Post-Tensioning...

Economical Engineering
AKHIL MITTAL

Table of Contents

Introduction ............................................................................ 4 What is Post-Tensioning? ...................................................... 5 How does Post-Tensioning affect the concrete? .................. 6 Process of Post-Tensioning .................................................... 8 The Benefits of Post-Tensioning Systems in Buildings:.... 10 Post-Tensioning at Waterfront ........................................... 11 How to carry out Post-Tensioning ...................................... 13 Costs ...................................................................................... 16 Annexure ............................................................................... 17 Conclusion ............................................................................ 18 Bibliography ......................................................................... 19

Introduction
Over the summer of 2011, I worked as an intern with a real estate developer, Kunal Corporation on a project site called Waterfront Tower located in Mumbai. The tower is proposed to be 158meters high with 25 residential flats, 9 floors of car parking and a floor for a swimming pool and gymnasium. The developers have kept the building modern using latest technology from different parts of the world including a 9 floor automated tower parking system from Germany. The building includes a sewage treatment plant as well as rain water harvesting. Being a part of a family that pioneered in real estate, I have developed a keen interest to work in this field. The Indian real estate market has undoubtedly been on a high growth path over the last 5 years. Currently, the market holds the ninth position among the retail markets in the world, growing at a rate of 30 percent per annum. India is currently one of the most attractive destinations for Foreign Direct Investment (FDI) in real estate. All these factors influenced my decision in pursuing this field as one of my possible career options. Needless to say that I learned a lot during my stint at Waterfront Tower, what grasped my attention was a new technology, recently introduced to the Indian real estate market called, Post-Tensioning. At Waterfront Tower, the developers decided to use this unique method of reinforcing concrete in their car parking floors and girder level floor. I was able to research and understand the Post-Tensioning method, as well as learn how this technique would be beneficial to the building. I decided to take the initiative along with professional engineers on site to research on this technique and provide my sample to the builder.

What is Post-Tensioning?
Post-Tensioning is a method of reinforcing concrete, masonry and other structural elements. It is a method of Pre-Stressing. Pre-Stressed concrete is made up of internal stresses (forces) included into it during the construction phase with the purpose of counteracting the anticipated external loads that it will encounter during its lifecycle. There are two methods of Pre-Stressing: 1. Pre-Tensioning: This method consists of stressing and reinforcing the inside of large steel buttresses, and then casting the concrete around the reinforcement. This method can only be done at a precast manufacturing facility. The completed pre-stressed concrete is then taken to the job site and assembled. 2. The other method of Pre-Stressing is called Post-Tensioning. Instead of stressing the reinforcing inside of the large steel buttresses at a manufacturing plant, the high tensile cables are installed on the construction site after the contractor forms up the slabs or constructs the walls and columns. The cables are housed in sheathing or ducts that prevent the steel from bonding to the concrete so that it can be stressed after the concrete cures (hardens). While the end result of both these methods are almost the same, the only benefit of the posttensioning method is that the builder can get the freedom to construct the members (walls, columns, slabs) in any shape or configuration. In pre-tensioning, the process is limited to standard shapes and sizes that can be transported from the manufacturing unit to the construction site.

How does Post-Tensioning affect the concrete?

Many would think that the technique of post-tensioning only helps the steel to get prestressed and tensioned; however this technique gives its advantages to concrete as well. While the steel element gets tensioned, the concrete gets compressed. Compression is that force that crushes while tension is that pulls something. Concrete in general is very strong in compression and weak in tension while steel counteracts it by the strength of its tension. Thus with the technique of providing tension to steel, we are compressing the concrete and making both forms of material in its strongest form. The result is stiffer concrete that has more capacity to resist tensile forces.

Due to heavy load on concrete slabs or other factors, concrete floors can often bend. This bending can often result in high tensile forces that can cause the concrete to form a crack and can be very dangerous for any building. In such cases, the use of reinforcing concrete is very beneficial. As steel has the capacity to resist tensile forces, it is embedded in the concrete at the highest tension unit it can withhold and thus allowing the tensile forces to be handles by the reinforcing steel.

There is another way of reinforcing the concrete; this is known as draped profile. A draped profile is an elevated concrete slab that has post tensioning strands routed through a high point over the slabs supports, and through a low point in between those supports. In this case, optimum efficiency is obtained because: the concrete is compressed the post-tensioning reinforcing is creating an uplift force in the middle of the spans, where it is needed the most the post tensioning forces is located in the tension zones

