile
quite well known bridge crossing the prestressing steel arranged inside the
valley basin and the railway lines at Aue, concrete section was used for 4 simply
Saxony, now the German Democratic supported girders of 33 m span. The pre-
Republic (Fig. 2, 3). For the main spans tensioning method was applied and the
Figure 2: Bridge at Aue; external Figure 3: First prestressed concrete bridge: Bridge over valley basin and railway at Aue,
prestressed bars of the drop-in span German Democratic Republic (designed by Dischinger)
2
EXTERNAL POST-TENSIONING
prestressing steel was therefore bonded and stress increase up to yield strength) Also during this period, the first
to the structure [ll]. This was actually the and the “free-of-charge ” corrosion applications of external tendons for the
first bridge in what is now called conven- protection by the surrounding concrete. strengthening of existing structures can
tional prestressed concrete. In 1949, Dischinger also was “converted” be found. An early example is the two-
In the same year, Finsterwalder and became an advocate of the bonded span steel truss bridge (48-48 m) over the
developed his concept of the “self- concept. Despite this pronounced trend, River Aare at Aarwangen, Switzerland
stressing ” concrete beam, which was external post-tensioning did not disappear (Fig 4). This bridge was built in 1889 and
put to the actual test for the bridge over completely. Several externally post-ten- was no longer capable of supporting
the same Autobahn at Rheda-Wieden- sioned bridges were constructed in modern traffic foads. In 1967 the bridge
brück, FRG (a simply supported girder of France [14], Belgium [15], Great Britain was strengthened with two locked-coil
34.50 m span). The external bar tendons and a few other countries. Not all of these strands 63 mm having an ultimate
65 mm with a yield strength of 520 N/ projects were successful. In some cases strength of 1,370 N/mm ² [16].
mm ² were stressed by the self-weight of the corrosion protection system chosen A rebirth of external post-tensioning
the superstructure using a hinge at mid- did not fulfill the required purpose and can be observed from the mid-seventies
span and a precamber of 272.5 mm. The tendons had to be replaced. onward. Freeman Fox and Partners
bar tendons were later encased in
concrete [12].
In the years 1938 to 1943, Haggbohm
designed and built the Klockestrand
Bridge (Fig. 5), near Stockholm, Sweden
[13]. For the main spans (40.50 - 71.50 -
40.50 m) the Dischinger concept was ap-
plied. The main span superstructure was
prestressed with a total of 48 bars of 30
mm having a yield strength of 520 N/mm ² .
3
EXTERNAL POST-TENSIONING
4
EXTERNAL POST-TENSIONING
1.3. Types and components materials is the much higher costs under which the suitability of a structure is
compared with prestressing steel. judged primarily on the basis of initial
of external tendons
construction costs, this seems to be the
1.3.3. Tendon anchorages normal choice.
1.3.1. General From a technical point of view, it
Until very recently, external tendons
A great variety of tendon types has should be remembered that the anchor-
were anchored with the same mechanical
been used and is described in the ages for external tendons must withstand
devices as those used for ordinary
technical literature. It is outside the scope the tendon force plus any potential
internal, bonded post-tensioning. Under
of this report to discuss all possibilities at subsequent force increase during the
the prevailing economic circumstances,
length.
Essentially, an external post-tensioning
tendon consists of the following elements:
- prestressing steel as tensile members,
- mechanical end anchorage devices,
- corrosion protection systems.
In the case of deflected tendons:
- saddles at points of deviation are also
required.
5
EXTERNAL POST-TENSIONING
lifetime of a structure. For anchorages post-tensioning anchorages of bonded protection are required. However, as for
meeting the requirements of approval systems. Specially designed devices are internal tendons, it seems advisable to
regulations such as those published by therefore required and have been apply a corrosion protection strategy
FIP [27], the effectiveness is normally developed accordingly (see Chapter 3). which is based primarily on environmental
given. conditions and also safety considerations
As mentioned earlier, external tendons 1.3.4. Corrosion protection (e.g. with regard to fire, strand failure,
can provide additional features such as systems etc.).
the possibilities of monitoring, adjustment, It is known that prestressing steel Many different solutions have been
replacement etc. These are increasingly needs careful protection against the adopted in the past [14]:
attracting the interest of maintenance- various types of corrosion attack. For
conscious bridge authorities. Such internal, bonded prestressing this a) Z inc coating: Its corrosion resistance
operations are not possible with typical protection is provided by the alkaline depends upon the type of galvanization
environment of the cement grout and the and the applied thickness. Z inc coated
surrounding concrete. Experience has prestressing steel has been used in
Evironmental Environmental shown, however, that there are several France on several occasions. There is
class conditions aspects to which attention must be paid, doubt, however, as to whether zinc
in both design and construction, to make coating provides a permanent corrosion
the protection really effective. protection. It seems to be durable only
1 Modest Structural elements always In [28] a corrosion protecting strategy under very favourable environmental
dry or under water is proposed, which is summarized in conditions. As reported in [14], coatings
Table II. It is in line with more recent have been damaged during handling
2 Moderate Structural elements sub- recommendations in various national and installation. Another problem arose
ject to moist conditions standards. In addition to the given design when zinc accumulated in the stressing
anchorage inside the wedges.
3 Severe Structural elements sub- measures, adequate materials and good
ject to permanent humid b) Polymer coating: This technology, in
workmanship are needed. From compari-
conditions and / or sons with the practice of the past and which polymers are bonded to the steel
changing wetting and experience gained with existing struc- by fusion, has been developed in the
drying conditions tures, it has been recognized for some United States primarily for the protec-
time that improvements are necessary tion of reinforcing steel. Polymer coated
4 Aggressive Structural elements sub- with regard to concrete quality, detailing strands have also been available for
ject to aggressive condi- and the amount of reinforcement. some time [29] and a number of appli-
tions For external tendons, other means of cations are reported (see para. 6.5.2.).
It remains to be seen whether this
Environ- Prestressing steel in Special protection Allowable design crack width (mm) Concrete cover (nominal values in mm)
mental tension zone under measures necessary under sustained loads
class (see sustained loads
above) Reinforced
Prestressed concrete Reinforced Prestressed concrete
concrete
concrete Post- Pre-
tensioning tensioning
Post- Pre- Post- Pre- Post- Pre-
Sheathing Steel
tensioning tensioning tensioning tensioning tensioning tensioning
1
Yes No 0.2 0.1 0.4 40*) 35 25
Yes Yes
**) **)
3 Yes No 0.2 0.25 50 45
No No 0.1 55
Yes Yes * *) * *)
* *) * *)
4
No No 0.2* * * ) 0.1* * * ) 0.25 60 65 55
*) Corrosion protection not relevant for cover of sheathing * * ) Not relevant for corrosion protection * * *) Under rare load combinations
Table II: Corrosion protection strategy for internai, bonded post-tensioning tendons, pre-tensioning and reinforcing steel
(as proposed in [28])
6
EXTERNAL POST-TENSIONING
system will prove to be a viable solution - Saddle arrangements: Various solutions Further innovation may be expected or
for prestressing steel. Problems could have been used in practice (see Fig. 9). indeed can already be seen on the
occur due to the fact that only the outer In most cases saddles consist of a pre- horizon. This will include progress in
strand surface is protected, the king bent steel tube cast into the surround- materials (e.g. corrosion protection
wire and inner surfaces of the six ing concrete or attached to a steel systems), in design proçedures, in
surrounding wires having no coating. At structure by stiffening plates. The structural concepts and in construction
the anchorages, the coating is locally connection between the free tendon technology.
