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Prestressed Concrete Design

Basic Principles

Samer Akil
Lecture 2
Hardware & Grouting for Prestressing

• Post-Tensioned Members
 Anchorage
 Ducts
 Jacks
 Post -Tensioning Procedure
•Pre-Tensioned Members
 Hold-Dawn Device
 Prestress Transfer (DE-TENSIONING)
•Measuring The Elongations
• Grouting
Samer Akil
Post-Tensioned Members

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Available systems :
There are many famous companies in this field over the world
such as:
(a) BBRV System (Switzerland).

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(b) CCL System (Britain).

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(c) KA System (Germany).
(d) VSL System (Switzerland).
(e) Freyssinet System (France)

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Ducts
Ducts are used to form a continuous void through
the concrete for later placement of the post-
tensioning tendon steel. Originally, little attention

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was paid to the possible role of the duct as a barrier
to corrosive agents. Today, strong emphasis is placed

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on the quality, integrity and continuity of the duct as
a corrosion barrier in itself. This has resulted in a
move toward the use of plastic ducts in some states.

Duct Installation ER
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Duct alignment and profile should be clearly and
sufficiently defined on the plans and approved shop
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drawings by dimensions to tangent points, radii,


angles and offsets to fixed surfaces or established
reference lines and by entry and exit locations and
angles at anchorage or intermediate bulkheads.
Multi-strand tendon protection systems

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Duct Size
•Strand Tendons
Section 5.4.6.2 of the AASHTO LRFD (also see ACI 318/18.17) calls
for the inside cross-sectional area of the duct to be at least 2.0

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times the net area of the strand tendon. The one exception cited

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by AASHTO is in the case where the tendons are to be placed by
the pull-through method. In this case, the inside duct area should
be 2.5 times the net area of the strand tendon.

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Corrugated Metal Duct Corrugated Plastic Duct


Oval “flat” ducts are commonly used for transverse tendons in deck
slabs of concrete box girders. These transverse tendons have typically
been made of up to 4 strands of 0.6in diameter, though there are
systems that will accept up to 5 strands. The internal clear dimensions

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of oval duct should be a minimum of 25mm (1 in) vertically and 75mm
(3 in) horizontally.

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Bar Tendons

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Tendons containing a single post-tensioning bar should have an
internal duct diameter at least 12mm (½ in) greater than the
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maximum outside dimension of the bar or bar coupler. A greater
clearance may be preferred or be necessary for some
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applications. Examples of this use would be to provide greater


tolerance for temporary bars or to accommodate bridges with
slightly curved alignments.
Distance Between Ducts According to AASHTO-LRFD 2007

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According to EC2
Jacks and Other Stressing Equipment
•Mono-Strand Jacks
Jacks for stressing single (mono) strands generally have two
cylinders, one on each side of the strand, with a wedge device for

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gripping and pulling the strand

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Mono-strand tendons are
often used in buildings, where
each tendon is a single strand

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in an extruded sheath. In
bridges, mono strand jacks are
normally used to stress
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transverse tendons, usually
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comprising 3 or 4 strands, in
deck slabs or similar
applications. Also, mono-
strands are often used for
repair or rehabilitation.
•Multi-Strand Jacks
Multi-strand post-tensioning tendons are usually stressed as an entire
group, using very large custom made jacks. This ensures that all
strands are tensioned together and avoids the risk of trapping an

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individual strand.

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Stressing jacks are
generally of the center-
hole type – i.e. tendons

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pass through a hole in
the middle and are
attached at the rear of
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the jack
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Prestressing jacks must


be very accurate and
should be carefully and
frequently calibrated.
•Bar Jacks
Bar jacks have a central hole through which the bar passes and is
secured by a nut at the rear of the jack.

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Most jacks have an enlarged nose to accommodate a bar-coupler.

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Many bar jacks
have a hand or
mechanical
ratchet to rotate ER
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and tighten the
anchor nut against
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the anchor plate


as the bar
elongates under
load.
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Jack for stressing single strand


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Jack for multi-strand tendon


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Jack for prestressing bar


Jacking Methods
 Single (Mono) Strand Stressing
-Single strand stressing using a monostrand jack is normal
practice for transverse tendons in deck slabs where each strand

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lies side by side in a flat-oval duct where it cannot interfere with

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or trap another strand.

-Similar applications might include relatively short longitudinal

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strand tendons in precast planks or solid or voided slabs.
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-Strand stressing can be used on multi-strand longitudinal tendons
only if they are straight or curve only in one direction so that the
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strands on the inside of the curve can be stressed before those on


the outside to avoid trapping. For this reason, single strand
stressing is not suitable for multi-strand tendons of reverse
curvature.
Single Strand, Single End and Alternate End Stressing
When single mono strand stressing involves short tendons, it is usually
only necessary to stress from one end because friction loss is small.

In order to maintain relatively even dispersal of post-tensioning,

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transverse tendons in deck slabs should be stressed from alternate

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ends “Alternate End Stressing”. – i.e. stress all the strands of one
tendon from one side of the bridge and switch to the opposite side
for the next tendon – and so on.

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Single Strand, Two End Stressing
Two end stressing means stressing the same strand from both ends. This
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may be done sequentially, from one end at a time or simultaneously
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using two jacks. However, stressing from both ends would normally only
be needed for long tendons where friction loss is significant.
Stressing from the second end should not be done if the calculated
elongation is less that the length of the wedge grip. Re-gripping in a
portion of the old grip length should be avoided.
 Multi-Strand Stressing
-Multi-strand tendons are the most frequent choice for main
longitudinal tendons in bridges.
-All the strands of one tendon are tensioned together using a multi-

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strand jack.

