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|a Despite the attractive merits of high-capacity strands, the application in bridge girders is limited due to concerns, including concrete cracking, excessive stress, and cambers. An efficient and defect-free production is the first step to wide application. The objective of this research was to alleviate the production concerns of prestressed concrete bridge girders using high-capacity strands. A gigantic prestressed concrete box girder using 18-mm strands was produced; its entire fabrication process (from strand stressing to detension) was introduced. Sixteen temperature gauges were embedded in the girder to monitor the hydration of the large volume of concrete and the adjacent environmental temperature. Moreover, displacement transducers were used to measure the camber at detension; load cells were installed to monitor the variations of the prestressing strand tensile forces during fabrication. Monitoring and analysis showed that the timing of the detension is determined by the hydration of the concrete, the compressive strength of the concrete, and its modulus of elasticity or age. Since the tensile forces in strands are affected by the concrete’s internal temperature, the detension is conducted after the concrete temperature falls back (close to its initial value); otherwise, unfavorable and considerable prestress losses are caused. Finally, a 4-d detension was suggested since the hydration was not a concern at the time; the predicted prestress loss and camber were acceptable and the concrete material properties at 4 d satisfied the requirements. © 2022 by the authors. Licensee MDPI, Basel, Switzerland.
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