SECTION 03380

POST-TENSIONED CONCRETE

TABLE OF CONTENTS

Item No Title Page No

PART 1 GENERAL............................................................................................................ 1

1.01 DESCRIPTION OF WORK .................................................................................. 1

1.02 SECTION INCLUDES .......................................................................................... 1

1.03 RELATED SECTIONS ......................................................................................... 1

1.04 REFERENCES..................................................................................................... 1

1.05 DEFINITIONS....................................................................................................... 3

1.06 SUBMITTALS....................................................................................................... 4

1.07 QUALITY CONTROL ........................................................................................... 7

1.08 HEALTH AND SAFETY CONSIDERATIONS...................................................... 8

1.09 DESIGN CRITERIA.............................................................................................. 9

1.10 DELIVERY, HANDLING AND STORAGE ........................................................... 9

PART 2 PRODUCTS ....................................................................................................... 11

2.01 MATERIALS ....................................................................................................... 11

2.02 TOLERANCES ................................................................................................... 17

PART 3 EXECUTION ...................................................................................................... 20

3.01 FALSEWORK..................................................................................................... 20

3.02 INSTALLATION.................................................................................................. 20

3.03 CONCRETING ................................................................................................... 24

3.04 STRESSING....................................................................................................... 24

3.05 GROUTING ........................................................................................................ 26

Rev 1 i Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

PART 1 GENERAL

1.01 DESCRIPTION OF WORK

A. The Work shall consist of the furnishing, installing, stressing and grouting
prestressed reinforcement for cast-in-place post-tensioned concrete structures,
including non-prestressed reinforcement required for the performance of the post-
tensioning, anchorages, ducts, embedded items and other accessories required in
accordance with details shown on the drawings and as specified herein this
Specification.

1.02 SECTION INCLUDES

A. Cast-In-Place Post-Tensioned Prestressed Concrete

1.03 RELATED SECTIONS

A. Section 01320 Construction Progress Documentation

B. Section 01330 Submittal Procedures

C. Section 01410 Regulatory Requirements

D. Section 01450 Quality Control

E. Section 01650 Product Delivery Requirements

F. Section 01660 Product Storage and Handling Requirements

G. Section 03105 Cast-In-Place Concrete Forms and Accessories

H. Section 03205 Reinforcement for Concrete

I. Section 03310 Structural Concrete

J. Section 03430 Precast Structural Concrete

K. Section 03930 Concrete Rehabilitation

1.04 REFERENCES

A. The referred codes and standards are intended to provide an acceptable level of
quality for materials, products and workmanship. In case of conflict between these
standards and the text of this Specification, the Specification text shall govern.

B. The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict, the Contractor shall propose equipment, materials and
processes confirming to one group of codes and standards.

Rev 1 1 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

C. AASHTO American Association of State Highway and Transportation

Officials

1. M182 Burlap Cloth made from Jute or Kenaf

D. ACI American Concrete Institute

1. ACI 301 Specification for Structural Concrete

2. ACI 305 Hot Weather Concreting

3. ACI 308 Standard Practice for Curing Concrete

4. ACI 318RM Building Code Requirements for Structural Concrete

and Commentary

5. ACI 423.3R Recommendations for Concrete Members

Prestressed with Unbonded Tendons

6. ACI 423.4R Corrosion and Repair of Unbonded Single Strand

Tendons

E. ASTM American Society for Testing and Materials

1. ASTM A36M Standard Specification for Carbon Structural Steel

2. ASTM A153M Standard Specification for Zinc Coating (Hot-Dip) on

Iron and Steel Hardware

3. ASTM A416M Standard Specification for Steel Strand, Uncoated

Seven-Wire for Prestressed Concrete

4. ASTM A421M Standard Specification for Uncoated Stress-Relieved

Steel Wire for Prestressed Concrete

5. ASTM A570M Standard Specification for Steel, Sheet and Strip,

Carbon, Hot-Rolled, Structural Quality

6. ASTM A611 Standard Specification for Structural Steel (SS),

Sheet, Carbon, Cold-Rolled

7. ASTM A700 Standard Practices for Packaging, Marking, and

Loading Methods for Steel Products for Domestic
Shipment

8. ASTM A722M Standard Specification for Uncoated, High-Strength

Steel Bars for Prestressing Concrete

9. ASTM A779M Standard Specification for Steel Strand, Seven-Wire,

Uncoated, Compacted, Stress-Relieved for
Prestressing Concrete

10. ASTM B117 Standard Practice for Operating Salt Spray (Fog)

Rev 1 2 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

Apparatus

11. ASTM C309 Standard Specification for Liquid Membrane-Forming

Compounds for Curing Concrete

12. ASTM C618 Standard Specification for Coal Fly Ash and Raw or
Calcined Natural Pozzolan for Use as a Mineral
Admixture in Concrete

13. ASTM C939 Standard Test Method for Flow of Grout for
Preplaced-Aggregate Concrete

14. ASTM C1107 Standard Specification for Packaged Dry, Hydraulic-

Cement Grout (Non-shrink)

F. AWS American Welding Society

1. AWS D1.1M Structural Welding Code – Steel

2. AWS D12.1 Reinforcing Steel Welding Code

G. PCI Prestressed Concrete Institute

1. PCI JR119 Recommended Practice for Grouting of Post-

Tensioned Prestressed Concrete

H. PTI Post Tensioning Institute

1. PTI (MAN) Post-Tensioning Manual

1.05 DEFINITIONS

A. anchorage: In post-tensioning, a device used to anchor the prestressing steel to the

concrete member.
B. bond breaker: A substance placed on a tendon or on existing concrete to prevent it
from bonding to the subsequently placed concrete.
C. bonded tendons: Tendons that are bonded to the concrete through grouting or other
approved means, and therefore are not free to move relative to the concrete.
D. bonding agent: A substance used to insure or increase the bond between an
existing piece of concrete and a subsequent application of concrete, mortar or grout
such as a patch or composite topping.
E. corrosion inhibitor or coating: Substance which delivers long term protection to
metal surfaces against corrosion and lubricates the prestressing steel within
enclosed air spaces during storage, shipping and in-service applications.
F. coupler: Are intermediate anchorages which are provided when prestressing bars
have to be lengthened progressively.
G. duct: Hole formed in the concrete for the insertion of prestressing steel that is to be
post-tensioned.
H. dynamometer: A device which will measure the tension applied to it when it is
connected between two tensile forces.

