SECTION 03 60 00

GROUTING

PART 1 - GENERAL
1.1. Scope
1.1.1. General

1.1.1.1. This specification sets out the route-wide requirements for grouting works in precast segmental
and cast in place concrete construction.

1.1.1.2. This specification shall be read in conjunction with Post Tensioned Concrete specification 03
38 00 and other relevant specification of the project.

1.1.1.3. The Contractor shall prepare detailed Construction Specifications in compliance with these
requirements.

1.1.1.4. The Contractor shall comply with the requirements of European Standards, Dubai Municipality
(DM) and Emirates Authority for Standardization and Metrology.

1.1.1.5. The Contractor shall complete the design and construction of the project in accordance with
the stipulations of the contract documents and standard list.

1.2. Related Sections

1.2.1. General

1.2.1.1. The Contractor shall comply with the following related Sections.

Section 01 33 00 SUBMITTAL PROCEDURES

Section 01 35 23 WORKSITE SAFETY REQUIREMENTS

Section 01 43 00 QUALITY ASSURANCE

Section 03 38 00 POST-TENSIONED CONCRETE

Section 03 41 00 PRECAST STRUCTURAL CONCRETE

Section 03 30 00 CAST-IN-PLACE CONCRETE

Section 03 32 00 CONCRETE CONSTRUCTION

Section 05 12 00 STRUCTURAL STEEL FRAMING

1.3. References
1.3.1. International Standards

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1.3.1.1. The Contractor shall provide detailed grouting specifications in compliance with the Employer
specification and primarily set with Euro Norm and British Standards.

1.3.1.2. The following list of the most up-to-date standards shall be applied to grouting works.

EN 1990 Eurocode - Basis of structural design and British National Annexure

EN 1991 Eurocode 1 - Actions on structures

EN 1992 Eurocode 2: Design of concrete structures

EN 1993 Eurocode 3: Design of steel structures

EN 1994 Eurocode 4: Design of composite steel and concrete structures

EN 1995 Eurocode 5: Design of timber structures

EN 1996 Eurocode 6: Design of Masonry structures

EN 1997 Eurocode 7 - Geotechnical design

EN 1998 Eurocode 8 - Design of structures for earthquake resistance

BS 5896 High tensile steel wire and strand for the prestressing of concrete.
Specification

EN 445 Grout for prestressing tendons. Test methods

EN 446 Grout for prestressing tendons. Grouting procedures

EN 447 Grout for prestressing tendons. Basic Requirements

EN 524 Series Steel strip sheaths for prestressing tendons. Test methods

EN 934 Part 4 Admixtures for concrete, mortar and grout. Admixtures for grout for
prestressing tendons. Definitions, requirements, conformity, marking
and labelling

EN 13391 Mechanical tests for post-tensioning systems

EN 13670 Execution of concrete structures

ISO 15630 -3 Steel for Reinforcement and Prestressing of Concrete. Test methods.
Prestressing steel

EN 13369 Common rules for precast concrete products

FIB BULLETING 33. Durability of post-tensioning tendons.

FIB BULLETIN 7 Corrugated plastic ducts for internal bonded post-tensioning

FIB BULLETIN 75 Polymer-duct systems for internal bonded post-tensioning

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FHWA -MANUAL FOR Post-tensioning tendon installation and grouting Manual
TENDON INSTALLATION &
GROUTING

PTI Post Tensioning Manual Post-Tensioning Manual

EAD 160004-00-0301 Post-Tensioning Kits for Prestressing of Structures

EAD 160027-00-0301 Special Filling Products for post-tensioning kits

AASHTO Construction AASHTO LRFD Bridge Construction Specification

Specifications

CONCRETE SOCIETY REPORT Durable Post-tensioned Concrete Structures

TR 72

U.S. FEDERAL Wrapping Materials, Volatile Corrosion Inhibitor Treated.

SPECIFICATION MIL-P-3420

ISO 15630 Part 3 Steel for Reinforcement and Prestressing of Concrete. Test methods.
Prestressing steel

BRE Digest 330 Alkali-silica reaction in concrete - Part2 Detailed guidance for new
construction.

AASHTO Guide Specifications AASHTO Guide Specifications for Design and Construction of
Segmental Concrete Bridges

ASTM C1090 Standard Test Method for Measuring Changes in Height of Cylindrical
Specimens of Hydraulic-Cement Grout

ASTM C942/C942M-21 Standard Test Method for Compressive Strength of Grouts for
Preplaced-Aggregate Concrete in the Laboratory

BS EN 480 Admixtures for Concrete, Mortar and Grout - Test Methods.

