Pre-Stressing

Prestressed Concrete Steel Wire Pulling Machine

Uniform HTS wire pre-tension to 2 kN before the stressing unit — replacing bare-hand pulling with custom couplers that caused uneven wire tension and production discrepancies.

Pre-Stressing HTS Wire IS: 1785 / IS: 6006 2 kN Setpoint

Uniform Pre-Pull Before the Stressing Bench

Before HTS wire enters the stressing unit, each strand must be lightly tensioned to remove slack and seat the grip. Plants traditionally used bare hands with improvised couplers — pulling force varied operator to operator and wire to wire, leaving some strands loose and others over-tensioned. This machine applies a controlled, repeatable 2 kN pre-pull on every wire so the stressing unit starts from a consistent baseline.

2 kN (setpoint)
Uniform per wire
HTS prestressing wire
Digital display
Before stressing unit
Machine-controlled
HTS WIRE PRE-PULL SEQUENCE

  Loose wire on bench
         |
         v
  +------------------+
  | Wire Pull Machine|  controlled pull to 2 kN
  | (uniform grip)   |
  +--------+---------+
           |
           v
  +------------------+
  |  Stressing Unit  |  hydraulic pull to target elongation
  |  (anchor plate)  |
  +------------------+
Why It Matters

Manual pre-pulling with bare hands and custom couplers cannot deliver the same force on every wire. Uneven initial tension carries through to final prestress — causing left/right discrepancies, rejected sleepers, and rework on the stressing bench.

Replaces bare-hand pulling and improvised couplers
Same 2 kN pre-tension on every wire, every cycle
Removes slack before hydraulic stressing begins
Reduces wire-to-wire tension variation on multi-wire sleepers
Consistent starting point for elongation measurement
Less operator fatigue and fewer grip-related injuries
Repeatable Force

Machine-controlled pull holds the 2 kN setpoint — not dependent on operator strength or technique.

Better Stressing Input

When every wire enters the stressing unit at the same pre-tension, final elongation and prestress values align more closely across the bench.

Fewer Discrepancies

Eliminates the uneven manual pre-pull that causes left/right gap differences and out-of-spec sleeper rejection.

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