Rev 1 3 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

I. final (effective) prestress: The prestressing forces in the concrete after

substantially all losses have occurred.
J. initial prestress: The prestressing force after anchorage losses applied to the
concrete at the time when post-tensioned concrete tendons are stressed and
anchored.
K. jacking stress: The temporary jacking stress before anchorage losses to which
tendon may be subjected for the purpose of minimizing creep in steel or for reducing
frictional losses.
L. load cell: A sensitive electrically operated strain gage attached to a calibrated cell to
provide direct readings of loads applied to the cell.
M. loss of prestress: The reduction of the prestressing force resulting from the
combined effects of relaxation in the tendons, friction between tendon and steel
conduits and or concrete, creep and shrinkage in the concrete, and elastic
deformation.
N. prestressing: The intentional creation of permanent stresses in a concrete member
or assembly, for the purpose of improving its behavior and strength under various
service conditions.
O. prestressing steel: High strength steel used to prestress concrete, commonly
seven-wire strands, single wires, bars, rods or groups of wires or strands.
P. post-tensioning: A method of prestressing in which the tendon is tensioned after
concrete has hardened whereby the tendon is kept from bonding to the concrete and
anchored directly against the hardened concrete, imparting stresses through end
bearing.
Q. proving ring: An elastic alloy steel ring used to calibrate or measure loads. A dial
indicator inside the ring measures deflection under load and a calibration curve
enable direct determination of load.
R. sheathing: An enclosure in which the prestressing steel is placed to prevent bonding
during concrete placement and, in the case of tendons that are to remain unbonded,
to protect the corrosion-inhibiting coating on the prestressing steel.
S. strand: A group of wires having a center wire enclosed tightly by six helically placed
outer wires with uniform pitch of not less than 12 and not more than 16 times the
nominal diameter of the strand.
T. tendon: A steel element, such as wire, cable, bar, rod, strand or a bundle of such
elements, primarily used in tension to impart compressive stress to concrete.
U. unbonded tendons: Tendons in which the prestressing steel is permanently free to
move (between anchors) relative to the concrete to which they are applying
prestressing forces.
V. wedges: The parts of a strand vise which actually contact or grip the wires or
strands.

1.06 SUBMITTALS

A. The Contractor shall submit to the Royal Commission, under the provisions of
SECTION 01330, the following items for review and approval before commencing
Work:

Rev 1 4 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

1. Product Data

a) Concrete
1) All submittals required in accordance with SECTION 03310.

b) Reinforcement
1) All submittals required shall be in accordance with
SECTION 03205.

c) Prestressing steel.

2. Prestressing System

a) Outline of proposed prestressing system and sufficient detail such that

all aspects can be clearly identified and readily evaluated. Submit to the
Royal Commission for review, not less than 60 days prior to
commencement of work and include, but not limited to the following:
1) Proposed prestressing system, past experience of the system on
similar projects and the manufacturer’s literature describing the
proposed method and procedure in detail.
2) Methods, equipment and facilities to be utilized for the production,
transport, erection, stressing and grouting.
3) Material specifications, kind or size of prestressing tendons,
anchoring devices, ducts, grout and all associated materials and
accessory items.
4) Past experience of the key personnel that will be responsible for
inspections, verifications and check list procedures for the
construction of all post-tensioning work; the submittal includes the
name and record of any subcontractor to be employed for the
stressing work.
5) The quality control program.

b) Post-Tensioning Procedure
1) The Contractor shall submit a Method Statement for the post-
tensioning procedure to be approved by the Royal Commission.

3. Calculations

a) Furnish signed and sealed detailed calculations prepared by qualified

registered Professional Structural Engineer to substantiate stressing
procedures. All losses accounted for in the calculations. Submit the
following:
1) Calculations of minimum force required, eccentricity, prestress
losses and stresses provided by the prestressing system, losses
due to anchorage seating, elastic shortening, creep, shrinkage,
relaxation, wobble friction, used to determine tendon sizes and
number.
2) Calculations of test results for adequacy of anchorage.

Rev 1 5 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

3) Statistical and field proof of stressing and fixed end seating

losses.
4) Calculations for final required jacking elongation corresponding to
final jacking force of tendons.
5) Calculations of any portion of the work not completely designed
and detailed on the Contract Drawings, any proposed
substitutions, additions, re-arrangement of prestress or reinforcing
steel and any proposed modifications of concrete dimensions.
Any deviation from Contract Drawings must be reviewed and
approved by the Royal commission prior to installation.

4. Shop Drawings

a) Submit fabrication and placement details reviewed and approved by

qualified registered Structural Engineer.
1) Shop Drawing complete with layout plan, member dimensions,
tendon support heights and chair sizes, location of tendons and
sheathings throughout their length, size, details, location,
materials and stress grade (where applicable) for tendons and
accessories, including anchorage device details, jack clearances,
jacking procedures, stressing sequence, initial tensioning forces,
gage pressures, tendon elongation and other related data shown
following recommendations contained in the Quality Control
Program.
(a) Dimensional conflicts and interference between non-
prestressed reinforcement and post-tensioning tendons and
anchorages investigated during the preparation of the Shop
Drawings and, if found, brought to the attention of the Royal
Commission promptly. The Contractor is responsible for
dimensional conflicts not specifically brought to the
attention of the Royal Commission.
2) Design of special reinforcement required for the performance of
the post-tensioning anchorages for resisting compressive, tensile-
bursting and tensile-spalling stresses, detailed on the post-
tensioning Shop Drawings and supplied and installed as a part of
the post-tensioning work.
3) Approved and reviewed Contract Drawings and Specifications are
the only basis on work to be done, which must be kept at all work
locations.

5. Mill Test Reports

a) Submit three certified copies of mill test reports, including chemical

analysis and physical properties for each heat of the prestressing and
reinforcing steel and for each lot of anchorage assemblies as required
by the applicable standards.

b) Submit typical stress-strain curves for prestressing steel for each

consignment of steel.

c) Along with test reports, submit a certification stating the manufacturer’s

Rev 1 6 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

minimum guaranteed ultimate tensile strength of all prestressing steel

and anchorage assemblies.

d) Where mill certificates are not available, an approved testing laboratory

to perform the required tests and chemical analysis to substantiate
conformance with this Specification shall be employed and paid by the
Contractor.

6. Project Record Documents

a) Cast-in-place Concrete
1) Furnish all submittals required in SECTION 03310.

b) Concrete Reinforcement
1) Furnish all submittals required in SECTION 03205.

c) Post-Tensioning
1) Record of post-tensioning stressing and grouting operation for
each member including concrete strength, jacking forces and
tendon elongation.

1.07 QUALITY CONTROL

A. The Contractor shall be responsible for the quality of work and shall develop and
propose programs and methods of construction and testing such as to achieve the
specified quality to the approval of the Royal Commission in accordance with
SECTION 01450.

