A Study on Rational Pre-Tensioning Schemes for 60 m Prefabricated Railway Box Girders Considering Steel Formwork Constraints

Early-age cracking is a common issue in the prefabrication of large-scale box girders, and the application of pre-tensioning techniques to introduce pre-compressive stress is an effective measure to mitigate such cracking. To determine an optimal pre-tensioning scheme for the 60 m large-scale box girder used in the Ningbo–Xiangshan intercity railway, friction coefficient tests and field stress monitoring were conducted. A numerical model simulating the pre-tensioning process of the box girder, accounting for the constraint of the steel formwork, was developed using Abaqus 2021. Based on the validated finite element model, a parametric study was performed to investigate the effects of friction coefficient, internal formwork roof, and prestressing tendon arrangement on the pre-compressive stress. The results indicate that the bond force between cast-in-place concrete and steel formwork is approximately 2.1 times the sliding friction force. As the friction coefficient increases, the pre-compressive stress in the box girder exhibits a notable decreasing trend. For the critical midspan section S40, the inclusion of frictional effects results in a more uniform distribution of pre-compressive stress. Compared to the case without the internal formwork roof, its inclusion leads to a 9.2% to 10.4% reduction in pre-compressive stress at section S40. To mitigate prestress losses transmitted from the ends to the midspan section, it is recommended that the internal formwork be completely removed prior to prestressing tensioning. The pre-compressive stress in the box girder varies considerably with different prestressing combinations. The comparative analysis of different prestressing combinations reveals substantial variations in pre-compressive stress distribution. After evaluating multiple schemes, the optimal pre-tensioning sequence for the 60-m railway box girder is determined as follows: sequentially tensioning tendon groups F1-2, F1-4, F1-5, F1-6, and B2-3, with an anchorage stress controlled at 558 MPa. This scheme ensures that all critical sections of the box girder remain in a pre-compressive state. In particular, the pre-compressive stress at the key midspan section S40 ranges from 1.12 to 1.26 MPa, achieving the desired effect and effectively suppressing early-age cracking in the large-scale box girder concrete.