Process of Post-Tensioning
Post-Tensioned reinforcement consists of very high strength steel strands. These steel strands are known as tendons. The strands are used in horizontal applications like foundations, slabs, beams and bridges; bars are used in vertical application like walls and columns. The prestressing steel is housed in a sheath or duct to allow it to move as the tensioning force is applied after the concrete hardens. A typical steel strand used for post-tensioning has a tensile strength of 1861 N/mm2 four times more than that a typical non-pressed piece of reinforcing that has a tensile strength of 413 N/mm2. Strands normally have a diameter of 12.7mm or 15.2 mm (0.60 in) and are stressed to a force of 228 N/mm2 using a hydraulic jack. The jack is supported by one of the anchors that is embedded in the concrete and pulls the steel to a preset force. The steel stretches as it is tensioned, and it is locked into place using an anchoring component that forms a mechanical connection and keeps the force in the strand for the life of the structure. After the tendons have been stressed and engineering approval given, they are cut off and permanently sealed. A free flowing cementitious grout is then pumped into the ducts to lock the cables in position permanently. This is classified as bonded post-tensioning. Bonded post-tensioning is generally used in flat slab situations where the maximum tendon eccentricity allows the slab depth to be kept at a minimum. The ducts or sheathing that houses the pre-stressing steel provides a layer of corrosion protection. Multiple pieces of pre-stressed steel in a duct is termed as multi-strand tendons; while a single prestressed steel strand is known as a mono-strand tendon.

Anchorage blockouts (Casting) with a bearing plate

The Benefits of Post-Tensioning Systems in Buildings:

It provides longer spans, which reduces structural floor depths, resulting in larger column-free areas Thinner concrete sections Stiffer walls to resist loads Stiffer foundations to resist the effects of shrinking and swelling soil Simpler stripping of formwork Fast construction cycles are envisaged Positive deflection control Improved constructability More architectural freedom Less material handling on site and storage Less labour needed Less environment impact as reduced concrete and steel volumes are needed

Therefore, post-tensioning helps the building structure to withstand more weight and protects it against natural calamities like earthquakes etc. The large amount of material that is saved also helps in reducing the cost for the developer.

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Post-Tensioning at Waterfront
At Waterfront Tower, the technique is used in the 9 floors of car parking, as well as the girder level floor which forms a second foundation to the building and makes it stronger to sustain a high rise load. The total area of post-tensioning used is 1656m2 in the podium level for car parking. Below are the details of the breakup used as provided by SF-MGC Systems, the company that designed and implemented Post-Tensioning at Waterfront Tower.

Specification / requirement of materials

Sr.No. 1 2 3 4 5 6 7 8 9 10 11 12 Item Nominal diameter of Strand Nominal Steel Area Nominal Mass Nominal UTS Minimum Concrete grade At Transfer At 28 days Water-cement ratio for grouting Grout Admixture Grout Pressure Stressing pressure to Strand Nominal pressure after stressing i.e. elongation Specification/ Remarks requirement 12.7 mm 98.7 mm2 0.775 KG/M 1860 N/mm2 M-40 25 Mpa 40 Mpa 0.45 SIKA INTRAPLAST,500 GRAM/BAG(50KG) 1 KN =1450 PSI 75 PSI 5500 PSI 0.65 100*100*100 mm3 (size of the cube mould) 100*100*100 mm3 (size of the cube mould)

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Cement Cube test of grouting at 7 days 17 N/mm2 Cement Cube test of grouting at 28 days Jacking Load Jack Ram 30 N/mm2 139 KN 37.09 mm2

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Above mentioned is a list of specifications of materials that was needed for the posttensioning done at Waterfront Tower.

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Below are the specifications of the materials used for the post-tensioning slabs and girder at Waterfront Tower.

Post Tensioning work of a slab (a typical podium floor) at Waterfront Tower

Sr. No. 1 2 3 4 5 6 7 8 9 Consumables Materials required for PT work of slab- ONE END LIVE Quantity UNIT M No No M No No Kg Bag

Tendon - Each tendon contains 5 no. of PC strand 176.4 ( 6 x 11 + 12 x 9.2 ), total no.of tendons = 18 Anchorage blockouts Wedges 20mm x 70mm galvanised flat duct Bearing plate 5-s Grout vent Grout additive (anti-shrinkage chemical) Ordinary Portland Cement - 53 Grade Other materials : Tie bars,sealent, chairs, masking tapes etc 18 90 139.44 18 36 2.5 5

Post Tensioning work of a Girder (G-7) at Waterfront Tower

Sr. No. 1 2 3 4 5 6 7 8 9 Consumables Materials required for PT work of Girder-7, Quantity UNIT ONE END LIVE Tendon=12 no., Each tendon cotains 12no. Strands of length11 1584 m , hence total no. of strands= 12 x12 = 144 Anchorage blockouts Wedges 20mm x 80mm galvanised flat duct Bearing plate Grout vent Grout additive (anti-shrinkage chemical) Ordinary Portland Cement - 53 Grade Other materials : Tie bars,sealent, chairs, masking tapes etc 12 144 132 12 24 3.5 7 M No No M No No Kg Bag

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How to carry out Post-Tensioning