interrupted by the indentations of the length and the saddle must be carefully The following few examples Will
wedge teeth. It is also possible that, as detailed in order not to harm the highlight what could be expected:
with zinc coated strands, problems may prestressing steel by sharp angular - Bridge superstructures with underlying
occur in the anchorages. Special care deviations during stressing and in external tendons: It is not an entirely
must be taken to prevent damage to service; also, the protective sheathing novel idea to arrange external tendons
the coating during handling and must be jointed properly. underneath the bridge girder. For
installation. example, this concept has been used
If tendon replacement is a design
c) Protective sheathing: The protective requirement, the saddle arrangement for steel bridges, such as the Neckar
sheathing represents an envelope must be chosen accordingly (e.g. Valley Bridge at Weitingen, Federal Re-
around the prestressing steel. Suitable double sheathing; see Alt. 3, Fig. 9). public of Germany [31], (Fig. 10), and
materials are steel or plastic tubes for the Bridge Obere Argen, Federal
- Minimum radii: L imits must be respect- Republic of Germany [32], [33]. In both
(polypropylene [PP] or polyethylene
ed because otherwise either the cases, the extremely difficult local soil
[PE]). In order to achieve an effective
prestressing steel or the protective conditions led to such a design. In [34]
protection system, proper solutions are
sheathing could suffer. Although some Wittfoht proposes underlying external
required for coupling these tubes with
tests exist indicating reasonable values, tendons as a standard solution for box
each other, with the anchorages and
which may be used for preliminary girder bridges for road or rail traffic.
with the saddles.
designs, more research work is Menn describes a similar system for
Injection of the remaining voids inside required in this respect. It is therefore slab bridges, by which the feasible
the sheathing with cernent grout has advisable to verify the feasibility of a span range can be extended up to
proven to be economical and reliable. In particular practical solution by tests. about 40 m [35], (Fig. 11). A compre-
the case of restressable anchorages, hensive test programme for determining
cernent grout must be replaced at least 1.4. Future developments the structural behaviour has been
focally by grease or similar soft plastic carried out at the Swiss Federal
material. Particularly in France, grease Institute of Technology (ETH), Z urich,
The revival of external post-tensio-
and wax products have been applied, Switzerland [36] (Fig. 12).
ning has been a stimulus for engineers.
instead of cement grout, on the entire
tendon length [14], [30]. Besides being
rather expensive, these products are
difficult to inject (e.g. preheating up to
100° C required) and special measures
are needed to prevent leakages (see also
para. 6.2.5.).
In this category, individually greased
and plastic-sheathed monostrands offer
many advantages. They are manufac-
tured under factory conditions. The
prestressing steel is therefore effectively
protected against corrosion during
transportation, storage on site and
installation, provided that proper care is
taken not to damage the sheathing.
Monostrands can be used either indivi-
dually or in bundles as multistrand
tendons. In the latter configuration they
are usually placed inside a plastic or steel
tube. The remaining voids are filled with
cernent grout.
7
EXTERNAL POST-TENSIONING
Figure 11: Details of slab bridge with underlying external tendons Figure 12: Scale model
8
EXTERNAL POST-TENSIONING
2.1.General
The purpose of this chapter is to
highlight some special aspects that
should be considered in the design of
externally post-tensioned bridge super-
structures.
As for any design, it is normally at the
conceptual stage that the “fate” of a
structure with regard to economy and
durability is determined. A straightforward
structural system, good detailing, and the
early integration of the construction proc-
ess are the major elements of a success-
ful design. In this respect, bridges with
external tendons are no exception.
To obtain a satisfactory behaviour of a
structure both under serviceability and
ultimate limit state conditions, it is
essential to recognize the peculiarities of
girders with external tendons. Fig. 13
shows moment-curvature curves for a
typical bridge cross-section with either
bonded or unbonded prestressing. For Figure 13: Moment-curvature curves for a typical bridge cross-section with bonded and
comparison, a curve for non-prestressed with unbonded prestressing
bonded reinforcement is also shown. The
cross-sections of the reinforcement and Good crack distribution can only be
- Girder with unbonded tendons: obtained if the flexural resistance at a
prestressing were chosen such that all
three sections would reach the same Because relative longitudinal displace- section exceeds the cracking moment.
ultimate moment. As can be seen from ments between concrete and steel are This principle is well known from minimum
Fig. 13, there is no fundamental differ- not prevented by bond, the tendon reinforcement requirements. For case a)
ence between girders with bonded or with force increases only due to deformation of Fig. 13 this principle is only barely met
unbonded tendons below decompression of the entire structural system. Similar and hence deformations may take place
moment. The section with unbonded to slabs with unbonded tendons [38], in just one or a few cracked sections.
tendons has a larger initial prestressing the tendon force increase depends This may lead to an undesirable strain
force and, therefore, a higher decompres- primarily on the geometry and the localization with a subsequent premature
sion moment than the section with overall deformation of the structure as failure.
bonded tendons. With regard to the well as the tendon profile.
fatigue behaviour, Dischinger [10] already For long tendons and slender struc- As a consequence of the described
mentioned the advantage that for behaviour, externally post-tensioned
tures this increase will be relatively
unbonded tendons only negligible stress structures are inherently more sensitive to
small, even for large overall deforma-
fluctuations occur in the prestressing secondary effects since, unlike bonded
steel under live load. tions of the system. Therefore in Fig.
13, the tendon force increase has been systems, they do not have the capability
A closer look at the behaviour of the neglected and hence the decompres- to adapt to local overloads by local
sections is required following decompres- sion moment is equal to the ultimate yielding. Hence, while a realistic assess-
sion: moment. Of course, friction at deviation ment of secondary effects is not of
- Girder with bonded tendons: After points would somewhat improve the be- primary importance for bonded systems,
decompression, the tendon force this is quite different for externally post-
haviour, but unless intermediate an-
increases up to the yield strength. The tensioned systems.
tendon force increase and the associ- chorages or partial bond at sufficiently
ated increase of the internal lever arm closely spaced locations along the In practice, continuous bonded
of the section provide a yield strength tendons and/or additional bonded reinforcement and partial bond of external
considerably larger than the decom- reinforcement are provided, it shoutd be tendons, at tendon deviations due to
pression moment of the section. Owing recognized that decompression friction or cernent grout will contribute to
to the bond between concrete and essentially means ultimate. increasing the ratio of flexural resistance
steef, the flexural behaviour at a section At any rate, the strength of an exter- to cracking moment and thus result in a
is more or less independent of adjacent nally post-tensioned girder at one par- more forgiving behaviour of the structure.
girder zones. ticular section depends on the behavi- Finally, it should be mentioned that
our of the entire structural system, or at prior to grouting of the tendons a structure
least parts of the system if intermediate with bonded tendons behaves similarly to
anchorages are used.