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Multi-Strand, Single End and Alternate End Stressing
When a multi-strand tendon is stressed from one end it is often
referred to as “single or one end stressing” to distinguish it from

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tendons stressed from both ends.
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However, with a number of similar and often symmetrical tendons
in a superstructure, that need only be stressed from one end, it is
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desirable to keep the overall post-tensioning effect as even as


possible by stressing similar tendons from alternate ends of the
structure.
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If stressing starts with T1 on the east side of the structure, tendons


T2 and T3 are stressed from the west side and T4 again from the
east side
Multi-Strand, Two-End Stressing
When the tendons are very long, losses over the length of the
tendon due to friction and wobble become large.

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Stressing the tendon from the second end results in a higher force in

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the tendon than if only stressed from one end.

for symmetrical tendons two-end stressing becomes effective when

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the effect of anchor set at the jacking end affects less than half of
the tendon.
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Stressing from the second end should not be done if the calculated
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elongation is less that the length of the wedge grip.


Re-gripping in a portion of the old grip length should be avoided.
There are two ways of
stressing the tendon. The
first and most common
method is to start stressing

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from one end.

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The second method involves

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a simultaneous jacking
operation at both ends
using two jacks. Each jack
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pulls approximately half of
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the total elongation. There


is no reason why these
elongations should be
exactly the same.
Stresses along tendon for different modes of stressing
 Bar Tendons Stressing

Bar tendons have either a coarse or fine thread and are anchored
by a nut bearing against an anchor plate.

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Curved bar tendons are rarely used nowadays.

With good clearance around the bars, there is no friction loss.

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Also, when the nut is gradually tightened using the ratchet on the
jack as load increases, there is little or no seating loss.
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Consequently, the force is the same throughout and there is
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no need to stress from both or alternating ends.


Calibration of Tensioning System
Calibration of the tensioning system gauges is required to assure that the correct
prestress force is applied to the strands.
Calibration Process
1. Configure the tensioning system such that the tensioning system

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applies force on the calibration device.

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• For single strand, this can be done with either a short piece of
strand in a test stand or on a one piece of strand placed on a
stressing bed. When a long piece of strand on a stressing bed is

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used, the calibration device is normally placed between the nose of
thejack and the live-end chuck. Avoid exceeding a safe application
of force on the strand during the calibration (80% of the specified
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tensile strength of the strand).
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• For multiple strand, several calibration devices may be placed


between the moveable jacking plate and the fixed abutment of a
multiple strand tensioning system. In this configuration, the
calibration devices are compressed as the tensioning jacks apply
force to the jacking plate.
2. Determine the working range that the tensioning system will
be expected to operate within.
For example, a plant may normally expect to apply force on a
single strand between 2500 lbs. and 34,000 lbs. For multiple

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strand tensioning, a plant may normally expect to apply a total

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force between 400,000 lbs and 1,000,000 lbs.

3. Divide the working range for single strand jacks into 3000 or
4000 lb. increments. Divide the working range for multi-strand

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into 100,000 to 200,000 lb. increments. These will be the
predetermined points at which the production gage and the
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calibration device will be compared.
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4. Beginning with the lowest point in the working range, record the
force measured by both the tensioning system and the calibration
device at each of the pre-selected points (see 3 above).
Measurements are made when the calibration device indicates a

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force at each of the predetermined points within the working range.
At this instant, read and record the indicated force measured by

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both the production and calibration devices. Once the tensioning
system has applied the pre-determined force on the strand through
the working range, the force applied by the tensioning system is

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released. The number of runs through the working range depends
on the accuracy of the system and the judgment of the calibration
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service.
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5. With the data collected from the trial, graph or tabulate the force
values measured by the production gage and the pre-determined
points within the working range.
6. Determine if the force values from the production gage are
all within 2 percent of the actual force.
7. Document the calibration data and results so the conditions
required for accurate measurements of force will be known by the
operators and QC/QA inspectors.

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“Load cells, dynamometers, and
hydraulic gauges of hydraulic
pumping and jacking systems

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shall be capable of measuring
the force applied to the tendons
within 2% of the actual force.”
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Equipment at prestress plants
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must be calibrated at least every


12 months. It must also be
calibrated anytime the tensioning
system indicates erratic results.
POST -TENSIONING PROCEDURE

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PRESTRESS TRANSFER (DE-TENSIONING)
•Prestress transfer means releasing the tensioned strands held by
the abutments or self-stressing bed. This causes the strand to
impose prestressing forces within the precast and prestressed

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concrete unit. Prestress shall not be transferred to the cast units
until the concrete compressive strength.

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•If the concrete has been cured using accelerated heat curing,
prestress transfer shall be performed immediately following the
curing period, while the concrete is still warm and moist. As the

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units begin to cool, after accelerated heat curing, the concrete
contracts. Tensile forces can develop within the unit if the concrete
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contracts but is restrained by the unreleased strand. This may
cause cracks to develop in the concrete prior to transferring the
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prestress forces to the units.


Note: the prestressing forces transferred must be kept nearly symmetrical about
the vertical axis of the units. Maximum eccentricity about the vertical axis should
be limited to no more than 10% of the strand group.
Draped Strand De-tensioning
After the form is removed, draped
strands are to be released first. The
hold-up devices at beam ends may

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be lowered simultaneously as
practical. If this is not feasible,

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draped strands may be flame cut in
each beam interval, in rotation, until
all draped strands are released. The

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flame cutting procedure is subject to
approval by the engineer.
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Straight Strand De-Tensioning
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All hold-downs or other devices


that would restrict longitudinal
movement of the members along
the bed shall be removed prior to
releasing the straight strands.
Straight Strand, Multiple Strand De-tensioning

In multiple strand de-


tensioning, strands are
released simultaneously by

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hydraulic jacking where the

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total force is taken from the
header by the jack, then
released gradually.