B. Process Control Sampling and Testing of prestressing strands, wires and bars shall
conform to the requirements of ASTM A416M, A421M and A722M or A779M and as
follows:

1. The Contractor’s facilities and equipment shall meet the requirement under
SECTION 03310.

2. The following samples shall be furnished by the Contractor and tested by the
Royal Commission’s approved independent testing laboratory.

a) Each size and each heat of prestressing bars.

b) Each manufactured reel of prestressing steel strand.

c) Each coil of prestressing wire.

d) Each lot of anchorage assemblies.

e) Each size of bar couplers.

3. All materials for testing shall be furnished at the Contractor’s expense. The
Contractor is not entitled to claim for additional compensation in the event the
work is delayed awaiting approval of the materials furnished for testing.

Rev 1 7 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

4. The Contractor shall assign individual lot number to all bars of each size from
each mill heat, all wire from each coil, and all strand from each manufactured
reel to be shipped to the site and shall be tagged in such a manner that each
lot can be accurately identified at the job site. Each lot of anchorage
assemblies and bar couplers to be installed at the site shall be identified. All
unidentified prestressing steel, anchorage assemblies or bar couplers received
by the site shall be rejected.

5. Grout Testing

a) Test grout for strength and shrinkage in accordance with ASTM C1107.

C. Qualifications and Experience

1. The Contractor shall ensure that production, transport and erection of post-
tensioned prestressed concrete shall only be performed by a company or
organization specializing in such services that is regularly providing items of
work of the types required under this Specification; having sufficient and
adequate plant, equipment, personnel and experience; and who can present
evidence of having previously and successfully completed similar or
comparable types of work.

D. Supervision

1. The Contractor shall be responsible for providing key personnel necessary for
continuously overseeing the prestressing construction work to assure
compliance with this Specification. Personnel for supervisory work shall be
sufficiently well qualified by training and experience.

2. Personnel for overseeing fabrication, prestressing and installation work can be

the same, provided they are sufficiently qualified in all phases of work.

3. The supervisory personnel shall be responsible for utilizing and recording the
confirmation records or check sheets and tests records. Such records shall be
maintained in orderly manner; and as the respective parts or portions of the
work are completed from time to time, copies of such records shall be
submitted to the Royal Commission for information.

4. The assigned and approved supervisory personnel shall not be changed

unless qualified personnel are available for replacement and are approved in
advance by the Royal Commission.

1.08 HEALTH AND SAFETY CONSIDERATIONS

A. All works undertaken in relation to this Specification are to be completed in full

accordance with the respective health and safety requirements established by the
following:

1. Kingdom of Saudi Arabia

a) Legislation, Regulation, Standards and Codes.

Rev 1 8 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

2. Royal Commission Regulations

a) Standards, Contractual Conditions, and Health and Safety Systems.

3. Contractor

a) Health and Safety Standards and Systems as accepted by the Royal

Commission.

B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.

1.09 DESIGN CRITERIA

A. Post-tensioned member concrete shall be Class C35 in accordance with the

requirements of SECTION 03310.

B. Concrete strength at the time of post-tensioning shall have reached the 28-days
compressive strength indicated on the Contract Drawing.

C. The allowable stresses for the concrete and prestressing steel shall be as per
AASHTO, Latest Edition.

D. The friction loss and other prestress losses shall be estimated as provided in
AASHTO, Latest Edition.

E. The load from anchoring device shall be distributed effectively to the concrete. Such
devices shall conform to the following requirements:

1. The final average unit compressive stress on the concrete directly underneath
the plate assembly shall not exceed 20 MPa, and shall also not exceed 90% of
the ultimate strength of concrete at the time of post-tensioning.

2. Bending stresses in the plates or assemblies induced by the pull of

prestressing steel shall not exceed the yield point of the material or cause
visible distortion in the anchorage plate when 100% of the specified ultimate
load is applied as determined by the Royal Commission.

F. Recommendations for spacing of ties for bundles of unbonded tendons are as

follows:

1. For bundles of 2 to 4 monostrand tendons, ties to a minimum of 10 mm

diameter stirrups at 760 mm on center.

2. For bundles of 5 or more monostrand tendons, ties to a minimum of 15 mm

diameter stirrups at 1070 mm on center.

1.10 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall deliver, handle and store equipment and material units in
accordance with SECTIONS 01650 and 01660, as well as the following

Rev 1 9 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

requirements:

1. Deliver post-tensioning materials crated, packaged, bundled and tagged to

identify placement and certify testing. Packaging of prestressing steel
conforming to the requirements of ASTM A700 and in addition, provided with a
vapor-phase corrosion inhibitor. The corrosion inhibitor shall have no
deleterious effect on the steel or concrete or bond strength of steel or
concrete. Packaging of forms damaged from any cause immediately replaced
or restored to original condition. The shipping package or form clearly marked
with a statement that the package contains high-strength prestressing steel,
and the type of corrosion inhibitor used, including the date packaged.

2. Post-tensioning materials transported to the site, stored and covered in a

manner insuring that no damage shall occur to it from moisture, dirt, grease,
heat, welding or any other cause that might impair bond to concrete or affects
its quality. The materials stored off the ground on concrete or wood dunnage to
protect against corrosion. Identification of materials maintained after bundles
are opened.

3. Material delivery, storage and handling for concrete required in post-tensioning

elements shall refer to SECTION 03310.

4. Store cement and pre-mixed grout to prevent bag set. Cement stored at the
project site shall be used for grouting only.

5. Material delivery, storage and handling for reinforcing steel bars required in
post-tensioning elements shall refer to SECTION 03205.

Rev 1 10 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

PART 2 PRODUCTS

2.01 MATERIALS

A. All goods and products covered by these Specifications shall be procured, when
available, from an in-Kingdom manufacturer. Procurement of all goods and products
manufactured out-of-Kingdom must be approved by the Royal Commission.

B. Prestressed Concrete Materials

1. Portland cement, water, admixtures, general aggregate requirements, fine

aggregate and coarse aggregate grading shall conform to the respective
requirements specified under SECTION 03310.