ASTM C939/C939M-16A Standard Test Method for Flow of Grout For Preplaced-Aggregate
Concrete (Flow Cone Method)

ASTM C940-16 Standard Test Method for Expansion and Bleeding of Freshly Mixed
Grouts for Preplaced-Aggregate Concrete in the Laboratory

EN 933-1 Tests for geometrical properties of aggregates. Determination of

particle size distribution - Sieving method

EN ISO 15630 Part 3 Steel for Reinforcement and Prestressing of Concrete. Test methods.
Prestressing steel

ISO 14824 Grout for Prestressing Tendons - Grouting Procedures

ASTM C 953 Standard Test Method for Time of Setting of Grouts for preplaced-
aggregate concrete in the laboratory

ASTM C1107/C1107M-20 Standard Specification for Packaged Dry, Hydraulic-Cement

Grout (Nonshrink)

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ASTM C 1202-19 Standard Test Method for Electrical Indication of Concrete’s
Ability to Resist Chloride Ion Penetration

ASTM C 348-21 Standard Test Method for Flexural Strength of Hydraulic-Cement

Mortars

BS EN 12190 Products and systems for the protection and repair of concrete
structures. Test methods. Determination of compressive strength of
repair mortar.

BS 6319-Part 3 Testing of resin compositions for use in construction. Method for

measurement of flexural strength

BS 6319-Part 7 Testing of resin and polymer/cement compositions for use in

construction. Method for measurement of tensile strength

BS EN 934-2 Admixtures for concrete, mortar and grout – Part 2

ASTM C 827 Standard Test Method for Change in Height at Early Ages of Cylindrical
Specimens of Cementitious Mixtures

BS EN 1504-3 Products and systems for the protection and repair of concrete
structures - Definitions, requirements, quality control and evaluation
of conformity. Structural and non-structural repair

BS EN 1504-6 Products and systems for the protection and repair of concrete
structures - Definitions, requirements, quality control and evaluation
of conformity. Anchoring of reinforcing steel bar

EN 1542 Products and systems for the protection and repair of concrete
structures - Test methods - Measurement of bond-strength by pull-off

EN 13412 Products and systems for the protection and repair of concrete
structures – Test methods – Determination of modulus of elasticity in
compression

BS EN 13295 Products and systems for the protection and repair of concrete
structures - test methods - determination of resistance to carbonation

EN 13501-1 Fire classification of construction products and building elements –

Classification using data from reaction to fire tests

ASTM-C579 Standard Test Methods for Compressive Strength of Chemical-

Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer
Concretes

ASTM C-1339-02 Standard Test Method for Flowability and Bearing Area of Chemical-
Resistant Polymer Machinery Grouts

ASTM C-580 Standard Test Method for Flexural Strength and Modulus of Elasticity
of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and
Polymer Concretes

ASTM D-638 Standard Test Method for Tensile Properties of Plastics

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 ASTM C-1181 Standard Test Methods for Compressive Creep of Chemical-Resistant
Polymer Machinery Grouts

ASTM C-884 Standard Test Method for Thermal Compatibility Between Concrete
and an Epoxy-Resin Overlay

ASTM C-531 Standard Test Method for Linear Shrinkage and Coefficient of Thermal
Expansion of Chemical-Resistant Mortars, Grouts, Monolithic
Surfacing, and Polymer Concretes

ASTM C307 Standard Test Method for Tensile Strength of Chemical-Resistant

Mortar, Grouts, and Monolithic Surfacing

1.4. Quality
1.4.1. General

1.4.1.1. The Contractor shall comply with the requirements of Section 01 43 00 Quality Assurance and
post-tensioned concrete specification 03 38 00, clause 1.5.2.

1.4.1.2. CE marking for the selected grout types shall be included in the material submittal.

1.4.1.3. The manufacturer shall be a company with at least fifteen years’ experience in the manufacture
of grouting materials.

1.4.1.4. Grouting shall be certified from an EIAC accreditation certificate.

1.4.1.5. The grout installer shall be qualified to perform the work specified by reason of experience for
post-tensioning supplier.