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Straight Strand, Single Strand De-tensioning
In single strand de-tensioning, both ends of the casting bed shall be
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released simultaneously and systematically, by flame cutting, to
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minimize sliding of members. Strands are not to be released one at a


time with a jack.
For stress to be released gradually, strands shall not be cut quickly, but
shall be heated until the strand gradually loses its strength.
Measuring The Elongations
For post-tensioning, measurement of elongations serves as a
check of the anticipated jacking force primarily given by the gauge
pressure and calibration chart.

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There are two basic pieces of information that need to be recorded:

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tendon elongations and gauge pressures. Both will give an
indication whether the tendon is stressed to the force required.

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The gauge pressure is a direct measurement of the force at the jack
and the elongation will give an indication how the remainder of the
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tendon is being stressed. Normally the tendon will be stressed to a
predetermined gauge pressure, representing a certain force in the
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tendon at the stressing end.

The elongation measured at this point is compared to the


theoretically determined elongation.
Measuring Elongations on Strand Tendons

When stressing a tendon a certain portion of jack extension will be


needed to remove the slack.
This gives a false initial elongation that should not be part of the

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real elongation measurements.

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For this reason, the first step is to stress the tendon an initial force
of approximately 20% of the final force to remove the slack. From
this point up to 100% of the required load, the extension of the

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jack will cause pure elongations of the tendon.
At the end of the operation, a correction can be made for the
unmeasured portion of the elongation by straight extrapolation.
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The accuracy of the determination of the elongation obtained
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during the first step, i.e. tensioning up to 20% of the jacking force,
can sometimes be improved by recording elongations at
intermediate gauge readings of 40%, 60% and 80% and plotting
results on a graph. Ideally, the graph should be a straight line.
For short, mono or multi-strand tendons it may suffice to check the
elongation for the stressing range between 20% and 100% load
against the calculated value for this range. Short tendons are those
generally less than about 30M (100 feet) long where the expected

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elongation is only about 0.2M (8 inches) or less and is easily made
with a single, steady and continuous stroke of the jack. Short

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tendons include, for example, transverse tendons in deck slabs.
elongation can be measured directly
from the face of the concrete to a

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mark on the strand tails. At least two
randomly selected strands are
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marked. The mark can be a scribed
mark or saw cut on the strand tail
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beyond the back of the jack or it can


be made with tape or spray paint and
pencil. The mark is placed after 20%
of the jacking force has been applied.
Elongation Calculation
Basic elongation is calculated using the following formula:
Δ = basic elongation.
P = pressure (force) required .

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L = length of strand between anchors to be tensioned .
A = cross-sectional area (in.²) of the strand (from manufacture certification)

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E = modulus of elasticity of the strand (psi) (from manufacture certification)
Temperature corrections in Pre tensioned Beam (Iowa DOT):

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The calculations to determine elongation and force are based on a strand
temperature of 70ºF. The temperature of the pretensioned strand will
naturally become the same as the concrete. If the temperature of the
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strands, when tensioned, is cooler than 70ºF. and no corrections for
temperature were made, the stress in the pretensioned strands would relax
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with the introduction of the concrete. This would cause the stress in the
strands to be less than specified. The alternate would be true if the strands
were tensioned, without temperature corrections, at a temperature higher
than 70ºF. Elongation and force calculations need to be adjusted by 1.0% per
10ºF deviation from 70ºF.
Example (1) Post-tensioned Beam
Consider a four-span, spliced I-girder as illustrated in Figure, stressed
from both ends .

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So the total elongation of the tendon before any wedge set is:
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38.53 (at A, from Table (a)) + 6.36 (at B from Table (b)) = 44.88 in.
The net elongation after wedge set at both ends is then:
44.88 – 0.38 (at A) – 0.38 (at B) = 44.12 in. (Table 3.1 (b)).
Note: (no account has been taken for the elastic shortening of the structure
under the axial compression force of the tendon.)
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Example (2) Pre-Tensioned Beam
3-D60 Beams ,
Single Strand Tensioning , 14 strands.
Initial Tension = 1,500 lb , Total Initial Prestress = 596 Kips.

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Use 0.6” Strand, A = 0.217 in² , E = 28,000,000 psi
Live End Seating = ¾” , Dead End Seating = ⅛”

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Abutment Rotation = 0”
Temperature = 37ºF
Determine Gross and Net Elongation and Forces for Parallel Strands

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SOLUTION
Determine the length of the strands in the setup
Setup Length = (256 ft)(12in/ft) + 8 in = 3080 in
Determine Basic Elongation
Δ = PL/AE = [Initial Prestress – Initial Tension] (lbf) X Length (in) / Area (in²) x

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Modulus of Elasticity (psi)
P = (596 kips)(1000 lb/kip) / 14 strands = 42,571 lb/strand >>>>

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Δ = (42,571 lb – 1,500 lb preload)(3080 in) / (0.217 in²)(28,000,000 lb/in²)
= 126,498,680/ 6,076,000 = 20.82 in
Determine Live End Seating Load

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PLE = ΔLE x A x E / L
ΔLE = 0.75 in
PLE = (0.75 in)(0.217 in²)(28,000,000 lb/in²) / (3080 in)
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PLE = 1479.5 lb ~ 1480 lb
Determine Temperature Corrections
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For 37ºF, adjustment is +3%