As seen in the picture above the process of post-tensioning occurs in systematic steps to make sure that the process is smooth and the steel and concrete reaches the optimum level of efficiency. 1. To begin with the first step, the formwork/ shuttering of the slab is put in place as per the rendered architect and structural drawings. 2. The labourers then put the re-bars as per the detailing of RCC plan (Fe500 for the podium slab). 3. As seen above, the G.I. (galvanized iron) Conduits of size 20mmX70mm flat ducts are placed horizontally in position as per PT drawing. (Annexure A)

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4. The above representation shows the ends of the tendons that are tied together with the main reinforcement bars 5. The tendons are then fixed together with the help of an anchorage block as shown below

6. The concrete is then poured on the formwork over the reinforcement bars. 7. The concrete is left to cure/ harden for 3 days, after which a cube test is performed which requires an average compressive strength of 25N/MM2 8. The bearing plate (shown in Annexure B) is then fixed at the end of Section 6-6 to stress the steel tendons.
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9. As the conduits have empty spaces in between them, there is a process called grouting that takes places at this stage which fills the voids with cement slurry between the strands.

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Costs
One of the important benefits of post-tensioning is the capacity to reduce the load of steel bearing beams and columns and thus reducing the costs significantly. For example, a typical podium cost at Waterfront Tower comprised of the following elements:
WATERFRONT TOWER Cost of a Typical Podium Floor S.No. A 1 2 3 B 4 C 5 6 D Description Concrete Work P/Laying RMC M30 grade concreting P/Laying RMC M50 grade concreting EPCO KP 200 @ KG/Cum Total Formwork P/Fabrication erection fixing in position, deshuttering Reinforcement P/Cutting, Bending in position of reinforcement bars Steel provided Total Post Tension Work As per Area Total VAT @ 5% Service Tax @ 4% 2% Education Cess on Service Tax 1% Higher Education Cess on Service Tax Grand Total Cost for Podium Slab Unit Rate (Rs) Quantity Amount (INR) Amount ($) CUM CUM KG 6449 8343 214 13.92 247.15 522.13 89,744.28 20,61,972.45 1,11,736.25 22,63,452.98 6,82,328.76 7,36,920.90 13,15,410.25 20,52,331.15 1,28,346.66 51,26,459.55 2,56,322.98 2,05,058.38 4,101.17 2,050.58 55,93,992.66 1,909.45 43,871.75 2,377.37 48,158.57 14,517.63 15,679.17 27,987.45 43,666.62 2,730.78 1,09,073.61 5,453.68 4,362.94 87.26 43.63 1,19,021.12

Sq. M MT MT

493 17717 31625

1384.03 41.59 41.59

SM

726.95

176.56

At the time of discussions on the implementation of post-tension, the builder realised that every podium would save approximately 20% of the steel cost and therefore the implementation of post-tensioning seems beneficial to the building.

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Annexure
My stint at Waterfront Tower also included regular meetings with the architect, M/s Talati and Panthaki Pvt. Ltd along with the structural engineer, Vora and Associates Pvt. Ltd. I had the opportunity to learn how to read and understand architect rendered drawings on AutoCAD, a CAD software that has a 2D and a 3D design and drafting application. The software is used by the architects and structural engineers for drawings. Enclosed are a few annexure that I worked on along with the architects and engineers. Annexure A depicts the laying of tendons on the PT slab. Each tendon has 5 strands placed at a distance of 1060mm apart. Annexure B shows the front cut view of an anchorage blockage bearing plate and how it is attached to the tendons that are protruding out. Annexure C depicts the drawing of the girder level plan with the size of each column and beam. The girder floor is one of the most important slabs of the building as it forms a second foundation to the building. Annexure D portrays how the tendons are placed in the girders. Annexure E shows the area used for post-tensioning in the car parking floor. Annexure F shows the area that would have been completed with regular RCC if post-tensioning hadnt been completed. Here you can see the two beams (shown in dotted lines) that would have been constructed if there was no post-tensioning. The beans would have obstructed the height of the slab thus reducing the height of each floor. As this was a car parking slab, the builder wanted to have a clear height so that large cars can fit easily.

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Conclusion
The advent of post-tensioning in the real estate market has re-defined the construction industry. It has not only led to a reduction in the amount of material but also helped increase the profitability for developers. By reducing the height of beams, it allows the builder to construct more floors within the permissible height. Post-tensioning tendons provide a tensile strength that is four times that of normal reinforcement steel bars. This helps make the foundation of the building much stronger. By using post-tensioning, the developer saved 20% of the steel cost in the podium and girder level slab, where the technology was implemented. Working with the engineers on site as well the Malaysian company, SF-MGC, I managed to learn a lot about this technology. It also helped increase my interest in the field of construction and enabled me to think out of the box and explore new ideas for the construction of the building. Researching on the technique of post-tensioning taught me that something as simple as tensioning the strands after the slab is casted, could make a big difference to the building structure.

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Bibliography
Innovative Post-Tensioning Partners The brochure for SF-MGC www.sf-mgc.com What is Post-Tensioning, Evaluation and Certification Service, LLC , http://www.builderspt.com/wpcontent/themes/builderposttension/basic_post_tension.pdf

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