1.4.1.6. The contractor personnel in charge of post-tensioning grouting operations – such as the
foreman of the grouting crew – shall be certified by valid PTI certification relevant for their work.

1.4.1.7. The PTI qualification requirement shall be applied to the lead construction inspector
responsible for inspection of the grouting operation.

1.4.1.8. The grouting foreman shall have three years of grouting experience.

1.4.1.9. Proof of applicator staff qualification shall be submitted with the grouting plan for The
Engineer’s Approval.

1.4.1.10. All other construction workers and construction inspectors involved with grouting shall trained
and certified by the post-tensioning supplier.

1.5. Submittals
1.5.1. Submittal’s requirement

1.5.1.1. The Contractor shall comply with the requirements of Section 01 33 00 Submittal
Requirements.

1.5.1.2. A method statement shall be submitted to the Engineer at least 30 days prior to execution.

1.5.1.3. Contractor shall submit the manufacturer’s product data, installation for each material and
product used, and manufacturer’s Material Safety Data Sheets.

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 1.5.1.4. The Contractor shall prepare a sampling and testing plan that clarifies the frequency and rate
of sampling.

1.5.1.5. The contents of sample and testing plan shall be approved by the Engineer before
commencement of work.

1.5.1.6. The Contractor shall ensure reasonable notice (minimum 24 hours) for all Witness Points.

1.5.1.7. Method statement for construction of materials and workmanship from the Contractor shall be
submitted and approved by the Engineer at least 30 days prior to concreting as an evidence
document of milestone.

1.6. Definitions, Acronyms and Abbreviation

1.6.1. Abbreviations

1.6.1.1. The following abbreviations are used in this Section.

m Meter
mm Millimeters
MPa Mega Pascal
NA National Annex
NOC No Objection Certificate
RTA Roads and Transport Authority
PT Post Tensioning
RC Reinforced Concrete
w/c Water/cement
EIAC Emirates International Accreditation Centre
PTI Post-Tensioning Institute

1.7. Warranty (Not Used)

1.8. Spare Parts (Not Used)

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PART 2 - PRODUCT
2.1. General
2.1.1. General requirements

2.1.1.1. Execution class of concrete work shall be EXC3 as per BS EN 13670.

2.1.1.2. The Contractor shall complete the design and construction of the project in accordance with
the stipulations of the contract documents and standard list.

2.1.1.3. The Employer’s requirements as specified in the project’s Documents (Specifications, Basis of
Design, etc.) shall take priority for all aspects of the Project, except where a particular
Authorities’ requirements for specific element are imposed.

2.1.1.4. In case of conflict between the Employer’s and any of the Authorities’ requirements, the
Contractor shall follow the most stringent requirement.

2.1.1.5. The most conservative clause shall prevail if conflicts / inconsistencies exist between these
clauses, the references, the standards, or the contract documents.

2.1.1.6. All pre-bagged grout shall be CARES approved or equivalent.

2.1.1.7. A method statement shall be submitted to The Engineer that includes the product details, how
the grout will be placed and the methods to be used to verify complete penetration of the
material so that air pockets and other defects are not present.

2.1.1.8. The Contractor shall provide high strength, non-metallic, Portland cement based non shrink
grout.

2.1.1.9. The contractor’s detailed grout specification shall include all technical requirements for the
grouting work, including the type of grout to be used, the grout components and proportions,
strength requirements, workability requirements, and any other relevant technical
specifications.

2.1.1.10. All grouting materials under this specification shall be a pre-packaged, single pack, to avoid
mixing dry grouting ingredients such as cement and admixtures in site.

2.2. Material
2.2.1. Delivery, Storage and Handling

2.2.1.1. Delivered products shall have an original packaging, labelled with product identification,
manufacturer, batch number and shelf life.

2.2.1.2. The Contractor shall store the products in a dry area.

2.2.1.3. The products shall be protected from direct sunlight.

2.2.1.4. The Contractor shall handle the products in accordance with manufacturer’s printed
recommendations.

2.2.2. Material

2.2.2.1. Performance and physical properties of the proposed grout shall be provided to The Engineer
for approval.

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 2.2.2.2. Grout properties shall be sufficient to take the loads applied on the proposed grouting material
and fit for purpose and the environmental conditions for the service life of the structure.

2.2.2.3. Grouting below bearing and base plate shall be non-shrink type.

2.2.3. Examination

2.2.3.1. Substrates under which grout materials will be installed shall be examined to meet the required
conditions.

2.2.3.2. The Contractor shall not proceed with installation until unsatisfactory conditions are corrected.

2.2.3.3. The Contractor shall coordinate the installation works with adjacent work to ensure proper
sequence of construction.

2.2.3.4. The Contractor shall protect the adjacent areas landscaping from contact due to mixing and
handling of materials.

2.2.4. Surface Preparation

2.2.4.1. Contractor shall comply with the manufacturer’s printed instructions.

2.2.4.2. For cementitious bedding grout, the substrate shall be flushed clean with water two hours
before placing and maintained wet until placing commences.

2.2.4.3. Substrate surface shall be dampened with clean water before patching and remove standing
water.

2.3. Grout for Bearings and Base Plates

2.3.1. General requirement

2.3.1.1. Grout mix designs for the grout shall be prepared by the Contractor and submitted for The
Engineer’s approval.

2.3.1.2. Cement grout shall be an intimate non‐bleeding combination of Portland cement Bleeding, final
is 0% @ 3 hours and water with a maximum water/cement ratio of 0.42.

2.3.1.3. The grout shall be mixed in an approved colloidal type of mixer until its color and consistency
are uniform.

2.3.1.4. The chloride ion content of the mortar determined in accordance with EN 933-1 shall not
exceed 0.3% of the mass of cement for mortar made with Ordinary Portland Cement and 0.2%
for mortar made with Sulphate‐Resisting Portland Cement (SRC).

2.3.1.5. Calcium chloride or admixtures containing calcium chloride shall not be used.

2.3.1.6. The Contractor shall prepare mock‐up for the proposed grouting condition for The Engineer’s
approval.

2.3.1.7. The constituent materials shall be accurately gauged, allowance being made for bulking of
sand.

2.3.1.8. Mock-up for critical bearing size (maximum size and minimum height of grout) shall be carried
by approved trained/certified team by the supplier for the proposed material as per ASTM
C1339-96A.

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2.3.1.9. Grouting work shall be carried out by only trained and certified team from supplier proposed
material.

2.3.1.10. The Contractor shall never in any circumstances exceed the maximum water content of
cementitious grout to increase flow or retemper the grout.

2.3.1.11. Grouting material shall be able to withstand exposure R5 as per EN 12190.

2.3.2. Bedding grout for Bearings and Base Plates

2.3.2.1. Mixing, placing, and curing proprietary bedding mortar shall be carried out in accordance with
the manufacturer’s written instructions.

2.3.2.2. Immediately after casting, the grout shall be protected to prevent evaporation for at least three
days.

2.3.2.3. The Contractor shall submit a Method Statement detailing the grouting procedures to The
Engineer for review and approval prior to commencement of the works by at least 30 days.

2.3.2.4. To ensure grout effectiveness the minimum thickness for grout shall be 25mm for 600x600
mm areas and 30mm for areas between 600x600 mm and 1300 x 1300mm.

2.3.2.5. Minimum strength of grout at 28 days shall be greater than the design concrete strength.

2.3.3. Testing for cementitious grout below base plates and Bearing

2.3.3.1. Sampling and testing shall be carried out as per the proposed supplier requirement.

2.3.3.2. The sampling for the test cubes shall be a composite sample made from at least three
individual samples.

2.3.3.3. Total volume of composite sample shall be based on the number of specimens required and
the specified consistency test, but with a minimum volume of 5 litres per batch.

2.3.3.4. Unless otherwise specified the number of specimens shall be at least one set of three cubes
per each specified test age for each batch, but not less than two sets of three cubes.

2.3.3.5. Testing for compressive Strength shall be carried out for grout in accordance with ASTM C 109
(at 1, 7, and 28 days), Test Method for Compressive Strength of Hydraulic Cement Mortars
using cube specimens.

2.3.3.6. Flexure strength and modulus of Elasticity in flexure tests shall be carried out as per ASTM C-
580.

2.3.3.7. Tensile resistance tests shall be carried out as per ASTM D-638 or BS 6319-Part 7.

2.3.3.8. The followability, consistency, and working time of the grout mixture shall be determined by
testing in accordance with ASTM C1437, ASTM C 827.

2.3.3.9. Minimum working time shall be 30 to 45 minutes for flowable grout, as per flow table in
accordance with ASTM C 1437.

2.3.3.10. The tests for creep characteristic of any grout shall be carried out as per ASTM C1181, not less
than 3.45 MPa.

2.3.3.11. Height Change of Hardened Grout shall be determined for hardened grout at 1, 3, 14 and 28
days in accordance with ASTM C 1090.

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2.4. Prestressing Duct Grout Materials
2.4.1. General

2.4.1.1. Grout admixture shall be a balanced blend of expanding, fluidifying, and water-reducing agents
containing no calcium chloride, nitrates or other chemicals causing steel corrosion.

2.4.1.2. Portland cement shall be as specified in Section 03 30 00: Cast-in-Place Concrete

2.4.1.3. Water shall comply with the requirements given in Section 03 30 00: Cast-in-Place Concrete

2.4.1.4. Mix design of the grout shall be in accordance with relevant standards (FIB Bulletin 20).

2.4.1.5. The Contractor shall submit the details of mix design including test details for Engineer’s review
and approval.

2.5. Properties of Prestressing Grout

2.5.1. Fluidity

2.5.1.1. The fluidity of grout during the injection period shall be sufficiently high for it to be pumped
effectively and adequately to fill the duct without excessive segregation.

2.5.1.2. The fluidity of grout during the injection period shall be also sufficiently low to expel the air and
any water in the duct.

2.5.1.3. The fluidity of the grout during the injection period shall be measured by either one of the
methods given in EN 445.

2.5.1.4. The grout fluidity shall be tested for the limits given in EN 447-2007 - Table 1 (Cone time
method as per EN 445 & Grout Spread Method).

2.5.1.5. Grout shall be tested for the fluidity characteristic as per immersion tube test method to satisfy
limits given in EN 447-1997, table 1, grouts prepared in mixer which have a high shear mixing
action is not allowed.

2.5.2. Bleeding

2.5.2.1. The bleeding of the grout shall be sufficiently low to prevent excessive segregation and
settlement of the grout materials, when tested by one of the methods given below in Article 2.6.

2.5.2.2. The grout shall not be subject to bleeding in excess of 0.3% after 3 hours kept at rest, as per
EN 447-2007.

2.5.2.3. Water shall be reabsorbed by the grout during the 24 hours after mixing.

2.5.3. Volume Change

2.5.3.1. When tested in accordance with the methods given in Article 2.6, the volume change of the
grout shall be less than 0.50% at 24 hours and no more than 1% at 28 days.

2.5.3.2. For grouts with expanding agents there shall be no decrease in volume.

2.5.4. Strength

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2.5.4.1. The compressive strength of grout shall be assessed using either of the specimen shapes and
sizes given in Table 2 as per BS EN 447-1997.

2.5.4.2. The grout compressive strength tests shall be carried out on a prism specimens of 40 x 40 x
160mm.

2.5.4.3. The grout compressive strength tests shall be carried out on halves of the prism broken as
described in EN 196-1 clause 9.2. In either case the compressive strength to be not less than
the compressive strength of the surrounding concrete at 28 days and not less than the limits
given in EN 447 clause 6.6.

2.5.4.4. The compressive cylinder strength shall be not less than 27 MPa at 7 days and at least 46 MPa
after 28 days

2.5.5. Batching and Mixing of Grout

2.5.5.1. The proportions of materials used in the mix shall be selected on the basis of prior documented
experience with similar materials and equipment, and under comparable field conditions
(weather, temperature, etc.).

2.5.5.2. The proportions of materials used in the mix shall be verified by tests made on the grout before
grouting begins.

2.5.5.3. The water content shall be the minimum necessary to obtain the required workability for proper
placement.

2.5.5.4. Under no circumstances shall the water/cement (w/c) ratio exceed 0.44.

2.5.5.5. The water content of any admixtures shall be considered when calculating the w/c ratio.

2.5.5.6. The materials shall be batched by weight with an accuracy of +2% for cement and admixtures
and +1% for water.

2.5.5.7. All materials shall be batched by mass except in the case of water (batched by mass or volume).

2.5.5.8. Mixing shall be carried out mechanically to obtain a homogeneous and stable grout with the
plastic properties given in the Specification.

2.5.5.9. Depending upon environmental or material influences (e.g., temperature, configuration of the
tendon and the properties of the cement use), the w/c ratio shall be kept as low as possible
having regards to the required plastic properties of the grout.

2.5.5.10. A sufficient amount of material shall be batched to ensure complete grouting of a duct
considering allowance for overflow.

2.5.5.11. The grout shall be mixed in a machine capable of producing a homogenous grout and after
mixing, keeping the grout in slow continuous agitation, until it is ready to be pumped into the
duct.

2.5.5.12. Water shall be added to the mixer as per manufacture requirement.

2.5.6. Temperature at Grouting

2.5.6.1. Records shall be kept of the maximum and minimum air temperatures and the temperature of
the members to be grouted.

2.5.6.2. Grouting shall be done when the ambient temperature is not above 35 ºC.

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 2.5.6.3. Grout temperature at duct inlet and outlet shall not be above 32 ºC during mixing or pumping.

2.6. Testing of Prestressing Grout

2.6.1. General Conditions

2.6.1.1. The grouts shall be tested by competent personnel experienced in the subject.

2.6.1.2. The grouts shall be tested in laboratory conditions of where temperature is (20 ± 2) ºC and
humidity > 65% R.H.

2.6.1.3. The grout for the tests shall be made from the materials specified in and mixed in accordance
with the requirements of these Specifications.

2.6.1.4. The temperature of the freshly mixed grout shall be given in all test reports.

2.6.2. Grout Setting Time

2.6.2.1. Grout setting time shall be in accordance with ASTM C 953.

2.6.3. Fluidity Test - Cone Method

2.6.3.1. Fluidity test using Cone Method shall be in accordance with EN 445.

2.6.3.2. Fluidity test shall ensure that grout completely fills the tendon ducts

2.6.4. Volume Change and Bleeding Tests

2.6.4.1. Volume change and Bleeding tests shall be conducted using Wick-Induced test in accordance
with EN 445.

2.6.4.2. Volume change test values shall be less than 0.50% at 24 hours and no more than 1% at 28
days

2.6.4.3. Bleed test shall ensure that the grout has less than 0.3% to limit free water inside the tendon
duct

2.6.4.4. Bleed test shall demonstrate that any bleed water is reabsorbed by the grout within the
specified time.

2.6.5. Compression Strength Test

2.6.5.1. The compression strength of grout shall be tested in accordance with EN 445.

2.7. Mock-up Testing for Grouting Operation

2.7.1. General

2.7.1.1. Full mock-up testing of grouting operation shall be performed for acceptance of proposed grout
material and grouting method statement.

2.7.1.2. Mock-up testing of grouting shall be performed on a rectangular beam of similar dimension and
length as of post tensioned girder with identical tendon geometry and drains / vents.

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2.7.1.3. Mock-up testing of grouting operation shall be performed using the geometry of the longest and
most complex tendon configuration.

2.7.1.4. Mock-up girder shall have similar reinforcement and duct fixing arrangement as of actual post-
tensioned girder.

2.7.1.5. Tendon in mock-up girder shall have similar numbers of PT strands.

2.7.1.6. After grouting of the mock-up girder, it shall be cut at several locations to expose the tendon
cross section to check the integrity of the grouting inside the duct.

2.7.1.7. Results of the grouting of the mock-up girder shall be presented to The Engineer along with
photographs and analysis of voids (if any) found in grouted duct cross section.

2.7.1.8. All grouted duct cross section shall be fully grouted with total voids area measured at any of
the grouted duct cross-section not to be more than 2% of the duct internal cross section area.

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PART 3 - EXECUTION
3.1. Grouting for Prestressing.
3.1.1. General

3.1.1.1. Grouting shall be carried out but specialist staff having sufficient experience in prestressing
grouting operations, preferably having training and certificates from reputable organization.

3.1.1.2. Grouting procedures shall be in accordance with the UK Concrete Society Technical Report 72
(Second edition).

3.1.1.3. Grout for prestressing systems shall be mixed by a machine capable of producing a
homogeneous colloidal grout and of keeping the grout in slow continuous agitation after mixing
and until the grouting operation starts.

3.1.1.4. Grouting equipment shall be capable of continuous operation with little variation of pressure.

3.1.1.5. Grouting equipment shall include a system of recirculating the grout when grouting is not in
progress.

3.1.1.6. Grout pumps shall be fitted with a safety valve to prevent the build-up of excessive pressure.

3.1.1.7. The connection of the grout pump to the duct shall be by a screw connector or other positive
method.

3.1.1.8. Baffles to the grout pump shall be fitted with 1.18 mm sieve strainers.

3.1.1.9. Suction circuits of the grout pump shall be airtight.

3.1.1.10. Grouting equipment shall be thoroughly washed through with clean water after every series of
grouting operations and at the end of use each day

3.1.1.11. The Contractor shall undertake grout trials in accordance with UK Concrete Society Technical
Report 72 (Second edition) Grout Materials.

3.1.1.12. The tendons shall be protected against corrosion by a plug at each end to prevent the passage
of air until the tendon is grouted.

3.1.1.13. Grouting mix shall be carried as detailed in EN 446 and test methods as per EN 445.

3.1.1.14. In the detailed grout specification, the contractor shall outline the procedures for cleaning up
any spills or excess grout that may occur during the grouting process.

3.1.1.15. The minimum permissible interval between tendon installation and grouting shall be (1) day for
other locations.

3.1.2. Frequency of Grout Testing

3.1.2.1. The testing of the grout made from certified or otherwise quality assured materials shall be
carried out prior to the start of grouting operations.

3.1.2.2. For Bleeding testing, one sample shall be taken at the mixer and one sample at the duct outlet
when the grout there has a satisfactory fluidity value.

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3.1.2.3. During the course of grouting, minimum testing frequency of the grout for Bleeding shall be 2
tests per day.

3.1.2.4. During the course of grouting, minimum testing frequency of the grout for Volume Change shall
be 1 test per day.

3.1.2.5. During the course of grouting, minimum testing frequency of the grout for Strength shall be 1
test per 7 days or a minimum of two tests per grouting operation whichever is greater.

3.1.2.6. During the course of grouting, fluidity shall be tested at outlet and inlet for each duct during
grouting operation.

3.1.3. Grouting Effectiveness for Prestressing.

3.1.3.1. Grouting of prestressing tendons shall be effective such that the duct is completely filled, and
the prestressing tendon is completely surrounded with grout.

3.1.3.2. Non-destructive monitoring (NDT) techniques shall be proposed with duct (for example using
internal sensors) by the Contractor for the investigation of tendon ducts and testing of grout
effectiveness to completely filling the ducts.

3.1.3.3. NDT tests shall be considered in the first structure of each viaduct type (ISO, Twin structure,
Balanced cantilever structure) only.

3.1.4. Grout injecting for Prestressing.

3.1.4.1. Prior to grouting, every duct shall be air pressure tested to ensure that there is no leakage.

3.1.4.2. The permission of The Engineer shall be obtained before prestressing tendons are grouted.

3.1.4.3. If grouting is not started within 24 hours of permission having been given, permission shall
again be obtained from The Engineer.

3.1.4.4. Tendons shall be grouted permissible interval given in specification 03 38 00, clause 3.2.3.4
after tensioning but not before 8 to 12 hours after tensioning.

3.1.4.5. The pumping pressure at the tendon inlet shall not exceed 1.8N per sq. mm.

3.1.4.6. When one-way flow of grout cannot be maintained, the grout shall be immediately flushed out
of the duct with water.

3.1.4.7. If more than 1 day elapsed from prestressing placement, corrosion protection as per post
tensioned concrete specification 03 38 00 shall be applied.

3.1.4.8. Check shall be made to ensure that the ducts, vents, inlets and outlets are capable of accepting
injection of grout.

3.1.4.9. Above check shall be done by blowing through the system with dry, oil-free air and testing each
vent in turn.

3.1.4.10. All ducts shall be always kept free of standing water, thoroughly clean, and dry before grouting.

3.1.4.11. All anchorages shall be sealed by caps and fitted with grouting connections and vents.

3.1.4.12. Sealing of anchorages shall be protected against damage by second stage concrete
(reinforced).

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3.1.4.13. Grouted ducts shall not be subject to shock or vibration within 24 hours of grouting.

3.1.5. Records of Grouting Operation for Prestressing.

3.1.5.1. Records of grouting operations for prestressing systems shall be kept by the Contractor on the
Site

3.1.5.2. The grouting operation report (includes the records) shall be submitted to The Engineer within
3 days of each grouting operation.

3.1.5.3. The report shall contain the following details: location of grouting operations, date and time of
starting and completing grouting operations, weather conditions, technical personnel
supervising or carrying out grouting operations, prestressing tendon reference numbers, grout
mix, including any admixtures, grout injection pressure, volume of grout used, and details of
any interruptions and topping up.

END OF SECTION 03 60 00

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