Pт = (42,571 lb)(+0.03) = 1,277.1 lb ~ +1,277 lb
Δт = (+1,277 lb)(3080 in) / (0.217 in²)(28,000,000 lb/in²) = +3,933,160/ 6,076,000
Δт = +0.65 in
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‫ﺍﻟﺷﺭﻭﻁ ﻭﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﻔﻧﻳﺔ ﺍﻟﻌﺎﻣﺔ ﻟﻠﻁﺭﻕ ﻭﺍﻟﺟﺳﻭﺭ ﺍﻟﺳــﻭﺭﻳﺔ‬
‫ﻣﻥ ﺑﺎﺏ ﺍﻟﺫﻛﺭ ﻧﻭﺭﺩ ﻣﺎﺟﺎء ﻓﻲ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﻔﻧﻳﺔ ﺍﻟﻌﺎﻣﺔ ﻟﻠﻁﺭﻕ ﻭﺍﻟﺟﺳﻭﺭ ﺍﻟﺳﻭﺭﻳﺔ ﺣﻭﻝ‬
‫ﻣﻭﺿﻭﻉ ﺣﺳﺎﺏ ﺍﻟﺗﻁﺎﻭﻻﺕ ﻓﻲ ﻛﺎﺑﻼﺕ ﺍﻟﺷﺩ ﺧﻼﻝ ﺗﻧﻔﻳﺫ ﺍﻟﻣﻧﺷﺂﺕ ﻣﺳﺑﻘﺔ ﺍﻹﺟﻬﺎﺩ‪:‬‬

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‫‪ 8.7.4.5‬ﻣﻌﺩﺍﺕ ﻭﺇﺟﺭﺍءﺍﺕ ﺍﻟﺷﺩ ﺍﻟﻼﺣﻖ‪:‬‬

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‫ﻳﺟﺏ ﺗﻁﺑﻳﻖ ﺍﻹﺟﺭﺍء ﺍﻟﺗﺎﻟﻲ ﻋﻠﻰ ﻣﺟﻣﻭﻋﺔ ﻛﺎﺑﻼﺕ ﺍﻟﺷﺩ ﺍﻟﻣﺗﻣﺎﺛﻠﺔ‪.‬‬

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‫ﺑﻌﺩ ﺳﺣﺏ ﻛﺎﺑﻼﺕ ﺍﻟﺷﺩ ﺍﻟﺛﻼﺛﺔ ﺍﻷﻭﻟﻰ ﺑﻣﻘﺩﺍﺭ ﻗﻭﺓ ﺍﻟﺷﺩ ﺍﻟﻣﻘﺭﺭﺓ ﻓﻲ ﻣﺧﻁﻁﺎﺕ ﺍﻟﻭﺭﺷﺔ‬
‫ﺍﻟﻣﻌﺗﻣﺩﺓ‪ ،‬ﻳﺟﺏ ﺃﻥ ﻳﺗﻭﻗﻑ ﺍﻹﺟﻬﺎﺩ ﺣﺗﻰ ﻳﺗﻡ ﺍﺳﺗﻛﻣﺎﻝ ﻋﻣﻠﻳﺔ ﺗﻘﻳﻳﻡ ﻗﻭﻯ ﺍﻟﺷﺩ ﻭﺍﻻﺳﺗﻁﺎﻻﺕ‬
‫ﻣﻥ ﺟﺎﻧﺏ ﺍﻟﻣﻬﻧﺩﺱ ﺑﺎﻟﻁﺭﻳﻘﺔ ﺍﻟﻣﺑﻳﻧﺔ ﻓﻲ ﻫﺫﻩ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ‪ .‬ﻭﻳﺟﺏ ﻣﻘﺎﺭﻧﺔ ﺍﻻﺳﺗﻁﺎﻻﺕ‬
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‫ﺍﻟﻔﻌﻠﻳﺔ ﺍﻟﺗﻲ ﺟﺭﻯ ﻗﻳﺎﺳﻬﺎ ﻓﻲ ﺃﻭﻝ ﺛﻼﺛﺔ ﻛﺎﺑﻼﺕ ﺷﺩ ﺑﺎﻻﺳﺗﻁﺎﻻﺕ ﺍﻟﻣﺣﺳﻭﺑﺔ ‪ .‬ﻓﺈﺫﺍ ﺗﺑﻳﻥ ﺃﻥ‬
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‫ﺍﻻﺳﺗﻁﺎﻻﺕ ﺍﻟﻣﻘﺎﺳﺔ ﺑﺎﻟﻔﻌﻝ ﻓﻲ ﻛﺎﺑﻼﺕ ﺍﻟﺷﺩ ﺍﻟﺛﻼﺛﺔ ﻟﻡ ﺗﻛﻥ ﺿﻣﻥ ﺣﺩﻭﺩ )‪ (8 %‬ﻣﻥ‬
‫ﺍﻻﺳﺗﻁﺎﻻﺕ ﺍﻟﻣﺣﺳﻭﺑﺔ‪ ،‬ﻓﺈﻧﻪ ﻳﺟﺏ ﺍﻟﺗﻭﻗﻑ ﻋﻥ ﻋﻣﻠﻳﺔ ﺍﻟﺷﺩ ﻟﻳﻘﻭﻡ ﺍﻟﻣﻬﻧﺩﺱ ﺑﺗﻘﻳﻳﻡ‬
‫ﻛﻝ ﻣﻥ ﻛﺎﺑﻼﺕ ﺍﻟﺷﺩ ﻭﺍﻻﺳﺗﻁﺎﻻﺕ ‪ .‬ﻓﺈﺫﺍ ﺗﺑﻳﻥ ﺃﻥ ﻛﻝ ﻭﺍﺣﺩﺓ ﻣﻥ ﺍﻻﺳﺗﻁﺎﻻﺕ ﺍﻟﻣﻘﺎﺳﺔ‬
‫ﺑﺎﻟﻔﻌﻝ ﻛﺎﻧﺕ ﺿﻣﻥ ﻧﺳﺑﺔ )‪ (8 %‬ﻣﻥ ﺍﻻﺳﺗﻁﺎﻟﺔ ﺍﻟﻣﺣﺳﻭﺑﺔ‪ ،‬ﻓﺈﻧﻪ ﻳﺟﺏ ﺗﻁﺑﻳﻖ ﺍﻹﺟﺭﺍء‬
‫ﺍﻟﺗﺎﻟﻲ‪:‬‬
‫‪ 1‬ﺗﺣﺩﻳﺩ ﺍﻟﻌﺎﻣﻝ ﺍﻟﺗﺎﻟﻲ‪:‬‬
‫‪f ={5+ (Tendon 1 A/ Tendon 1 C )+ (Tendon 2 A/ Tendon 2 C) + (Tendon 3 A/ Tendon 3 C)} /8‬‬