C. Grout for Tendons

1. The grout shall consist of portland cement and water, OR

2. The grout to be used for large ducts having large void areas shall be a mixture
of portland cement and fine sand passing a 600 micron (No. 30) sieve in the
approximate proportion of 1 part cement to ¾ part sand by weight, the exact
proportion to be adjusted to form a grout having the proper consistency. In
addition, the grout shall conform to the following requirements:

a) Maximum Water Cement Ratio: 0.40

b) Minimum Compressive Strength (at 28 days): 35 MPa

c) Admixtures
1) Mineral admixtures shall conform to ASTM C494. Admixtures
should impart the properties of low water content, good flowability,
minimum bleed and expansion. Its formulation should contain no
chemicals in quantities that may have harmful effect on the
prestressing steel or cement.
2) Admixtures containing chlorides (as Cl in excess of 0.5% by
weight of admixture), fluorides, sulfites and nitrates are not
permitted to be used.

d) Aluminum powder of the proper fineness and quality or other gas

evolving material which is well dispersed through the other admixture to
obtain 5 to 10% unrestrained expansion of the grout is permitted to be
used upon approval of the Royal Commission.

e) All admixtures shall be used in accordance with the instruction of the

manufacturer and as approved by the Royal Commission.

D. Concrete Reinforcement

1. Concrete reinforcement shall be in accordance with the requirements of

SECTION 03205.

Rev 1 11 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

E. Prestressing Steel

1. Prestressing steel shall be high-tensile strength steel wire, high-tensile

strength seven-wire strand or high-strength alloy bars as called for in the
Contract Drawings, shall conform to one of the following specifications:

a) Uncoated stress-relieved steel wire shall conform to ASTM A421M, OR

b) Uncoated seven-wire low relaxation strand shall conform to

ASTM A416M, or

c) High-tensile strength alloy bars shall conform to ASTM A722M and in

addition, it shall be stress-relieved and then cold stretched to a minimum
of 900 MPa. After cold stretching, the physical properties shall be as
follows:

Minimum Ultimate Tensile Strength 1,000 MPa

Minimum Yield Strength, measured by the

0.70%elongation under load methods shall be not 900 MPa
less than

Minimum Modulus of Elasticity 173,000 MPa

Minimum elongation in 20 mm bar diameter after

4%
rupture
+ 0.75 mm
Diameter Tolerance
- 0.25 mm

1) In addition to the requirements of ASTM A722M for deformed

bars, the reduction of area shall be determined from a bar from
which the deformations have been removed. Such a bar shall be
machined no more than necessary to remove the deformations
over a length of 300 mm and reduction will be based on the area
of the machined portion.

d) When bars are to be extended by the use of couplers, the assembled

units shall have a tensile strength of not less than the manufacturer’s
minimum guaranteed ultimate tensile strength of the bars. Failure of any
one sample to meet this requirement will be a cause for rejection of the
heat of bars and lot of couplers.

e) Wires shall be straightened to produce equal stress in all wires or wire

groups or parallel lay cables that are to be stressed simultaneously to
insure proper positioning in the ducts.

f) Where wires are to be button-headed, the buttons shall be cold formed

symmetrically about the axes of the wires. The buttons shall develop the
minimum guaranteed ultimate tensile strength of the wire. No cold
forming process shall be used that causes indentations in the wire.
Button heads shall not contain wide open splits, more than 2 splits per
head, or splits not parallel with the axis of the wire.

Rev 1 12 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

g) All prestressing reinforcement shall be free from detrimental dirt, mill

scale, rust, paint, grease, oil or other foreign substance, fins or tears.
Slight rusting which discolors the metal may exist, but all loose mill scale
and scaly rust shall be removed. Brushing to clean blue metal is not
required. There shall be no evidence of pitting or visual flaw in the test
specimen or on the sheared ends of the bars. The development of
visible rust or any other physical damage shall be cause for rejection
when directed by the Royal Commission.

h) All the prestressing steel materials used shall be of the same type and
grade.

F. Coating or Corrosion Inhibitor

1. Unbonded Tendons

a) Coat unbonded tendons completely with grease conforming to

performance criteria of ASTM B117 Rust Grade 7, to ensure corrosion
protection. Tendon covering shall be continuous over the entire length to
be unbonded and shall prevent intrusion of cement paste or loss of
coating materials during concrete placement. Protect unbonded single-
strand tendons against corrosion in accordance with the Post-
Tensioning Institute’s “Specification for Unbonded Single Strand
Tendons”.
1) Corrosion preventive coating material shall have the following
properties:
(a) Provide corrosion protection to prestressing steel.
(b) Provide lubrication between strand and sheathing.
(c) Resist flow from sheathing within anticipated temperature
range of exposure.
(d) Provide a continuous non-brittle film at lowest anticipated
temperature of exposure.
(e) Chemically stable and non-reactive with the prestressing
steel, sheathing material and concrete.
2) Film shall be an organic coating with appropriate polar, moisture
displacing and corrosion preventive additive.
3) Minimum weight of coating material on prestressing strand shall
be not less than 1.1 kg of coating material per 30 m of 13 mm
diameter strand and 1.3 kg of coating material per 30 m of 15 mm
diameter strand. Amount of coating material used shall be
sufficient to ensure complete filling of annular space between
strand and sheathing. Extend coating over entire tendon length.

G. Sheathing

1. For Bonded Tendons

a) Sheathing and duct-forming materials shall not react with alkalis in the
cement, shall be strong enough to retain their shape and resist damage
during construction, and shall prevent the intrusion of water from the

Rev 1 13 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

cement paste. Sheathing and duct-forming material left in place shall not
cause directly or indirectly electrolytic action or deterioration. Sheathing
shall be capable of transmitting forces from the grout to the surrounding
concrete.

2. For Unbonded Tendons

a) Sheathing for unbonded tendons shall have sufficient strength and water
resistance to prevent damage or deterioration during transportation,
storage at project site, installation, and concrete placement and
tensioning. The sheathing shall be continuous over the unbonded length
of the tendons. The sheathing shall prevent the intrusion of water from
the cement paste and the escape of coating material. Chemical stability
without embrittlement or softening over anticipated exposure
temperature range and service life of structure. Non-reactive with
concrete, steel and tendon corrosion preventive coating. For
applications in corrosive environments, the sheathing shall be
connected to stressing end, intermediate and fixed end anchorages to
provide a complete encapsulation of prestessing steel.

H. Ducts

1. Ducts left in place shall be of a type that would not permit the entrance of
cement paste. They shall transfer bond stresses as required and shall retain
their shape under the weight of the concrete. Ducts shall be of rigid or semi-
rigid galvanized ferrous metal and shall be fabricated with either welded or
interlocked seams. Galvanizing of the welded seam is not required.

2. All ducts shall have grout openings at both ends. For draped cables all high
points shall have a grout vent except where cable curvature is small such as in
continuous slabs. All grout openings or vents shall include provisions for
preventing grout leakage.

