The estimation of prestressed strand stress levels is of great significance in ensuring the structurally reasonable performance of post-tensioned concrete structures, cable-stayed bridges, and arch bridges. This paper proposes a method to evaluate the remaining tensile stress on the strand through the ultrasonic mixing technique. The relationship between the strand tension and the nonlinear harmonics is established based on the theory of contact acoustic nonlinearity, and the acoustic nonlinear parameters at different tension levels are investigated by finite element analysis and step-loading experiments. The results show that the nonlinear parameters follow a power-law decrease with the increase in the tensile stress. To overcome the shortage of decreasing sensitivity of theoretical nonlinear parameters in monitoring early loosening, support vector regression is introduced to utilize complex high-order nonlinear generations in stress evaluation. With this approach, the accuracy of early-stage stress evaluation based on wave mixing has been remarkably improved.
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