PRESTRESSING OPERATION A.

Preparation for Stressing 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, to compare with field
measurements taken between 20% and 100% of jacking force. A
measurement taken at 20% 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. 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 shop
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
28,000 ksi (193,000 MPa) for strand. The strand area is commonly
assumed to be 0.153 in2 for 0.5- inch strand, and 0.207 in2 for 0.6-inch
strand. The actual Young’s modulus (E) and cross-sectional area (A) for the
individual strand packs must be used to re-calculate tendon elongations.
While the values of (E) and (A) from the quality assurance testing
performed by METS will be recorded on the materials release tag for the
prestressing steel, these values represent averages as determined from
the limited samples performed on the lots. The current policy is to utilize
the actual values for (E) and (A) provided by the strand fabricator on the
individual strand packs to calculate elongations. Often packs of strand
arrive with varying (E) and (A). In this case, it is best to separate the
strand packs so that all strand in a given tendon are the same. 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
Specifications24 requires the Contractor to have two pressure gages or
one pressure gage and a load cell for each jack. During the stressing
operation, the Contractor does not have to use both pressure gages at the
same time. The intent of the extra gage requirement is to have a
calibrated back-up gage on hand if needed. Re-certification of the
Contractor’s gages and jacks is required every 12 months. State pressure
cells usually monitor the Contractor’s jack and gage during the stressing
operation. Up-to-date information regarding jack calibration is available by
accessing the Structure

administrative instructions relevant to the pressure cell. B. Field Inspection

The practice of stressing both simple-span and shorter continuous frames
from one end only is common, and must be shown on the contract plans or
specifications. When two-end stressing is required, the Contractor must
stress both ends to Pjack and show the actual method and sequence of
stressing on the shop drawings. In order to minimize the possibility of
undesirable construction stresses, the Standard Specifications26 states,
“Sequence the stressing of post-tensioned bridge girders such that no
more than 1/2 of the prestressing force in any girder is applied before an
equal force is stressed in the adjacent girders. The maximum temporary
force variation between girders must not exceed the prestressing force of
the largest tendon used in all girders. Do not apply an eccentric force
about the centerline of the structure that exceeds 1/6 of the total
prestressing force at any time during the prestressing.” Structure Design is
responsible for checking for compliance to the requirements of Standard
Plan B8-5. In addition, Structures Design will check the shop drawings to
confirm the correct duct profiles, prestressing force, elongation
calculations, and anchorage systems used before approval. If compliance
with these requirements is overly difficult because of field conditions,
Structure Design should be consulted before deviating in any manner from
the authorized shop drawings. Duct ties are always required in girder flares
near the exterior girder prestress anchorages. Refer to Standard Plan B8-5
for limits and details of these ties. Bridge Memos to Designers, 11-31,
Curved Post-Tensioned Bridges, applies to girders with horizontal radii of
2,000 ft. or less.27 The limits of, and details of these ducts ties and stirrup
ties should be included in the contract plans. See Figure 8- 1. If the

In order to efficiently monitor stressing operations, a record in chart form

must be kept for each tendon stressed. Figure 8-2 shows form SC-4301
(formerly DS-C87) titled Post-Tensioning Field Monitoring Chart.28 Note
that some of the information shown can be entered prior to stressing.
Remember, that this form is a guide. You may custom design your own
chart. After completion, place this form in the job files. 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 actual area of ½″ prestressing strand typically varies between 0.151
(97.4 mm2 ) and 0.154 (99.4 mm2 ) square inches. However, some
strands have been received with an area as small as 0.149 square inches
(96.1 mm2 ). 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 (97.4 mm2 ). With the
Dywidag bar system, counting the turns of the anchor nut during stressing
can also monitor the elongation. 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″ (10 mm) 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 1/12″ per foot (0.72% strain) of jack measured from the
anchorage to the pulling head. When measuring or computing anchor set
loss, do not include the length of the tendon within the jack. Refer to
Appendix D for calculating the effect that anchor set has on tendon stress.
For a complete jacking sequence including anchor set, see Figure 8-3,
which is provided by the VSL Corporation. Structure Construction
procedures state that the pressure cell is used at the start of stressing to
verify the Contractor’s calibration chart and at least one calibration curve
must be made per structure of frame. The Structure Representative may
require additional monitoring of the prestressing operation as needed.
Figures 8-4 and 8-5 are examples of completed forms SC-4302 and SC-
4202A29 for recording the Contractor’s gage readings versus pressure cell
readings. After completion, place these forms in the job files.