9
EXTERNAL POST-TENSIONING
an externally post-tensioned system. In A reasonable prestressing force may after all losses in order to get an estimate
one case a bridge failed during construc- be estimated using the load balancing of the ultimate resistance. Alternatively, a
tion [39] primarily because the special method. If a substantial part of the dead rigorous analysis can be performed by in-
conditions of the construction stage were load is balanced by the prestressing, a tegrating the strain increments in the
overlooked. This failure clearly exhibited satisfactory behaviour of the structure structure along the tendon axis (Fig. 15a),
the effects of strain localization and points may be expected regarding both deflec- or an estimate of the tendon elongation
to the need for a careful evaluation of all tions and cracking. can be obtained from the consideration of
possible effects of loads and imposed de- As soon as the tendons and their a rigid body mechanism (Fig. 15b).
formations when designing externally profiles are selected, the tendon force Integration of the strain increments
post-tensioned systems. diagram can be determined. As external along the tendon axis requires an iterative
tendons are generally arranged in a non-linear analysis [14], [40]. For a given
2.2. Serviceability and polygonal shape, the force diagram will load increment and an assumed tendon
ultimate limit states have steps at the deviation points. Fig. 14 force the strain increments at each
shows the forces applied to a deviation section and the associated tendon force
2.2.1. Serviceability limit state point. increase can be computed. Repeating the
Usually, the amount of prestressing is Long-term losses due to relaxation of calculations with the new value of the
selected at a relatively early stage in a the prestressing steel, as well as creep tendon force will result in an improved
project. This selection is influenced by and shrinkage of the concrete, cause a estimate and after a few iterations a
considerations regarding serviceability decrease in the tendon force. As long as reasonable approximation will be ob-
and economy of the structure: no relative displacements between tained. Similar computations can then be
tendon and concrete occur at the devia- made for the next load increment and so
- Under dead load only, the structure tion points, either because of the pres- on.
shall remain substantially uncracked or ence of high friction coefficients or
existing cracks shall be closed. On the because of partial bond, these losses
other hand, the requirement of an may be estimated section by section as
uncracked structure for dead and live for bonded tendons. However, for low
load inctuding secondary effects might friction coefficients there will be some
lead to undesirable long-term hogging slippage between tendon and concrete
deflections under dead load only. and the losses may be estimated from
However, under such loading condi- mean axial deformations due to creep
tions cracked sections can normally be and shrinkage of the entire structure.
accepted if the stresses in the rein- As mentioned in Section 2.1. structures
forcement are limited such that the with external tendons may be sensitive to
cracks close again after removal of the secondary effects. Therefore, it is
load. essential to assess tendon forces and
- From an economic point of view, one secondary effects due to temperature,
should ideally provide just enough creep, shrinkage and other effects as
non-prestressed reinforcement and re- realistically as possible when performing
stressing steel as necessary to obtain checks at serviceability limit states. The
the required resistance. effects of prestressing may be considered
either by the primary and secondary
moment method or by the load balancing
method. The first method is generally
used for the final design of a structure
because it allows for an easy considera-
tion of friction losses. On the other hand,
the second method is prlmarily suited for
preliminary designs if friction losses are
neglected. Figure 15: Tendon elongation +L
10
EXTERNAL POST-TENSIONING
P(X) = P 0 e - ( Pα+kx)
where
11
EXTERNAL POST-TENSIONING
its long-term stability and its suitability in 3.2.6. Anchorages Type 1 Type 2
providing corrosion protection of the The anchorage principle of VSL
prestressing steel. The sheathing is of Externat Tendons corresponds in
polyethylene (or alternatively polypro- Environmental con-
essence to the VSL Post-Tensioning ditions (see Table II):
pylene) and has a minimum thickness of System. Figures 21 to 29 represent a
1 mm for straight tables and 1.5 to 2 mm
class 1 n
variety of possible anchorages. Different class 2 n
for curved tables. class 3
parameters, such as required adjustabil- n
ity, replaceability, load monitoring,
class 4 n
3.2.4. Characteristic breaking loads installation procedure, access to the end
of VSL External Tendons
Table VI gives the nominal breaking anchorages (e.g. for the strengthening of Need for tendon force
structures), static considerations and adjustement:
loads for the VSL External Tendons no n
according to the four strand types as environmental conditions as per para.
3.2.2., influence the selection of the
yes n
detailed in Table V. The characteristics of
the strand may, however, slightly deviate particular anchorage type.
Tendon friction
from these values, depending on the The exposed surfaces of the anchor- shorter tendon and
manufacturer and applicable standard. ages are properly coated for corrosion small ∑α n
protection. longer tendon and
3.2.5 Tubing high ∑α n
The strand bundle (consisting of either 3.2.7. Grouting compounds
bare or greased and plastic-coated Table IV: Main technical criteria for
The tubing around the strand bundle selection of tendon type
strands) is usually encased in a plastic
tube. Alternatively, steel tubes may be constitutes its primary corrosion protec-
used. In certain areas, such as deviation
saddles or parts of the tendon embedded
in concrete, regular corrugated steel duct
as normally used for post-tensioning 13 mm (0.5”) 15 mm (0.6”)
Strand type
tables may be chosen. The latter,
(A) (B) (C) (D)
however, is only applicable when the
Euronorm ASTM Euronorm ASTM
tendon does not need to be replaceable
138-79 A 416-85 138-79 A 416-85
(see also para. 3.2.6.), and tendons Type
Super Grade 270 Super Grade 270
1 are used.
Nominal diameter (mm) 12.9 12.7 15.7 15.2
In general, the plastic material is 140
Nominal steel area (mm2) 100 98.7 150
polyethylene and meets the requirements
of appropriate standards such as DIN Nominal mass per m (kg) 0.785 0.775 1.18 1.10
8074 and 8075, ASTM D 1248 and 3035
or equivalent. Alternatively, polypropylene Yield strength (N/mm2) 1,580
1,670 1,500
1,670
may be used. The ratio of internal 1,770
Ultimate strength (N/mm2) 1,860 1,860 1,860
diameter to wall thickness is approxi-
mately 16:1. In general carbon black is 186.0 183.7 265.0 260.7
Min. breaking load (kN)
added as ultraviolet stabilizer. This
material is chemically inert against 1) 0.1 % proof load method 2) 1 % extension method
tion. In addition, the tendon is completely and fulfills the same requirements
filled with a grouting compound. As as the one used in traditional post- Due to the fact that the envelope
mentioned under 3.2.1.. normally cement tensioning. With its alkaline properties, reduces or eliminates the diffusion of
grout is used. it provides active corrosion protection. gases and liquids, carbonation of the
The grout is made from Portland cement The grout completely fills the interstices cement grout is inhibited.
between the strand bundle and the outer
Notes: *Bursting steel not shown for clarity. tubing.
*Figures 26 to 29 have been omitted.
14
EXTERNAL POST-TENSIONING
Composition: Anchor block with wedges, retainer plate on passive side to secure
wedges, steel case. Tube for strand overlenght if detensionability or ad-
justability required.
Features: For tendons with insuficient access for stressing at end anchorages
(e.g. strenghtening of structure) or for circular tendons.