3. For tendons made up of a plurality of wires, bars or strands, duct inside cross-
sectional area shall be at least twice the net area of the prestressing steel. For
tendons made up of a single wire, bar, or strand, the duct diameter shall be at
least 6 mm larger than the nominal diameter of the wire, bar or strand.

4. Ducts shall have sufficient strength to maintain their correct alignment without
distortion during placing of concrete. Joints between sections of cuts shall be
positive metallic connections which do not result in angle changes at the joints.
Waterproof tape shall be used at the connections. Ducts shall be bent without
crimping or flattening.

5. Transition couplings from ducts to anchoring devices shall be metallic and

need not be galvanized.

6. All ducts shall be provided with pipes or other suitable means necessary for
the proper injection of grout and venting of air and shall be provided with
connections, valves, caps and other accessories so that the grouting can be
carried out in accordance with the requirements of the specifications. Vents
shall be provided at all intermediate support locations in tendons having
significant vertical curvature.

Rev 1 14 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

7. Vents and drains shall be not less than nominal 12.5 mm diameter size and
may either be metallic or plastic. Plastic components shall not contain water-
soluble chlorides, shall be non-reactive with the concrete and grout and shall
not cause corrosion of the prestressing steel. Vent and drain connections to
ducts shall be metallic unless otherwise noted.

I. Anchorages

1. For Bonded Tendons

a) Anchorages for bonded tendons tested in unbonded state shall develop

90% of the minimum specified ultimate strength of the prestressing
steel, without exceeding anticipated set at time of anchorage, and
without slip. Anchorages that develop less than 100% of the minimum
specified ultimate strength shall be used only where the bond length
provided is equal to or greater than the bond length required developing
100% of the minimum specified ultimate strength of the tendon. Provide
the required bond length between the anchorage and the zone where
the full prestressing force is required under service and ultimate loads.
Determine the bond length by testing a full-sized tendon. If in the
unbonded state the anchorage develops 100% of the minimum specified
strength, it need not be tested in the bonded state.

2. For Unbonded Tendons

a) Unbonded tendon anchorages shall develop the minimum specified

ultimate strength of the prestressing steel with an amount of permanent
deformation that will not decrease the expected ultimate strength of the
assembly. Total strain of the tendon under ultimate load of the tendon
shall be not less than 2% when measured over minimum gage length of
3 m.

3. Should the Contractor elect to furnish an anchoring device of a type which is

sufficiently large and which is used in conjunction with a steel grillage
embedded in the concrete that effectively distributes the compressive stresses
to the concrete, the steel distribution plates or assemblies may be omitted,
provided the Royal Commission approval is obtained in advance.

4. Where the end of a post-tensioned assembly will not be covered by concrete,

the anchoring devices shall be recessed so that the ends of the prestressing
steel and all parts of the anchoring devices will be at least 50 mm inside of the
end surface of the members, unless a greater embedment is shown on the
Contract Drawings. Following post-tensioning, the recesses shall be filled with
concrete to protect against corrosion.

5. Where concrete or grout encasement cannot be used, the tendon anchorage

should be completely coated with a corrosion-resistant paint or grease
equivalent to that applied to the tendons. A suitable enclosure should be
placed where necessary to prevent the entrance of moisture or the
deterioration or removal of coating. The anchorage encasement should
provide fire resistance at least equal to that required for the structure.

Rev 1 15 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

J. Couplings

1. For Bonded Tendons

a) Couplings of bonded tendons shall be used only at locations specifically

indicated on approved Shop Drawings. Coupling shall not be used at
points of sharp tendon curvature. All couplings shall develop the
specified ultimate strength of the prestressing steel without exceeding
anticipated set. The coupling of tendons shall not reduce the elongation
at rupture below the requirements of the tendon itself. Coupling and
coupling components shall be enclosed in housing long enough to
permit the necessary movements and fittings shall be provided to allow
complete grouting of all the coupling components.

2. For Unbonded Tendons

a) Use couplings only where indicated on the approved Shop Drawings or

as acceptable to the Royal Commission. All couplings shall develop
strength in excess of the minimum specified ultimate strength of the
prestressing steel without exceeding anticipated set of either the
coupling or the prestressing steel, and shall not reduce the ductility of
the tendon below the minimum 2% strain. Enclose couplings in housings
that permit necessary movements during stressing.

K. Equipment
1. Hydraulic Jacks

a) Each jack used to stress tendons shall be equipped with either a

pressure gage or a load cell for determining the jacking stress at the
option of the Contractor.
1) The pressure gage shall have an accurate reading dial at least
150 mm in diameter and each jack and its gage shall be
calibrated as a unit with the cylinder extension in the approximate
position that it will be at final jacking force and shall be
accompanied by a certified calibration chart, OR
2) The load cell shall be calibrated and shall be provided with an
indicator by means of which the prestressing force in the tendon
may be determined. The range of the load cell shall be such that
the lower 10% of the manufacturer’s rated capacity will not be
used in determining the jacking stress.

2. Grouting Equipment

a) Grouting equipments shall be capable at a pressure of at least

0.669 MPa. Grouting equipment shall be furnished with a pressure gage
having a full-scale reading of not more than 2.07 MPa. Reciprocating
pumps or equipment that produces a pulsating flow shall not be used.
Grouting equipment shall be thoroughly washed with clean water at
least once every 3 hours during the grouting operations and at the end
of each day, after using. A set of complete grouting equipment for
immediate use in case of emergency or breakdown of the equipment in
operation shall be available on standby.

Rev 1 16 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

L. Miscellaneous Materials

1. Burlap

a) Cloth made of jute or kenaf conforming to AASHTO M182.

2. Anchors and Inserts

a) Anchors and inserts shall conform to ASTM A36M, hot-dipped

galvanized as per ASTM A153M.

M. Bearing Pads

1. Bearing pads shall be as specified in SECTION 03430.

2.02 TOLERANCES

A. The following Table 2A contains dimension tolerances that will be used as guide for
acceptance of post-tensioned members. The Contractor shall make every effort to
furnish acceptance members of uniform high quality that are within these dimensional
tolerances. Any member not within these tolerances is subject to rejection depending
on the effect of the deficiency on the structural adequacy and visual quality of the
member in the completed structure as approved by the Royal Commission.

TABLE 2A: TOLERANCES FOR I-BOX BEAM AND SLAB UNITS

Description Tolerance

Length ± 19 mm

Width (overall) ± 6 mm

Depth (overall) ± 6 mm

Depth (top flange) ± 13 mm

Depth (bottom flange) ± 13 mm

Width (web) ± 10 mm

Sweep(1)
Up to 12 m member length ± 6 mm
12 to 18 m member length ± 10 mm
Greater than 18 m member length ± 13 mm
Variation from end squareness or skew ± 10 mm
Horizontal ± 13 mm, max.
Vertical ± 13 mm

Rev 1 17 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

Description Tolerance

Camber variation from design camber ± 3.1 mm / 3 m, ± 13 mm, max.