‫ﺣﻳﺙ )‪ (A‬ﺗﻣﺛﻝ ﺍﻻﺳﺗﻁﺎﻟﺔ ﺍﻟﻔﻌﻠﻳﺔ ﺍﻟﻣﻘﺎﺳﺔ ﻓﻲ ﺍﻟﻣﻭﻗﻊ ﻭ )‪ (C‬ﺗﻣﺛﻝ ﺍﻻﺳﺗﻁﺎﻟﺔ ﺍﻟﻣﺣﺳﻭﺑﺔ ﻟﻛﻝ‬

‫‪IL‬‬
‫ﻛﺎﺑﻝ ﻣﻥ ﻛﺎﺑﻼﺕ ﺍﻟﺷﺩ ‪ .‬ﻭﺑﺿﺭﺏ ﺍﻟﻌﺎﻣﻝ ) ‪ (f‬ﻓﻲ ﻗﻳﻡ ﺍﻻﺳﺗﻁﺎﻻﺕ ﺍﻟﻣﺣﺳﻭﺑﺔ ﻟﺑﻘﻳﺔ ﻛﺎﺑﻼﺕ‬
‫ﺍﻟﺷﺩ ﺍﻟﺗﻲ ﻳﺭﺍﺩ ﺷﺩﻫﺎ ﻓﺈﻧﻪ ﻳﺗﻡ ﺍﻟﺗﻭﺻﻝ ﺇﻟﻰ ﺩﻟﻳﻝ ﺍﻻﺳﺗﻁﺎﻟﺔ ﺍﻟﺟﺩﻳﺩ ﻟﺑﻘﻳﺔ ﺁﺍﺑﻼﺕ ﺍﻟﺷﺩ ﻓﻲ‬

‫‪AK‬‬
‫ﺍﻟﻌﻧﺻﺭ ﺍﻹﻧﺷﺎﺋﻲ‪.‬‬
‫‪ 2‬ﺳﻳﺗﻡ ﻗﺑﻭﻝ ﺃﻱ ﻛﺎﺑﻝ ﺷﺩ ﻣﻥ ﺍﻟﻛﺎﺑﻼﺕ ﺍﻟﻣﺗﺑﻘﻳﺔ ﺇﺫﺍ ﻛﺎﻧﺕ ﺍﺳﺗﻁﺎﻟﺗﻪ ﺿﻣﻥ ﻧﺳﺑﺔ )‪ (5 %‬ﻣﻥ‬
‫ﺩﻟﻳﻝ ﺍﻻﺳﺗﻁﺎﻟﺔ ﺍﻟﺟﺩﻳﺩ ﻋﻧﺩ ﻗﻭﺓ ﺍﻟﺷﺩ ﺍﻟﻣﻁﻠﻭﺑﺔ‪.‬‬

‫‪ER‬‬
‫‪ 3‬ﻓﺈﺫﺍ ﻛﺎﻧﺕ ﺍﻻﺳﺗﻁﺎﻟﺔ ﺍﻟﻣﻘﺎﺳﺔ ﻷﻱ ﻣﻥ ﻛﺎﺑﻼﺕ ﺍﻟﺷﺩ ﺗﺯﻳﺩ ﺑﻧﺳﺑﺔ )‪(5 %‬ﻋﻥ ﺩﻟﻳﻝ ﺍﻻﺳﺗﻁﺎﻟﺔ‬
‫ﺍﻟﺟﺩﻳﺩ‪ ،‬ﻓﺈﻧﻪ ﻳﺟﺏ ﺇﺧﺿﺎﻉ ﻛﺎﺑﻝ ﺍﻟﺷﺩ ﻟﻠﺗﻘﻳﻳﻡ ﻭﻳﻛﻭﻥ ﻋﺭﺿﺔ ﻟﻠﺭﻓﺽ‪.‬‬
‫‪M‬‬
‫‪ 4‬ﺃﻣﺎ ﺇﺫﺍ ﻛﺎﻧﺕ ﺍﻻﺳﺗﻁﺎﻟﺔ ﺍﻟﻣﻘﺎﺳﺔ ﺃﻗﻝ ﻣﻥ ﺩﻟﻳﻝ ﺍﻻﺳﺗﻁﺎﻟﺔ ﺍﻟﺟﺩﻳﺩ ﺑﻣﺎ ﻳﺗﺟﺎﻭﺯ ﻧﺳﺑﺔ )‪،(5 %‬‬
‫ﻓﺈﻥ ﺑﺎﻹﻣﻛﺎﻥ ﺷﺩ ﺍﻟﻛﺎﺑﻝ ﺇﻟﻰ ﻧﺳﺑﺔ )‪ (80 %‬ﻣﻥ ﻗﻭﺗﻪ ﺍﻟﻧﻬﺎﺋﻳﺔ‪ ،‬ﻭﻳﺟﻭﺯ ﺷﺩ ﻫﺫﺍ ﺍﻟﻛﺎﺑﻝ ﻣﻥ‬
‫‪SA‬‬