Figure 25: Centre-stressing anchorage Type Z Figure 30: Intermediate tendon supports
3.3. Experimental evidence by VSL (Fig.31). The first test aimed at tendon was slightly stressed from both
Several tests have been conducted
during the development of the VSL determining the groutability of a bundle of anchorages prior to grouting. The tendon
Extemal Tendons. These tests have monostrands, especially in the saddle was then stressed to 70% of the breaking
provided valuable data for material area. The second test involved stressing load, again applying a 600 mm relative
selection and procedures, anchorage the tendon in stages up to 70% of the displacement. The fourth test was similar
design, and friction losses in saddles. For breaking load. To simulate actual to the third, but incorporated the improve-
the Bois de Rosset Viaduct project conditions, a relative displacement of ments obtained through the earlier tests.
(para.6.2.9.), four tests were performed 600 mm was applied. In the third test, the
15
EXTERNAL POST-TENSIONING
16
EXTERNAL POST-TENSIONING
Stage 2
Stage 3
18
EXTERNAL POST-TENSIONING
boxes. The construction procedure was 6.2.2. Seven Mile Bridge, Florida,
chosen accordingly. Construction of the USA
superstructure was split into two phases. Owner Florida Department of
First the boxes were constructed on Transportation, Tallahassee,
falsework, while the cantilever slabs were Florida
added later, using movable shuttering. Engineer Figg and Muller Engineers,
The technique applied in the construc- Inc., Tallahassee, Florida
tion of the boxes was as follows (Fig. 36): Contractor Misener Marine Construc-
- Stage 1: Construction of span 1 plus tion, St. Petersburg Beach,
115th of span 2 by successively Florida
concreting diaphragms, base slab and Erection of
webs, soffit slab. superstruc-
- Stage 2: Installation and stressing of ture and
the first half of the span 1 tables, con- post- VSL Corporation,
creting of the remainder of span 2. tensioning Los Gatos, California Figure 38: Saddle detail
- Stage 3: Moving of scaffolding and Construction
from span 1 to span 3 formwork, Period 1979-1982
installation and stressing of tendons
covering spans 1 and 2, concreting of The Seven Mile Bridge, which leads
span 3. from south of Marathon to Little Duck
- repetition of cycle. Key, is the longest in the chain of road
structures connecting the mainland of
The tendons were made up from Florida to Key West. With a total length of
monostrands and are not encased in any 10,931 m (35,863’) it is also the longest
additional sheathing between the dia- concrete box girder bridge in the world. It
phragms. In each span, there are 16 VSL consists of 266 spans, most of them
tendons type 6-19 dyform (breaking load having the standard 41 .15 m (135’) span
approx. 5,700 kN each) having normal length. The superstructure with its single-
VSL anchorages type E at both ends. The cell box section has a total width of
tendons caver two spans and overlap at 11.89 m (39’) and a constant depth of
the piers. Thus the maximum tendon 2.13 m (7’).
length is approx. 170 m (Fig. 37). Profiling The design especially aimed at speed
was achieved by means of saddles cast of construction, in addition to economy.
into the diaphragms. The saddles Thus some structural details are quite
consist of mild steel tubes of 110 mm unusual, even somewhat bold, with
outside diameter welded into a steel box regard to concept and durability. These
(Fig. 38). details are:
The tendons were prefabricated in the - No gluing material to bond or seal the
Figure 39: Construction phase
workshop and introduced into the box joints of the match-cast segments.
through a hole in the deck slab. Tendons Multiple keys only were provided to
near the top of the box or inclined transfer shear forces. temporary prestressing strands. The pier
tendons showed a considerable sag - Segments stressed together with segment, accompanying the assembled
between diaphragms, due to their dead external tendons running inside the box spart, was also transferred to the shuttle
load. As this would have created prob- and connected to pier diaphragms and barge, which then moved beneath the
lems during stressing, intermediate props deflector blocks. erection truss (Fig. 39).
were temporarily placed between The truss was a very sophisticated
- No overlay or wearing surface on the gantry combining innovative engineering
neighbouring diaphragms.
segments; the traffic runs directly on with proven techniques and practical
Originally, stressing at both tendon
the precast concrete. experience. VSL proposed to use such a
ends was required to compensate for the
friction losses, as in the design a friction The segments of the superstructure truss as a variant to the construction
coefficient u = 0.30 was adopted. Tests were cast in a yard in Tampa, Florida, scheme given in the contract documents.
on site, however, showed an effective of approx. 400 km (250 miles) north of the The following are the main factors that led
between 0.05 and 0.10. A revised bridge site. The five sets of forms allowed VSL to alter that scheme:
calculation with these values proved that for an average production rate of three - The segment alignment is taken off the
unilateral stressing was therefore accept- spans (i.e. 24 segments) per week. After critical path. thus increasing speed of
able for obtaining the required forces. proper curing, the segments were barged construction and adding flexibility to the
Post-tensioning work started in June to site. There, the segments of a span operation.
1975, and was completed in Cctober were placed aboard a shuttle barge, then - A cleaner division is achieved between
1976. The total quantity of strand incorpo- winched together, aligned to the required the work performed by the general
rated in both viaducts is 1,100 tonnes. alignment and connected with four contracter and by VSL.
19
EXTERNAL POST-TENSIONING
- VSL can control all its operations Additional details about the Seven Mile type EE 5-12 are installed, providing
overhead. Bridge and its construction can be found forces from 600 to 1,200 kN. The tendons
in [ 46] . are encased in PE tubes and were
The truss, designed and operated by grouted after stressing (Fig. 42).
VSL, in a typical operation lifted the pier 6.2.3. Châtelet Viaduct, Charleroi, As the Belgian standard in force at that
segment into place, then cantilevered Belgium time did not contain any prescriptions for
itself forward to position its centre on that Owner I.A.C. (Intercommunale this type of construction, full size model
newly placed pier segment and finally Autoroute Charleroi), tests were performed with tendons of the
raised the lifting frame bearing the Charleroi above-mentioned unit in order to assess
preassembled span from the barge. Engineer Office J. Rondas, Brussels the fatigue behaviour of the tendon itself
Concrete blocks were then inserted into Contractor Joint Venture Socol S.A., and especially of the anchorages. In this
the gap and the post-tensioning tendons Brussels/ Ateliers de Con- way an anchorage design fulfilling the re-
stressed to 15% of the ultimate force. struction Jambes-Namur; quirements was found. Another detail
After the closure concrete had reached a later Ateliers de Construc- checked was the tightness of the tendon
strength of 17.5 N/ mm²² (2,500 psi) tion Jambes-Namur/ Société system at every point, in particular at the
overnight, the tendons were fully Pieux Franki S.A., Liège anchorages and the saddles.
stressed. Post- Civielco B.V., Leiden, The tables being practically straight,
VSL started erection of the first span of tensioning Netherlands saddles were required only near the
the bridge on May 30, 1980. On average, Construction anchorages, for reasons of space. These
three spans were installed per week, with Period 1981-1982 saddles consist of thick-walled steel tubes
a maximum of six spans in a six day In order to take the transit traffic off the welded to the web of the steel girder. The
single shift period. The structure was city centre and to connect the industry PE tubes of the tendons are fitted into the
completed in May 1982. zones at the periphery, an outer ring road saddles and the joints tightly sealed.
Each span contains 4 VSL tendons was built around Charleroi, an industrial
5-27 (breaking load approx. 4,960 kN centre in southern Belgium. In the suburb
each) and 2 of the unit 5-19 (Fig. 40). The of Châtelet the ring road crosses the
tendons are anchored in the pier dia- valley of the river Sambre, which is
phragms by VSL stressing anchorages densely built-up and through which the
type EC. In the five central segments of a railway line Paris-Cologne also passes.
span, the tendons are deflected in To cross the valley a 1,097 m long
deviation saddles. In the pier segment, viaduct had to be constructed.
semi-rigid duct was embedded to bring The design adopted was put forward in
the tendon to the anchorage, while a the tender stage as an alternative to the
short piece of galvanized pipe guides the tender design. It comprises two independ-
tendons through the deviation saddles. ent superstructures, each made up of two
Between these, the tendons are encased 3.00 m deep steel girders carrying a
in plastic pipes. Plastic pipe and duct or 16.00 m wide light-weight concrete deck.
pipe are connected with rubber boots and Most of the 25 spans, the lengths of
hose clamps (Fig. 41). All tendons were which vary between 34.98 and 58.60 m Figure 41: Detail of deviation saddle
prefabricated and pulled in by hydraulic (except the main span which measures
winch; they were cement-grouted for 68.40 m), are simply supported beams.
corrosion protection. In view of the bad soil conditions, the
Transverse post-tensioning was lightest possible structure was sought. For
also applied, in the deck slab of the pier this reason the steel girders are post-
segments only. The tables used are tensioned with external tables. At the
internal, consist of four strands 13 mm base of each girder, up to 6 VSL tendons
(0.5”) and are provided with VSL anch-
orages.
20
EXTERNAL POST-TENSIONING
21
EXTERNAL POST-TENSIONING
22
EXTERNAL POST-TENSIONING
Engineer Figg and Muller Engineers, of 3.66 m (12’) by inclined struts ending at
Inc., Tallahassee, Fla. the intersection point between web and
Contractor Paschen Contractors, Inc., bottom slab. The main structure is
Chicago, Ill. followed on each side by 18 spans of
Post- VSL Western, 41 .15 m (135’) standard length twin
tensioning Campbell, Cal. single-cell box girders (Fig. 52).
Construction All box-sectional parts were made up
Period 1983-1987 from precast segments joined together
The Sunshine Skyway Bridge replaces with an adhesive, some with in-situ
a section of the bridge structure leading concrete. In the main structure, the
across Tampa Bay between St. Peters- segments were hoisted from barges and
burg and Sarasota. The replacement placed at alternate ends in the free
Figure 50: Tendons inside the box became necessary, as in May 1980 a cantilevering manner. In the 41.15 m
tanker veered out of the navigation (135’) spans, however, the erection truss
channel and rammed one of the main from the Seven Mile Bridge (see para.
piers, thus sending 400 m (1,300’) of 6.2.2.) was reused after adaptation and
- Permanent tendons which were bridge into the water. In October 1982, complete spans were placed by the
stressed before a new increment was the owner opened bids for a replacement contracter, who had bought the truss from
jacked forwards. These tables are bridge. VSL.
polygonal and parabolic and are within The winning design for the high-level The superstructure is post-tensioned
the concrete section. and main approach spans consisted of a longitudinally and partially transversely.
- Temporary tendons that were stressed concrete box girder structure with a The latter tables consist of VSL tendons
before jacking and afterwards were 365.76 m (1,200’) table-stayed main SO/ SO 6-4 placed in the concrete section
destressed and removed. After span. It should be noted that all stays are in flat corrugated ducts of high-density
completion of the first superstructure, VSL Stay Cables System 200 with up to polyethylene. Longitudinal post-tensioning
these temporary tendons were reused 82 strands of 15 mm (0.6”). The rebuilt in the free cantilevered part consists of
in the second one. All of these tendons crossing was opened to traffic in April tendons within the concrete section
were external. Some were straight, 1987 (Fig. 51).
while others followed a polygonal The table-stayed part with spans of
profile to give, in conjunction with the 164.59-365.76-164.59 m (540’ -1,200’ -
first group, a central prestress. 540’) is adjoined on each side by three
- Permanent tendons which were spans each of 73.15 m (240’) and one
stressed after the increments were span of 42.67 m (140’). The superstruc-
jacked forwards. They are all external ture of this main part consists of a 4.47 m
and either straight or polygonal in (14’ -8”) deep single-cell box girder with
layout. steeply inclined webs. The deck slab is
Figure 52: Cross-section of twin, single
All tendons are of the VSL unit 6-12 28.78 m (94’ -5”) wide. Along the central
box girder structure
(breaking force 3,024 kN each) and have axis it is supported in the box at intervals
stressing anchorages type EC at both
ends. The temporary tendons and the
final external tendons were placed in
polyethylene tubes, while steel pipes
were used for the final internal tendons
(Fig. 50). All final internal tendons were
grouted with cement grout.
The external tendons are deviated in
concrete frames provided in the boxes,
into which curved steel tubes are placed.
A short piece of PE tube is placed on the
ends of the steel tubes and fixed in the
concrete. To this the PE tube of the
tendon is joined by means of a joint
welded on both ends of the PE tubes.
installed during free cantilevering while has two river piers. The height above the stresses desired by the engineer.
the continuity cables run inside the box. river varies from 24.38 m (80’) at the north All tendons were cement-grouted for
These are VSL units 5-17 and 5-27, up to end to 58.22 m (191’) at the south end, corrosion protection. A special detail was
238 m (781’) long. In the 41.15 m (135’) making it one of the world’s steepest required for the trumpet to allow for
spans, VSL tendons 5-19 to 5-27 are bridges (Fig. 53). structure movement during stressing
arranged inside the box similarly to the The new bridge makes use of some while maintaining a seal capable of
cables of Seven Mile Bridge (see para. innovative structural techniques. Although withstanding the high grouting pressure.
6.2.2.). Anchorages used were standard the main river span appears to be a
EC type. After stressing (double end traditional arch, it does not function as 6.2.9. Bois de Rosset Viaduct near
stressing for longer tendons) the cables such. The structural loads are distributed Faoug (VD), Switzerland
were cement-grouted. in cantilevered action through the use of Owner Département des Travaux
the half arches on either side of the main Publics du Canton de Vaud,
6.2.8. High Bridge, St. Paul, Mn., span and the tensioned tables beneath Lausanne
USA the deck. This unique structural system Engineer CETP Ingénieurs-Conseils
allows steel members to be lighter than SA, Lausanne/DIC
Owner State of Minnesota, conventional arches and this contributes Ingénieur Conseil, Aigle
St. Paul, Mn. to the graceful aesthetic qualities of the Contractor Joint Venture of
Engineer Strgar-Roscoe, Inc., structure. Frutiger SA, Yvonand/
Wayzata, Mn./ Eight VSL tendons 5-27, 166.12 m Ramella + Bernasconi SA/
T.Y. Lin International, (545’) long, tie the cantilevered arches Reymond SA
San Francisco, Cal. together at the south pier. Similarly eight Post-
Contractor Lunda Construction, black tendons of the same unit, 146.61 m (481’) tensioning VSL International SA
River Falls, Wi. long, were used at the north pier. The Crissier
Post- VSL Corporation, tendons, which are straight, were Construction
tensioning Burnsville, Mn. anchored at both ends by means of period 1988-1990
Construction normal E type stressing anchorages
Period 1985-1987 provided with a special cover cap. Each The Bois de Rosset Viaduct consists of
tendon was pulled from ground into a two parallel structures with 15 spans each
The new High Bridge, which replaces a galvanized steel pipe of 101.6 mm (4”). (23.00-34.20-11x42.75-51.30-38.50 m). It
structure that was built in 1889, is the first Stressing was carried out in three stages: has a total length of 617.25 m, a width of
bridge in the USA to use a combination Stage I stressing closed the gaps in the 2x13.0 m, and crosses a railway line at a
of table and steel tension-tie design for a slotted connections at the ends of the height of approx. 10 m. The composite
deck-tied arch bridge. It is 839.72 m wide flanges, Stage II took place after the superstructures consist of steel trough
(2,755’) in length with a width varying concrete deck was cast and Stage Ill fine- girder sections connected to a transverse-
from 20.02 to 27.13 m (65’ -8” to 89’). It tuned the arch to the camber and ly post-tensioned concrete deck slab.
The structures are longitudinally post-
tensioned with four VSL External Ten-
dons in each span. Each tendon consists
of 12 individually greased and plastic-
sheathed VSL Monostrands which are
grouted inside a thick-walled polyethylene
tube. Tendon lengths range from 196 m
to 216 m, and are located inside the steel
troughs, routed over a maximum of five
upper deviation saddles and ten lower
saddles.
24
EXTERNAL POST-TENSIONING
This project represents the first use of b) Surrounding the masonry with stressed entirely surrounds the flue gas pipe and is
monostrand external tendons in Switzer- steel bands. The installation of these anchored in a steel buttress. To minimize
land, and the installation is monitored as bands and the disc springs required be- the effect of friction losses, successive
part of a long-term observation program. tween band segments are expensive as pairs of tendons are alternately anchored
Four tendons are equipped with perma- exterior scaffolding is needed around at buttresses on opposite sides. Each
nent VSL load cells, and all tendons are the chimney. The same is also true for tendon is stressed to 100 kN. Tendon
adjustable and replaceable. additional stressing of the bands at a spacing is 1 m. Before reaching the
As mentioned in para. 3.3, extensive later date, which is necessary as the buttress, one table end undergoes a
testing was performed for the develop- springs do not provide long-term com- deviation in a special construction, so that
ment of this tendon system with regaid to pensation for creep of the gap-filling
materials, procedures, anchorage design, compound. it can be anchored in the buttress. The
and friction losses in the saddles. For two chimneys a new method was deflection device and the anchor buttress
applied in 1986/87, in particular to avoid are coated with an anti-corrosive paint
6.3. Other structures the above-mentioned disadvantages. This (Fig. 56).
originally designed with method consists of surrounding the flue The installation of the special bricks,
external tendons gas pipe at regular intervals with external, the PE protective pipes containing the
individual post-tensioning tendons. These monostrands, and the buttresses was
6.3.1. Flue gas chimneys, Federal must fulfill the following requirements: carried out as part of the brickwork of the
Republic of Germany - easy installation, flue gas pipe. Thus, no special outside
For environmental reasons, coal-fired scaffolding was required. For stressing,
- easy stressing operation, however, a scaffold was used, which
power plants in the Federal Republic of
Germany are equipped with flue gas - possibility of additional stressing, could be displaced vertically in front of the
sulphur removal systems. The purified - possibility of monitoring the tendon
flue gases are normally expelled through force,
the cooling tower, together with the - easy replacement.
cooling steam. In the case of a break-
down, however, the flue gases are The tendons used are VSL Monos-
diverted past the desulphurization system trands 15 mm. They rest on special
and fed into the chimney. bricks containing a groove into which the
The shaft of the chimney ( approx. 10 tendon is fitted. These bricks are thermal-
to 17 m) is made of reinforced concrete; ly insulated from the flue gas pipe so that
the tendons are subject to a maximum
inside is the flue gas pipe made of acid-
temperature of 40°C which both grease
resistant ceramic masonry. The flue gas
and PE coating are able to withstand
pipe is surrounded by thermal insulation
without problems. Nevertheless each
made of foam glass (Fig. 55). Upon
monostrand is additionally inserted into a
breakdown of the desulphurization
protective pipe of PE in order to prevent
system, the temperature of the flue gas Figure 55: Cross-section of the flue gas
the coating of the tendon from bearing
rises quickly by 90°C to 180°C. The shock chimney
directly onto the bricks. Each tendon
of the sudden change in temperature
leads to high compressive and tensile
stresses in the heat-resistant ceramic
masonry. The tensile stress exceeds the
stress limit allowed in the standard DIN
1056. To ensure the serviceability of the
flue gas pipe, special methods must
therefore be taken.
Up to now the following methods have
been used:
a) Reinforcing steel with anti-corrosive
coating. The disadvantages of this
solution are that the reinforcing steel
does not prevent cracks and that
bonding problems can occur as a result
of the differing thermal expansion
coefficients of reinforcing steel and
ceramic brick.
25
EXTERNAL POST-TENSIONING
row of buttresses. The post-tensioning after checking of the design, it was found and because of the length and the weight
force cari be checked at a later date, if that no temperature gradient had been of the tendons. Thus only the push-
required, the anchor heads being considered and that the cover of the through method was applicable. Tests
externally threaded for this purpose. prestressing tendons was insufficient. The made by VSL enabled the best way of
Before the system was actually applied structure therefore had to be repaired in operating to be found. They showed that
on site, tests were carried out in order to: the shortest possible period. A complete two intermediate pushing posts were
- verify that the edge of the bricks would interruption of the highway being unac- required. According to the access
not cause any long-term damage to the ceptable, the owner had to allow for the possibilities, pushing sections of 135, 160
PE coating of the monostrands repair work to be done under light traffic. and 135 m were selected. Two pushing
- test and practise proper installation, Therefore, the consultant proposed to machines had to be placed at the first
stressing and replacing of the tendons apply external longitudinal prestressing intermediate post in order to obtain the
after the cracks had been grouted with required pushing force (Fig. 58).
The tests gave fully satisfactory results resin. In addition, the following measures When a certain number of strands had
which were confirmed during application. had to be taken: been introduced, the pushing force
available was no longer sufficient for
6.4. Bridges with - Construction at either end of the bridge overcoming the friction in the steel tubes
subsequently added external of a prestressed concrete cross-beam, and an auxiliary strand running between
tendons incorporating the anchorages of the the first two posts was used, to which the
new tendons and transmitting the strands to be installed were coupled. The
6.4.1. Roquemaure Bridge near additional forces to the superstructure first machine pushed the auxiliary strand
Avignon, France of the bridge. while the second machine pulled it. After
- Construction of a working chamber pulling, the auxiliary strand was pushed
Owner Autoroutes du Sud de la behind each cross-beam, from which back to the first post and the operation
France, Védène the strands would be fed into the ducts then repeated. When the pushing
Engineer Etudes Ouvrages d’Art and where the cables could be operation was finished, the openings in
(Bouygues), St. Quentin en stressed. the tubes were closed by previously
Yvelines - Installation of hangers beneath the mounted coupling sleeves.
Additional bridge deck carrying the cable ducts. Before the tables were stressed each
Post- VSL France s.a. r.l., individual strand was pretensioned to
tensioning Boulogne-Billancourt The longitudinal prestressing force
required amounted to 54,000 kN after 1 N/mm² by means of a monojack to bring
Execution 1975-1976 all strands to the same length.
losses. VSL thus proposed to use 8
This bridge is part of Motorway A9 tendons of the unit 5-55 (ultimate force
Orange-Narbonne in Southern France, 9,169 kN) running from one end of the
which it carries across the river Rhône bridge to the other without any coupler
near Avignon. The structure is 420 m long (table length thus 430 m!). Four spare
and has spans of 50-4x80-50 m. The ducts were also installed in case addi-
21.60 m wide superstructure consists of a tional prestressing should be needed.
double-T section with a depth between VSL was awarded the post-tensioning
5.40 m at piers and 1.80 m at mid-spans contract because, besides a reasonable
(Fig. 57). It was built in 1971 to 1974 by price, VSL could prove its experience, in
the free cantilevering method, with cast- pushing through strands and it had
in-place segments up to 6.12 m in length. available equipment for this method,
In 1975 a surveillance campaign revealed including several high capacity jacks.
the presence of major cracks (as wide as Placing of the tendons was the most de-
8 to 10 mm) at the mid-span sections. manding part of the job. Placing preas-
After examination of the damage and sembled strand bundles was excluded
from the beginning because of the limited
space available in the working chambers Figure 58: Pushing trough strands
26
EXTERNAL POST-TENSIONING
Stressing had to be done on two cables grouted cracks. Furthermore, it was stressed at the anchorages behind the
simultaneously and at both ends for established that the stress variation in the pier diaphragm. Elongations measured
symmetry reasons. The time available for post-tensioning steel considerably 440 mm on average. Post-tensioning
stressing 4 x (of the 8) tendons was fixed exceeded the allowed value. work lasted for seven days. All cracks
at 6 hours and therefore great mobility of Thus a static strengthening was closed after stressing.
the equipment was required. Five VSL required, not only corrosion protection The rehabilitation work overall took five
jacks ZPE-1000 (one as spare) and corre- measures. In view of the limited space months.
sponding accessories, as well as five available inside the box cells, which did
pumps were engaged (Fig. 59). The not allow for adding reinforcement, 6.4.3. Bridge over Wangauer Ache
jacks, each weighing 2.5 tonnes, were strengthening the larger span by means near Mondsee, Austria
mounted on specially constructed of post-tensioning tables offered the best Owner Republic of Austria, Federal
hydraulic carriages. Stressing was done solution. Straight unbonded tendons were Road Administration, Vienna
in steps of 5 N/mm². The cable extension selected, the number of which had to be Engineer
amounted to 3,150 mm. The cables of the the smallest possible. (Repair) Kirsch-Muchitsch, Linz
end cross-beams (16 No. EE 5-12 on A total of 24 tendons VSL type 5-16 Contractor Hofman u. Maculan,
each side) were stressed in groups of two (breaking force 2,833 kN each) with (Repair) Salzburg
at the same time as the longitudinal threaded anchor heads and an average Additional
tendons. length of 75 m were required. At the post-
In view of the quantity of material to be abutment side these were anchored in tensioning Sonderbau GesmbH, Vienna
injected and of the length of the cables, anchor blocks added to the web prolonga- Execution 1987-1988
the use of a special grout mix with tions, while buttresses were provided
retarded hardening and consisting of behind the pier diaphragm, which itself This bridge is part of the highway
clinker and resin was required by the also had to be post-tensioned to take the Vienna-Salzburg. It was built in 1962-
client. Grouting was executed in sections, additional forces. 1964. In recent years improvements have
which made movable equipment neces- The monostrands were placed in PE been made several times, but a thorough
sary. The grout mix was injected over a ducts which were provided with two inspection revealed a large number of
distance of 180 m before the installation movable joints to absorb temperature deficiencies, making a general rehabilita-
had to be moved. Two tables were movements. As strand deviations could tion necessary. In particular, a lack of
grouted per day, requiring 12 m3 of not be avoided and inaccuracies in the longitudinal prestressing force was
boring had to be expected and in view of detected, which had become obvious in
grouting material.
the large elongations, the likelihood of opened construction joints. Thus, rehabili-
damage on the strand coating due to tation had to include also the installation
6.4.2. Ruhr Bridge Essen-Werden,
transverse pressures caused by strand of additional tendons. Since a closure of
Federal Republic of Germany
deviations was evaluated in tests. The the motorway was not acceptable, one
Owner City of Essen
coating remained safe in these tests. structure was strengthened first, followed
Engineer
Borings had to be carried out with high by the other.
(Repair) Prof. Dr. G. Ivanyi, Essen
accuracy. Boring distances were 10 to
Contractor Polensky & Zollner AG, The twin bridge has spans of 25-6x28-
12 m (in pier diaphragm). Oblique boring
(Repair) Bochum 2x41.25-3x28-25 m, i.e. a total length of
(in plan view) was also required through a
Additional span diaphragm and subsequently 384.50 m. Each superstructure has a
post- SUSPA Spannbeton GmbH, through a web. double-T cross-section, 13.05 m wide and
tensioning Langenfeld The strand bundles were prepared in 2.20 m deep. Since the existing longitudi-
Execution 1985-1986 the workshop. The diaphragm tables nal post-tensioning was bonded, and no
were placed by means of a movable spare ducts were available, the additional
This two-span post-tensioned concrete crane. The longitudinal tendons were post-tensioning had to be placed on the
bridge (spans 66.40-47.00 m) has a multi-
cell box superstructure with a deck width
over the intermediate pier of 34.41 m.
This width increases on both sides
towards the abutments (Fig. 60).
In the bottom slab and in the web of
the larger span, numerous cracks due to
bending had developed making rehabilita-
tien measures necessary especially in
view of the corrosion protection of the
post-tensioning tables in the cracked
area. Grouting the cracks (which were up
to 0.4 mm wide) was disregarded since it
was established that the cracks originated
from temperature gradients; thus new
Figure 60: Plan view of Ruhr Bridge Figure 61: Anchorages inside the box
cracks would have appeared near the
(showing cracks) prior to concreting
27
EXTERNAL POST-TENSIONING
28
EXTERNAL POST-TENSIONING
so that now the repaired structure out. Top-of-slab cracking adjacent and Approx. 10% of the tendons were
appears to have four buttresses (Fig. 63). parallel to many beams, and beam replaced. Most stressing work was carried
deflections of up to 38 mm (1 1/2”) in out from the outside of the building (Fig.
6.5.2. Pier 39 Parking Structure, many instances were found. Also several 66). The repair job started in August 1986
San Francisco, USA strands popped out of beam ends. All and was substantially complete by April
Owner Pier 39 Associates, strands were subsequently examined; 1987.
San Francisco, Cal. they all showed some signs of corrosion. It should be emphasized that short-
Engineer Bijan, Florian & Associates Several strands had even failed. comings encountered in early application
(Repair) Inc., Mountain View, Cal. The central issue to the rehabilitation of of unbonded strands in commercial
Contractor the structure, besides economy, was that buildings and parking structures have
(Repair) and a new system had to be built around or long been recognized and fully rectified.
Additional added to the existing structural members Today, post-tensioning of such structures
post- VSL Corporation, while the parking garage remained is commonly the most economical and
tensioning Los Gatos, Cal. essentially operational. The beams, and performance-healthy mode of design and
Execution 1986-1987 to a lesser degree the slabs, were the construction.
primary targets of rehabilitation.
This structure, which is part of a Two major options of rehabilitation
shopping centre, was originally con- were reviewed in detail, one using steel
structed in 1978/79 in the Fisherman’s members (trusses or channels) and the
Wharf area; it has space for 1,000 cars other post-tensioned tendons. The latter
(Fig. 64). It has five parking levels was adopted.
including the roof, and a rectangular plan The structural design followed UBC
with overall dimensions of 118.90 x 63.00 1982. Two tendons per beam, each
m (370’ x 196’); at one corner there is a consisting of six strands 13 mm (0.5”)
square recess of 20.90 x 54.60 m (65’ x were added, one on each side of the web.
170’). At mid-spans and over columns the
The original structural system con- tendons are deviated by means of
sisted of post-tensioned beams, 914 mm deflectors. These were made of 114
(36”) deep and spanning 21.00 m mm (4 1/2”) extra-heavy pipe. In order to
(65 1/2’), which frame into columns to obtain the best possible corrosion protec-
form a parallel plane frame in the trans- tion, the strands were coated with epoxy.
verse direction. One-way post-tensioned The 51 mm (2”) corrugated PVC pipe
slabs, 114 mm (4 1/2”) thick, span the was used as tendon sheathing (Fig. 65).
longitudinal direction with spans of 5.80 m The work was carried out to allow
continuous use of the garage by the
(18’). The beams contained seven public. Deflectors, end brackets and
15 mm (0.6”) monostrands while the slab precast members were erected on a night
had 13 mm (0.5”) monostrands at shift, tendons in a day shift. The slab
660 mm (26”) centres. When in 1985 tendons were inspected and replaced by
severe slab cracking at the roof level and removing 1.22 m (4’) closure strips
substantial water leakage from the roof located at approximately one-third points
were noted, further inspection was carried along the longer side of the structure.
Figure 65: Scheme of added beam tendons Figure 66: Stressing added tendons
29
EXTERNAL POST-TENSIONING
[34] Wittfoht H.: Outstanding and Innovative [45] VSL Post-tensioning. Pamphlet issued [57] Aalami B.O., Swanson D.T.: Innovative
Construction Methods in Concrete by VSL INTERNATIONAL LTD., Berne, Rehabilitation of a Parking Structure.
Structures - Recent and Future Trends Switzerland, 1980/1986. CONSTRUCTION INTERNATIONAL,
(from the Viewpoint of the Main Contrac- February 1988, PP. 30-35.
tor). 10th international Congress of the [46] Closing the gaps with assembly line
FIP, New Delhi, India, 1986, Proceed- span placement. Engineering News [58] Post-tensioning turns inside out.
ings Vol. 1, pp. 349-357. Record, Mc Graw-Hill, New York, Engineering New Record, Mc Graw-Hill;
September 3, 1981. New York, March 12, 1987, p. 32FC.
[35] Menn Ch.: Brückentrager mit Unterspan-
nung (Bridge girder with underlying [47] FIP 9th Congress Stockholm 1982 June
tendons). Schweizer Ingenieur und 6-10 (Extract from Annales des Travaux
Architekt, 1987, pp. 200-204. Publics de Belgique No. 2 - 1982).
Ministry of Public Works/Belgian Con-
[36] Menn Ch., Gauvreau P.: Scale model crete Society, pp. 6/7.
study of an externalty prestressed
concrete slab bridge. International [48] MARTA Rapid Transit Bridges Going Up
Conference on Cable-Stayed Bridges, Full Speed. Journal of the Prestressed
Bangkok, Thailand, 1987, Proceedings, Concrete Institute, July-August 1983, pp.
pp. 919-926. 184/185.
[37] Haas G. et al.: Die Stahlüberbauten der [49] MARTA Rapid Transit Bridges. Journal
Far-Brücken, Dane-mark (The steel of the Prestressed Concrete Institute,
superstructures of the Far Bridges, March-April 1985, pp. 188-194.
Denmark). Der Stahlbau, 1985, No. 12,
pp. 353-363. [50] US rapid transit bridge built span-by-
span with precast elements. VSL News
[38] Ritz P.: Beigeverhalten von Platten mit Letter August 1985, pp. 20/21. VSL
Vorspannung ohne Verbund (Flexural INTERNATIONAL LTD., Berne, Switzer-
behaviour of slabs prestressed with un- land.
bonded tendons). Institut für Baustatik
und Konstruktion ETH Zürich, Bericht Nr. [51]Virlogeux M., Placidi M., Hirsch D.,
80, Birkhauser Verlag Basel und Lacoste G., Mossot J., Fesnais P., Colas
Stuttgart, Mai 1978. M.: Le nouveau pont sur le Loir a la
Fléche (Sarthe). (The new bridge across
[39] Wittfoht H.: Betrachtungen zur Theorie river Loir at La Fléche [Sarthe]). Travaux,
und Anwendung der Vor-spannung im July-August 1983, pp. 3-23.
Massivbrückenbau (Considerations on
the theory and application of post- [52] Bridge halves constructed parallel to the
tensioning in concrete bridge construc- river and connected together after
tion). Beton-und Stahlbetonbau, 1981, rotating. VSL News Letter May 1983, pp.
No. 4, pu. 78-86. 21/22. VSL INTERNATIONAL LTD.,
Berne, Switzerland.
[40] Zimmermann J.: Tragverhalten und
Systemtragfähigkeit von Trägern mit [53] Autoroute A.55, Ouvrage d’art 33
Vorspannung ohne Verbund (Behaviour (Motorway A.55, Structure No. 33).
ai-id ultimate strength of beams with Brochure issued by Dragages et Travaux
unbonded prestressing). Thesis, Publics.
Technische Hochschule Aachen, 1985.
[54] Unconventional table layout for
[41] Post-tensioned Slabs, January 1981/ incrementally launched bridge with
1985. VSL INTERNATIONAL LTD., varying spans. VSL News Letter August
Berne, Switzerland. 1985, pp. 7/8. VSL INTERNATIONAL
LTD., Berne, Switzerland.
[42] DIN 4227, Teil 6: Spannbeton, Bauteile
mit Vorspannung ohne Verbund [55] Skyway bridge boasts a record and
(Prestressed Concrete, Structural parts innovations. Engineering News Record,
with unbonded prestressing). Vornorm Mc Graw-Hill, New York, September 11,
Mai 1982, Beuth-Verlag, Berlin und köln. 1986.
[43] SlA E 162: Betonbauten (Concrete [56] Ivanyi G., Fastabend M., Lardi R., Pelle
Structures). Draft March 1987. K.: Statisch-konstruktive Verstarkung
Schweizer lngenieur- und Architekten durch zusatzliche Vorspannung (Static-
Verein, Zürich, pp. 13 and 29. constructive reinforcement by means of
additional post-tensioning). Bautechnik
[44] CAN 3 - A 23.3 - M 84: Oesign of 1987, No. 6, pp. 181-187.
Concrete Structures for Buildings.
Canadian Standards Association,
Toronto, 1984, p. 170. 31
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