Differential camber between adjacent members

6.2 mm / 3 m, 19 mm max.
of the same design

Position of Strands
Individual
± 6 mm
Bundled
± 6 mm
Position from design location of deflection points
± 510 mm
for deflected strands

Position of plates other than bearing plates ± 25 mm

Tipping and flushness of plates ± 6 mm

Position of inserts for structural connections ± 13 mm

Position of handling devices

Parallel to length ± 150 mm
Transverse to length ± 25 mm
Position of stirrups
Longitudinal spacing ± 25 mm
Projection above top ± 6 mm, - 19 mm max.

Tipping of beam seat bearing area ± 3 mm

Position of dowel tubes ± 16 mm

Position of tie rod tubes
Parallel to length ± 13 mm
Vertical ± 10 mm
Position of slab void
End of void to center of tie hole ± 13 mm
Adjacent to end block ± 25 mm
± 6 mm in every 3 m any
Local smoothness(2)
surface

Post-Tension Members
Position of post-tensioning ducts ± 6 mm

Position of tendon anchorage bearing plates ± 6 mm

(1)
Note: Variation from straight line parallel to centerline of member.
(2)
Does not apply to top surface left rough to receive a topping or to visually
concealed surfaces.

Rev 1 18 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

TABLE 2B: TOLERANCES FOR I-BEAM

Description Tolerance
Length ± 8 mm/m, ± 25 mm max
Width (overall) + 10 mm, - 6 mm
Depth (overall) + 13 mm, - 6 mm
Depth (flanges) - 6 mm

Width (web) + 10 mm, - 6 mm

(1)
Sweep 3.1 mm/ 3 m
Variation from end squareness of skew ± 16 mm/ m, + 25 mm max.
Camber variation from design camber ± 3.1 mm / 3 m
± 13 mm, max. 24 m length
± 25 mm, max. over 24 m
length
Position of strands
Individual ± 6 mm
Bundled ± 13 mm
Position from design location of deflection points for ± 510 mm
deflected strands

Position of plates other than bearing plates ± 25 mm

Position of bearing plates ± 16 mm
Tipping and flushness of plates ± 6 mm
Tipping and flushness of bearing plates ± 3 mm
Position of insert for structural connections ± 13 mm
Position of handling devices
Parallel to length ± 150 mm
Transverse to length ± 25 mm

Position of stirrups
Longitudinal spacing ± 50 mm
Projection above top ± 19 mm
Local smoothness(2) ± 6 mm in 3 m any surface
(1)
Note: Variation from straight line parallel to centerline of member.
(2)
Does not apply to top surface left rough to receive a topping or to visually
concealed surfaces.

Rev 1 19 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

PART 3 EXECUTION

3.01 FALSEWORK

A. General

1. The Contractor shall conduct a visual inspection to ensure that the

requirements of this Specification are met.

B. Formwork

1. The Contractor shall comply with the formwork and shoring operation
requirements of SECTION 03105.

C. The Contractor shall ensure that formwork does not restrain elastic shortening, or
camber resulting from application of the prestressing force and is sufficiently rigid to
prevent displacement of tendons beyond the tolerances. Anchor tendon supports to
the formwork to maintain the tendon profile during concrete placement.

D. The Contractor shall not remove formwork supports until sufficient prestressing force
has been applied to support the dead load, formwork and anticipated construction
loads. When a structure will be prestressed in two directions, formwork shall support
the load that is redistributed by partially completed stressing operation.

E. The Contractor shall comply with the provisions for the following in inclusion with the
formwork:

1. Supports and working space for tensioning jacks.

2. Permanent tendon location markers.

3. Anchorage and connection devices.

4. Reglets.

3.02 INSTALLATION

A. The Contractor shall ensure that installation of the following components shall comply
with this Specification and as stated below:

1. Concrete

a) All work involving concrete shall be carried out in accordance with

SECTION 03310.

b) Concrete shall not be placed in forms until the placing of reinforcement,

conduits, anchorages, and prestressing steel has been inspected and
approved by the Royal Commission.

2. Reinforcing Steel

a) Fabrication, placement, concrete protection, splicing and all incidental

Rev 1 20 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

operation of bonded reinforcing steel complying with the requirements of

SECTION 03205.

3. Ducts

a) Post-tensioning ducts must be fixed as accurately as possible to the

profile shown on the approved Shop Drawings and should be securely
fastened at close enough intervals to avoid displacement during
concreting. Tolerances for tendon placing shall be in accordance with
Tables 2A or 2B.

b) After completion of the duct assembly and taping of all joints, an air or
water test to be carried out before the completion of formwork fixing so
that all holes and slits are detected before concreting and can be sealed
with waterproof tape.

c) Large holes to be repaired with a split metal sleeve taped on to the duct.
Deep indentations cut out and treated as for large holes.

d) Ducts supplied in lengths are jointed on site using a metal collar of

similar material which screws over the adjoining lengths. All joints taped
at the ends to ensure adequate sealing. Avoid excessive wrapping of
the duct with sealing tape, particularly at the anchorages. Wrapping
shall not conceal poor jointing between anchorage and duct, resulting in
the anchorage being supported largely on tape.

e) After installation, maintain all duct and other openings closed or covered
such as to preclude intrusion of water, dirt, debris or other foreign
matter.

f) Immediately following completion of concrete placements for each

prestressed concrete member, clean out all tendon ducts using air
applied under sufficient pressure to break up and remove any cement
matrix or water which may have entered the ducts. All compressed air
used to blow out ducts must be oil free.

g) All water used for flushing ducts shall contain either quick lime (calcium
oxide) or slaked lime (calcium hydroxide) in the amount of 10 g/L of
water but otherwise comply with the requirements under
SECTION 03310.