‫ﺃﻱ ﻁﺭﻑ ﻣﻥ ﻁﺭﻓﻳﻪ ‪ .‬ﻓﺈﺫﺍ ﺃﻋﻁﺕ ﻫﺫﻩ ﺍﻟﻌﻣﻠﻳﺔ ﺍﺳﺗﻁﺎﻟﺔ ﻓﻲ ﺣﺩﻭﺩ )‪ (5 %‬ﻣﻥ ﻗﻳﻣﺔ ﺩﻟﻳﻝ‬
‫ﺍﻻﺳﺗﻁﺎﻟﺔ ﺍﻟﺟﺩﻳﺩ‪ ،‬ﻓﺈﻧﻪ ﺳﻳﺗﻡ ﻗﺑﻭﻝ ﻛﺎﺑﻝ ﺍﻟﺷﺩ‪ .‬ﻭﻓﻲ ﻏﻳﺭ ﺫﻟﻙ ﻣﻥ ﺍﻷﺣﻭﺍﻝ ﻓﺈﻧﻪ ﺳﻳﺗﻡ‬
‫ﺇﺧﺿﺎﻉ ﻫﺫﺍ ﺍﻟﻛﺎﺑﻝ ﻟﻠﺗﻘﻳﻳﻡ ﻭﻳﻛﻭﻥ ﻋﺭﺿﺔ ﻟﻠﺭﻓﺽ‪.‬‬
‫‪.‬‬
Elongation Problems
Too small elongation at jacking end under full load
Too small elongation may occur due to a kink close to the stressing
anchor; the jack may reach full load, but the elongation will be

IL
very small. When this happens, the required elongation may
possibly be achieved by stressing the tendon from the other end.

AK
However, this will not be feasible if low elongation is due to duct
misalignment over the whole length of the tendon.

ER
Low elongation for whole tendon
When low elongation is due to duct misalignments occur over the
whole length of the tendon, stressing from the other end may not
M
be enough to attain elongation. Consideration may be given to
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lubricating the tendon with water soluble oil or with graphite


powder. This can reduce friction and result in better elongations.
After a tendon has been successfully stressed, water soluble oil
should be thoroughly removed by flushing. Flushing water should
be thoroughly drained and blown from the ducts.
Elongation greater than tolerance
An elongation can be more than expected. This may be because of
less friction than anticipated or because of slip of strands and
wedges that went unnoticed. The wedges should be examined at

IL
both ends. It is for this reason that marks should always be made on
strand tails at both ends the tendon. If there is no wedge slip and

AK
tendons persistently give an elongation greater than expected, the
stressing calculations should be examined and appropriate
adjustments made.

ER
Low stressing force
It would be very unusual to not to be able to stress a tendon to a
M
required jacking force; more often a problem is revealed by lack of
SA

elongation, not force. If force cannot be attained, the system should


be checked. The possibility of increasing the jacking force may be
considered. However, it should be checked by calculations using a
higher wobble and friction coefficient tomake sure that the stress in
the tendon after anchor set does not exceed allowable stresses.
Overall Tolerance on a Group of Tendons
If none of the above lead to a satisfactory solution, it is possible
to consider a problematic tendon as part of a whole tendon
group – for example, one tendon out of perhaps sixteen to

IL
twenty in a cantilever, or similar. A tolerance for the whole group
should be given in specifications or project special provisions. If

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all other tendons have a good stressing record, one poorly
stressed tendon ought not to influence the group tolerance too
adversely.

ER
To make up for a loss of force in one tendon a compensating
M
increase in force in other tendons may be considered, if there is
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sufficient reserve holes in the wedge plates to accommodate


additional strands. Alternatively, if the shortfall is significant, it
may be necessary to introduce or install additional tendons
through provisions made on the plans or shop drawings.
Grouting

Purpose

IL
Cement grout is chemically basic and provides a passive
environment around the post-tensioning bars or strands. The

AK
grout also serves to bond internal tendons to the structure.
Appropriate protection of post-tensioning tendons begins with
complete filling of the ducts with high quality grout.

ER
Since the early 1990s, the UK has seen a series of refinement in the
M
requirements for the grouting of tendons, including more detailed
and exacting specifications. The collapse of the Ynys-y-Gwas
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Bridge, in December 1985, highlighted historical deficiencies in the


grouting process and related design and specification issues. It also
emphasised the importance of effective grouting to prevent
corrosion.
IL
AK
ER
M
SA

Grouted duct and tendon


Cement and other Pozzolans for Grout

The primary constituent of grout is ordinary Portland cement (Type


I or II) that meets the requirements of ASTM C150/C150M.

IL
Other cementitious material may be added to enhance certain

AK
qualities of the final product. Fly ash and slag cements can improve
corrosion resistance in aggressive environments. The addition of
dry silica fume (micro-silica) can improve resistance to chloride

ER
penetration because the particles help fill the interstices between
hydrated cementitious grains thus reducing the permeability.
M
The water-cementitious material ratio should be limited to a
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maximum of 0.45 to avoid excessive water retention and bleed and


to optimize the hydration process. Any temptation to add water to
improve fluidity on-site must be resisted at all times. Fluidity may
be enhanced by adding a high range water-reducer, HRWR.
Admixtures

Grouts made of only cement and water often exhibit segregation


and voids due to excessive bleed water. Like concrete, admixtures

IL
may be used to improve workability and reduce the water

AK
required, reduce bleed, improve pumping properties or entrain air.
Care must be exercised to use the correct quantities in the proper
way according to the manufacturer’s instructions and to remain

ER
within the mix properties established by qualifying laboratory
tests.
M
SA

Note: Water content shall be minimum necessary for proper


pumping of grout; however, water-cement ratio shall not exceed
0.45 by weight (ACI318/18.18.3)
Pre-bagged Grouts

Grouts where the constituent materials are measured and


batched on site do not always have uniform properties. This arises

IL
from variations in materials, day to day mixing differences, crew
changes, weather conditions, and so forth.

AK
In an endeavor to eliminate problems related to grout variations,
several State DOT’s have obtained greater quality control by

ER
requiring “pre-bagged” grouts.
M
In a pre-bagged grout, all the constituent materials have been
thoroughly mixed and blended at the factory in the dry condition.
SA

This ensures that nothing other than water needs to be added


while mixing on site.
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ER
M
SA

Grout-mixing equipment
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M
ER
AK
IL
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ER
M
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Anchor cap with grout inlet


Laboratory Tests
Acceptance of a grout is usually based upon the results of laboratory
tests. Laboratory tests on trial batches of the proposed grout using
the same materials and equipment to be used on site are used to

IL
qualify a grout. In the following some of these tests:

AK
Setting Time
The setting time should be more than 3 but less than 12 hours.

Grout Strength
ER
The strength should be 21MPa (3000 psi) at seven days and 35MPa
M
(5,000 psi) at 28 days.
SA

Volume Change
A value of 0.0% to less than +0.1% at 24 hours and no more than
+0.2% at 28 days is acceptable.
Pumpability and Fluidity (Flow Cone)
Grouts should be tested according to ASTM C939 modified by filling
the flow cone above the standard level, and measuring the time to
fill a one-liter container. The efflux time should be between 5 and

IL
30 seconds immediately after mixing. After allowing the grout to
stand for 30 minutes without agitation and then remixing for 30

AK
seconds, the efflux time should be less than 30 seconds.

ER
M
SA
Bleed
The “Wick Induced Bleed
Test” involves completely
immersing a 0.5M (20 in)

IL
length of strand in a
cylinder of carefully

AK
prepared grout and
following a modified
version of ASTM C940 to
record the bleed water
ER
above the grout. A bleed
M
of 0.0% after 3 hours at
normal room temperature
SA

(70º F) is acceptable
Corrosion
An Accelerated Corrosion Test (ACT) may be used to quantify the
expected level of corrosion for a specific grout.
Pre-grouting test (pressure testing) of the ducting system
There is a need to prove the integrity of the duct system before
grouting starts, to ensure that leaks do not occur.

IL
For internal tendons with plastic ducts, this is carried out before

AK
concreting and, for external tendons or internal tendons with
corrugated steel ducts, before grouting.

Air pressure testing

ER
Air testing under pressure is used primarily on plastic and HDPE
ducts to check the integrity and potential watertightness of the duct
M
and fittings. The testing process can also indicate, by opening all the
inlets and vents and allowing the air to flow through, that the vents,
SA

ducts, anchorages and other areas are all free from blockages.

However, the passage of air is no guarantee that grout will also be


able to flow freely.
•Testing in two phases can be useful. First, the unvented system is
tested to locate major leaks in the duct itself; and, second, testing
is carried out with all vents and associated fittings added to
determine the soundness of the vent work. The fittings for some

IL
plastic duct systems may not be able to sustain high pressures,
even though the duct may still give an overall satisfactory

AK
performance, and this needs to be considered when choosing the
system to be used.

ER
•In summary, air testing does not necessarily indicate that water
egress will occur at connections during grouting or that there is any
risk of water ingress at connections later; however, the test is useful
M
for determining the integrity of the ducting and in identifying
SA

potential problem areas.

•With regard to the issue of reasonable percentage loss in pressure,


TR47 (Concrete Society, 1996, 2002) suggests that 10% of 0.01
N/mm2 over five minutes is acceptable.
Water pressure testing
•This test is often used to identify leaks in internal corrugated steel
ducts and is carried out before or after installing the tendons. It has
been a common practice to water-test internal tendons in precast
segmental construction, It is also used in non-segmental construction

IL
and in cast in situ segmental construction.

AK
Water is pumped through the ducts and out of all the vents and
outlets to ensure that an even flow can be achieved. The vents and
outlets are then closed and the water pressurised to a level similar to

ER
that required during the grouting process. The pressure drop over a
period of time is monitored as an indication of the integrity of the
ducts and the seriousness of any leaks.
M
•During water testing, locations where water emerges on the inside
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or outside faces of the concrete are easily identified and repaired.

•After completion of the water testing, all residual water is removed


from the duct by blowing air through and by providing drainpipes or
vents at all low points where appropriate.
Grouting procedure
•Once pressure testing has been carried out successfully, grouting of
the duct can take place. Where possible, groups of tendons should
be grouted together so as to minimise any risks of leakage between

IL
adjacent ducts and to simplify the overall grouting process.

AK
•If there is any water in the ducts this should be removed as much
as possible before the start of grouting. It is not always practical to

ER
remove all the water from the ducts and a small quantity left
behind does not usually present a problem.
M
•Grout is introduced via the inlet at a slow, even rate, maintaining a
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pressure of 0–1 N/mm2, and grout is allowed to emerge sequentially


from intermediate vents before they are sealed. For external
tendons the rate of progress of the grout along the tendon should
be established audibly by tapping of the duct
•At intermediate vents and at the anchorage outlet at the end of the
tendon, a quantity of grout is allowed to vent, before the tap is
slowly closed. All vents should be closed in sequence in the direction
of grout flow, with the outlet being closed last. It is useful to hold the
end of the vent pipe below the surface of the collected grout in a

IL
bucket. Any air being pushed out of the duct is seen as a series of

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bubbles in the bucket of grout.

•Grouting should continue until the air bubbles are no longer visible.

ER
The outlet grout should be collected and subjected to a fluidity test
using the flow cone discussed earlier, to ensure that it still complies
with the specified requirements.
M
•The grout in the duct system should be pressurised and held for a
SA

short period, allowing any air voids to rise up to the crests in the
duct profile. The vents at the crests are then reopened one at a time
to release any air present. Finally, with all vents closed again, the
system is re-pressurised and held for another short period before
finally being sealed.
•Following grouting, vibration on the structure should be
prevented for 24 hours to allow the grout to set and harden.

IL
•Post-grouting checks should include inspection of vent pipes to
ensure that they remain full of grout.

AK
For external tendons, tapping of the duct can indicate if any air
voids are present when a hollow sound is recorded. Investigations
involving drilling into ducts should be carried out with care to

ER
avoid damage to the tendons.
M
SA

Note: usually require provision to be made for adequate flushing


out of a duct with water if there is a problem during the grouting
operation, such as equipment failure or grout blockage. The
specification usually requires ‘complete removal of the grout.
Grease and wax grout
Grease and wax grout is used with external prestressing to enable
easy de-stressing or replacement of the tendons. The grease or
petroleum wax is injected into the duct at between 808C and 908C,

IL
before cooling to become a soft, flexible filler. Additives are often
included in the wax to help penetration through the wires and to

AK
inhibit corrosion. With pre-assembled tendons or where tendons are
individually sheathed, the wax is injected at the factory in controlled
conditions.

ER
Wax grouting follows a similar procedure to cement grouting, except
that injection pressures are typically 0.2 N/mm2.
M
Where external tendons are required to be re-stressable, sufficient
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length of strand is left protruding to allow a stressing jack to be re-


attached. An elongated cap covers the protruding strand so that the
length of tendon immediately behind the anchorage can be
protected by grease or wax infill.
Examples of Grouting Procedures

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ER
M
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GROUT VENTS
Example 1: Two-Span Spliced Ι-Girder

Consider duct profile and longitudinal gradient and establish


direction of grouting.

IL
• Orient end anchors (A and G) so that the vents are at the top.
• Determine location at lowest point of profile for injection vent (in

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this example, point B).
Because, in this case, the profile change in the depth of the spliced
Ι-girder is significant

ER
(i.e. greater than 0.5m (20in)) grout should be injected from the
low point. If two or more low points are at the same elevation,
M
then select one.
• Provide a vent at crest (D) and at 1 to 2m (3 to 6 feet) beyond
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crest (at C and E) in both


directions (to avoid potential confusion between work at precast
plant and site).
• Provide drainage vents at other low points (B and F).
• Provide grout outlet at end anchor (G).
• Show direction of grouting.
• Sequence of closing vents: A, C, F, E, D, G, B.

IL
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ER
M
SA
Example 2: Four-Span Spliced Ι-Girder

• Consider duct profile and longitudinal gradient and establish


direction of grouting.
• Orient end anchors (A and O) so that the vents are at the top.

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• Determine which location is at lowest point of profile for

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injection vent (in this example point B). Because, in this case, the
profile change in the depth of the spliced Ι-girder is significant (i.e.
greater than 0.5m (20in)) grout should be injected from the low

ER
point. If
two or more low points are at the same elevation, then select one.
• Provide vent at all crests (D, H, L) and at 1 to 2m (3 to 6 ft)
M
beyond crests (at C, E, G, I, K, and M). Although it is only necessary,
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in theory, to install outlets at the high points and on the


downstream side of each crest, in order to avoid confusion and
risk of a mistake (such as turning girder end for end) during
erection, it may be prudent to install vents on both sides of a crest.
• Provide drainage vents at all other low points (B, F, J, and N)
• Provide grout outlet vent at end anchor (O).
• Show direction of grouting.
• Sequence of closing vents: A, C, F, E, D, G, J, I, H, K, N, M, L, O, B.

IL
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ER
M
SA
Example 3: Cantilever or Top Continuity Post-Tensioning

For a typical cantilever tendon, where the cantilever is on a rising


longitudinal gradient, the following procedure would. It would

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also apply to a similar top slab continuity tendon.

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• Consider duct profile and longitudinal gradient and establish
direction of grouting.
• Orient end anchors (A and D) so that grout injection and

ER
evacuation vents are at top.
• Provide grout inlet at lowest, end anchor, (A).
M
• Provide a grout outlet vent at the highest point of the tendon
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profile (C).
• Provide outlet vent at the end anchor (D)
• If the tendon is longer than 50M (150 ft), provide intermediate
vent near mid-length (B).
• Show direction of grouting.

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• Sequence of closing vents: B, D, C, A.

AK
ER
M
SA
Example 4: Lateral Tendons in Hammerhead Pier Cap
• Consider profile and slope and establish the direction of grouting
• Place an outlet at the high point
• Inject from one end of cap

IL
• First close vent at opposite end of cap after evacuating grout
• Vent grout at high point outlet

AK
• Close high point vent, then close inlet

ER
M
SA

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