4. Anchorages

a) Install stressing anchorages perpendicular to tendon axis. Curvature in

tendon profile not closer than 900 mm from stressing anchorage.

b) Attach stressing anchorage to bulkhead forms by either bolts, nails or

threaded pocket former fitting. Connections sufficiently rigid to avoid
accidental loosening due to construction traffic or during concrete
placement. Minimum cover for anchorage should not be less than
minimum cover to reinforcement at other locations in structure.

c) Pocket formers used to provide a void form at stressing and

intermediate stressing anchorages shall positively preclude intrusion of

Rev 1 21 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

concrete or cement paste into the wedge cavity during concrete

placement. Depth of the pocket former from edge of concrete to face of
anchorage shall not be less than 50 mm.

d) Intermediate Anchorage
1) Install Intermediate anchorages either embedded in concrete or
bearing against hardened concrete at construction joint. In the
hardened concrete, anchorage should have a flat-bearing side
and concrete bearing area should be smooth and without ridges.
2) When placing intermediate anchorages against already hardened
concrete, special attention must be paid to the bulkhead form
being perpendicular to the tendon during tendon placement.
3) Apply minimum cover requirements, as specified in
par. 3.02 A.4.b, to intermediate anchorages.

e) Fixed Anchorages
1) Install fixed end anchorages on tendon at supplier’s plant prior to
shipment to job site.
2) For wedge type anchorages, seat fixed end wedges with a load of
not more than 80% of minimum ultimate tensile strength of
tendon. Seating load should be sufficient to ensure adequate
capacity of non-stressing anchorages.
3) Place fixed end anchorages in the formwork at locations shown
on Shop Drawings and securely fastened to reinforcing steel.
Apply minimum cover requirements, as specified in
par. 3.02 A.4.b, to fixed end anchorages.
4) Fixed end anchorages should be closed or capped at wedge
cavity side with a watertight cover. Cover to be shop installed,
after filling void around wedge grips with a corrosion preventive
coating material.

5. Sheathing Inspection and Repair

a) After installing the tendons in forms and prior to concrete casting,

sheathing should be inspected for possible damage.

b) Repair damaged areas by restoring corrosion preventive coating in

damaged area and repairing sheathing. Repairs of sheathing must be
watertight.

c) Repair sheathing using adhesive moisture proof tape, spirally wrapped

around tendon to provide at least two layers of tape.

6. Installation of Prestressing Tendons

a) General
1) Install the prestressing tendons prior to or following the concrete
placement and curing in accordance with the prestress program
as approved by the Royal Commission.

Rev 1 22 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

2) Inspect all tendons prior to installation. The Quality Control

Supervisor shall reject all kinked, nicked, pitted or otherwise
damaged lengths, and lengths incorporating tendon splices or
points previously gripped by tendon vises. All tendon surfaces
should be clean and free of dirt, oil and foreign matter. For pre-
fabricated tendons, the Quality Control Supervisor shall inspect
the end fitting installations and wire bending while such fabrication
is in progress at the plant and shall arrange for the required
testing of the materials to be shipped to the site.
3) Position each tendon in a manner and sequence that will avoid
entanglement, kinking or damage of the tendon during placement
and initial tensioning. Contamination from bond breaker, form
release agent or from any other source should be avoided.
4) For patented prestressing system, comply with the manufacturer’s
procedures and instructions strictly.
5) All couplers and splices shall be enclosed in properly installed
approved housing to permit all necessary movements during
alignment, initial tensioning and final stress transfer.
6) Avoid exposure of tendons to excessive temperature, welding
sparks or electric ground current.

b) Tendon Profile
1) The placement of tendons should precisely follow the specified
profile within the tolerances as shown in Tables 2A and 2B. Any
inadvertent local reversed curvature should be corrected prior to
concreting. Maintain tendon profile by tying to reinforcing steel,
chairs or other supports with wire ties. Install ties so that they do
not visibly imprint or dent the sheathing. See par. 1.09 F for
recommended spacing of ties for bundles of unbonded tendons.

7. Tolerances

a) Deviations in tendon location and position tolerance are as shown in

Tables 2A or 2B.

8. Openings

a) Deviation of tendons in the horizontal plane to avoid interferences such

as openings, ducts, chases, inserts and others should be considered in
view of potential cracking due to lateral forces. Means to avoid or control
cracking include an adequately large radius of curvature, sufficient
clearance of the tendons from the edge of an opening, a straight tendon
extension beyond the opening corners and hairpin reinforcement to
transfer the lateral forces to the surrounding concrete.

9. Post-Tensioning Tendons Installed Before Concrete Placement

a) Prestressing tendon for post-tensioning which is installed in members

prior to placing and curing of the concrete should be continuously
protected against rust or other corrosion until grouted by means of a
corrosion inhibitor placed in the ducts or applied to the steel in the duct.

Rev 1 23 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

b) When steam curing is used, installation of prestressing tendon for post-

tensioning to be done after the steam curing is completed.

10. Post-Tensioning Tendons Installed After Completion of Concreting

a) Prestressing tendon for post-tensioning which is installed in the ducts

after completion of concrete curing and tensioned and grouted within
10 days do not require the use of corrosion inhibitor in the ducts.
Prestressing tendons installed but not grouted within 10 days require
protection with the use of corrosion inhibitor.

3.03 CONCRETING

A. The Contractor shall ensure the receiving, placing, consolidating, finishing, curing
and repairing of all cast-in-place portion of post-tensioned prestressed concrete work
shall be in accordance with the requirements of SECTION 03310.

B. The Contractor shall place concrete in such a manner that tendon alignment and
reinforcing steel positions remained unchanged. Special attention should be given to
vibration of concrete at tendon anchorages to insure uniform compaction at these
points. Voids behind the bearing plate, or insufficient concrete strength will cause
concrete failure. Careful vibration and proper curing should be done accordingly to
eliminate most of the difficulties. Voids behind the bearing plate should be repaired
prior to the stressing operation.

3.04 STRESSING

A. The Contractor shall ensure that the requirements of this Specification for stressing
operation are met and as mentioned:

1. General

a) Strictly implement the post-tensioning program approved by the Royal

Commission.

b) The stressing operation may begin when test cylinders cured under job
site conditions and representative of the concrete strength in the
immediate vicinity of the anchorages indicated from tests that the
concrete has attained the strength specified for stressing.

c) Unless indicated in the Contract Drawings, all tendons shall be

simultaneously jacked from both ends.

d) Hydraulic gages, dynamometers, load cells or other devices for

measuring the stressing load having an accuracy of reading within 2%.
Gages are calibrated by an approved testing laboratory at intervals not
greater than 12 months.

e) Pressure gages full pressure capacity is approximately twice their

intended working pressure.

f) Keep not less than one spare hydraulic jack capable of prestressing the

Rev 1 24 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

largest tendon at the job site in case of breakdowns.

g) Stressing equipment for post-tensioning tendons incorporate reasonable

factors of safety. Occasionally, flaws in material are undetected or the
equipment may have been misused. For this reason, extreme caution
should be exercised at all times, as stressing is carried out at extremely
high pressure. The primary safety rule is to keep personnel from directly
in back, over or under stressing equipment.

2. Initial Tensioning

a) After tendons have been positioned, an initial force of 15% of the design
prestressing force are applied to each tendon to provide an initial stress
condition in all tendon that will result in a uniform final stress.

b) Initial tension load are determined from load gages only. Elongation
measurement as a method of determining initial stress is not acceptable.

3. Measuring Tendon Elongation

a) After completion of initial tensioning, establish reference marks from

which elongations by final tensioning forces can be measured.
Elongations are then accurately measured from these reference points.
Measure the tendon elongation to the nearest 2 mm.

b) Elongation measurement shall take into account operational losses in

the tensioning system as strand slippage, movement of anchorages,
strand rotation and others.

c) Accuracy of measurement is within 5% of calculated elongation.

4. Post-Tensioning

a) Before any stressing operations start on site, comprehensive stressing

instructions are supplied for the post-tensioning system being used and
blank record sheets for the Royal Commission approval.

b) Tendons are tensioned in accordance with the required sequence, to

keep stresses within pre-determined limits of symmetry about the axes
of the member.

c) Stresses are determined from both measured elongation and gage

reading.

d) If tendons required jacking from both ends, both jacking operations done
simultaneously applying uniform tensioning force at each end unless
otherwise approved by the Royal Commission. This can be
accomplished by using, a single pump and similar lengths of pressure
hose to both jacks. When stressing commences, it is essential to take
out any slack in the tendon and to ensure that jack is firmly bearing
against the anchorages before commencing extension measurements.
The stressing force at both ends, as measured by jacking pressure and
also by total elongation calculations shall check the theoretical values
within 5%. If the measurements cannot be reconciled within this range,

Rev 1 25 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

the procedure is examined and sources of error determined, so the

measured force can be verified within this limit.

e) The excess lengths of the strands are cut with an abrasive cutting tool.
Before cutting the large strand, the ends of the strand must be bound in
an approved manner to prevent the wires coming out of lay. Flame
cutting is not permitted.

f) Anchor prestressing tendons at an initial or “Transfer Stress” that will

result in retention of working forces or stresses of not less than those
shown on the Contract Drawings as the final prestress force after all
losses. In no case shall tendons be anchored at stresses above 80% of
specified tensile strength of tendon.

g) Extra precaution is taken to avoid damage to tendons. In the event that

a single wire in a multiple wire strands is broken, replacement will not be
required provided total loss caused by broken strand is less than 2% of
total prestress in the member. Replace tendon at no additional cost in
the event prestress loss through breakage is greater than 2%.

h) Tendons are not welded within the length to be tensioned and unless
methods of cutting are approved by the Royal Commission, tendon shall
be sawn or cropped using an abrasive disc cutter.

3.05 GROUTING

A. The Contractor shall ensure that grouting of post-tensioned tendons are in

compliance with the procedures stated below:

1. Bonded Post-Tensioned Tendons

a) All bonded post-tensioned tendons are grouted by completely filling the

entire void space between the duct and the tendon, not sooner than
2 hours and not later than 24 hours after completion of the stressing
operation. Grouting procedures shall conform to PCI JR 119.

b) The dry mix and water are carefully measured and the mixed batch
screened to remove all lumps before using.

c) Grout is mixed and pumped using equipment designed and produced for
these specific purposes. Equipment not approved by the Royal
Commission is not allowed to be utilized for the work.

d) All equipment are motor powered, designed and equipped with seals
and other devices such as to preclude intrusion of grease, oil, water or
other substances not intended to be mixed into the grout.

e) The mixing and delivery system are of sufficient size and capacity that
the largest tendon duct in the work can be completely grouted in not
more than 20 minutes.

f) Mixing equipment is capable of continuously mixing and agitating the

grout until passed on to the grout pump and provided with suitable

Rev 1 26 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

devices such that both solid and liquid ingredient materials can be
accurately measured in accordance with the approved grout proportions.

g) The grout is mixed for a minimum of 2 minutes and until a uniform

consistency is obtained. The pumpability of the grout is determined in
accordance with ASTM C939. The efflux time of the grout sample
immediately after mixing should not be less than 11 seconds. The flow
cone test does not apply to grout which incorporates a thixotropic
additive.

h) The equipment shall include a standby flushing system capable of

developing a pumping pressure of not less than 1.75 MPa and of
sufficient capacity to flush out any partially grouted ducts.

i) Grout injection pipes are fitted with positive mechanical shutoff valves.
Vents and injection pipes are fitted with valves, caps or other devices
capable of withstanding the pumping pressures. Valves and caps are
not allowed to be removed or opened until the grout has set.

j) Leakage of grout through the tendon anchorage assemblies should be

prevented by positive mechanical means.

k) Additions of water or other materials not in accordance with the

approved grout mix proportion are not permitted.

l) Immediately prior to grouting, all ducts thoroughly flushed with clean or

lime water, then all excessive water are cleaned with compressed air. All
air and water used for this purpose shall meet the requirements
specified herein.

m) The grouting shall commence as soon as possible after mixing and

screening the grout. The pumping operation shall be applied toward an
open vent and continuously under moderate pressure at one end of the
duct or void until all entrapped air is forced out at the open vent at other
end, and until a steady stream of grout is discharging from the vent.
Then, the vent is closed against the steady discharging stream of grout,
and the pumping pressure gradually increased to 0.669 MPa. This
0.669 MPa pressure are maintained at least 20 seconds before the
grouting inlet is sealed off. The pumping pressure at the tendon inlet
should not exceed 1.75 MPa.

n) After screening, the grout not in use is re-circulated continuously until

completion of the grouting operation.

o) In the event of blockage or interruption before completion of grouting for

any reason, the ducts are thoroughly flushed as specified above for
preparation for grouting.

p) No mixed grout can be re-used beyond the time limit recommended by

the manufacturer.

2. Temperature Consideration for Grouting

a) The grout temperature should not exceed 25°C during mixing or

Rev 1 27 of 28 Contract No:

 SECTION 03380
POST-TENSIONED CONCRETE

pumping. Ice can be used to cool the temperature of the grout.

b) The temperature of the prestressed concrete member which is to be

grouted should not exceed 25°C during the pumping of the grout.
Additionally, the temperature of the member is kept below 25°C for a
minimum period of 72 hours after completion of the grouting operation.
This requirement can be met by covering the surface with wet layers of
burlap which are kept moist.

c) Grouting operations is not advised to be conducted if the ambient

temperature is less than 2°C.

END OF SECTION

Rev 1 28 of 28 Contract No: