Proposed Marassi Park - Plot 99

Marassi Al Bahrain, Kingdom of Bahrain January 2020

SECTION 03 38 00: POST TENSIONED CONCRETE

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CONTENTS

PART 1 GENERAL

1.1 Summary

1.2 References and quality assurance

1.3 Definitions

1.4 Outline services

1.5 Submittals

1.6 Inspections

PART 2 PRODUCTS

2.1 Post tensioning tendond and accessories

2.2 Grout

2.3 Non specialist materials

PART 3 EXECUTION

3.1 Design

3.2 Infill strips

3.3 Formwork

3.4 Handling and placing of tendons

3.5 Observation

3.6 Placing of concrete

3.7 Prestressing equipment

3.8 Prestressing

3.9 Treatment of anchorages.

3.10 Grouting equipment

3.11 Grouting

3.12 Patching

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PART 1 GENERAL

1.1 SUMMARY

A. Provide design and shop drawings for the post tensioning works.

B. Provide labor, materials, necessary equipment and services to complete the post-
tensioned concrete work, as indicated on the drawings and as specified.

C. Provide additional materials required for post-tensioned cast-in place concrete not
otherwise specified and perform job site post-tensioning operations necessary to
complete the work as shown and specified.

D. Related Sections:

1. 03 11 00 – Concrete Formwork
2. 03 15 00 – Concrete Accessories
3. 03 20 00 – Concrete Reinforcement
4. 03 30 00 – Cast-In-Place Concrete
5. 03 35 00 – Concrete Finishing

1.2 REFERENCES AND QUALITY ASSURANCE

A. The design shall comply with provisions of following codes, specifications and
standards, except where more stringent requirements are shown or specified:

1. ACI 318M-05 Building code requirements for structural concrete.

PCI “Losses” PCI Committee on Prestress Losses,
"Recommendations for Estimating Prestress
Losses", Prestressed Concrete Institute, Volume 20,
No.4, July/August 1975, pp. 43-75.
or
BS8110 pt 1:1997 Structural Use Of Concrete. Code of Practice for
Design and Construction.
BS8110 pt 2:1985 Structural Use Of Concrete. Code of Practice for
Special Circumstances.
CSTR 43 Post Tensioned Concrete Floors

2. All applicable codes, specifications, and standards referenced in Sections

031100, 031500, 032000, 033000, 033900.

B. The materials shall comply with provisions of following codes, specifications and
standards where relevant, except where more stringent requirements are shown or
specified:

1. A416/A-96 Specification for Steel Strand, Uncoated Seven-Wire

for Prestressed Concrete
or
BS 5896: 1980 High Tensile Steel Wire and Strand for Prestressing
of Concrete
or
Eurocode prEN 10138 Design of prestressing steel
3. All applicable codes, specifications, and standards referenced in Sections
031100, 031500, 032000, 033000, 033900.

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C. Specialist Contractor Qualifications: Firms with at least 5 years successful

experience including projects of similar or larger scope and complexity.

D. Supervisor Qualifications: Person with not less than 3 years field experience in
supervisor's capacity on projects of similar or larger scope and complexity.

1.3 DEFINITIONS

A. Post-tensioning: Any method of prestressing where the tendon is tensioned after the
concrete has reached a specified strength.

B. Tendon: Refers to any single post-tensioning unit used to apply prestress force to
the concrete member whether composed of one or more elements.

C. Unbonded Tendons: Refers to ungrouted tendons that are shop-coated and

encased in slippage sheathing to prevent bond, to retard corrosion, and to reduce
friction.

D. Bonded Tendons: Refers to grouted tendons that are installed in a duct on site, and
grouted after stressing in order to achieve bond and prevent corrosion.

E. Main Contractor: Contractor hired to execute the main parts of the structural work.

F. Specialist Contractor: Contractor hired to provide a specified set of services related

to the post tensioning.

G. Supervisor: a trained, skilled, experienced, full-time representative of the Specialist

Contractor who will supervise the post tensioning works and coordinate with the
Main Contractor.

H. Lead Structural Designer: structural designer responsible for the overall structural
design of the project.

I. Post Tensioning Design Drawings: specialist post tensioning drawings required by

the lead structural designer to check the design and by the relevant statutory
authority for approval.

J. Post Tensioning Shop Drawings: specialist post tensioning drawings which are not
required under point I but are required to execute the design on site. They include
shop drawings for any specialist PT elements but exclude shop drawings for
conventional elements such as normal reinforcement.

1.4 OUTLINE SERVICES

A. Main Contractor to employ and pay for services of a Specialty Contractor to perform
prestressing work.

B. Require Specialist Contractor to perform the following:

1. Before start of work on site, establish complete sequence and schedule of

concrete placement and post-tensioning work. Discuss construction joints,
stressing points, intermediate stressing points, and dead end locations.
Submit plans of joints, stressing points, etc. for approval.
2. Before start of work on site, provide the relevant members of the Main
Contractor’s staff with the necessary training regarding the post tensioning
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works. This will also include organizing a “preinstallation conference” on site,

attended by the Main Contractor, A/E and client representative.
3. Before start of work on site, discuss the relevant safety issues with all parties
who will be present on site during the post tensioning works, and provide the
necessary training / briefing sessions regarding hazards associated with the
post tensioning works.
4. Before start of work on site, review Contract Documents for items at variance
with established procedures. Variances shall be highlighted to the A/E and
shall be resolved to satisfaction of A/E and at no additional cost to the Client.
5. Before start of work on site, provide supervisor(s), approved by the A/E to be
present during work in insure installation and prestressing operations are
conducted in compliance with Contract Documents and relevant standards
and specifications.
6. Before start of work on site, provide the necessary material samples and
certificates for approval by the A/E. The Specialist Contractor shall be
responsible for the delivery of all specialist post tensioning materials,
including but not limited to strand, duct, anchors, and duct tape. The
Specialist Contractor shall also provide all specialist equipment such as
jacks, grout pumps, pressure gauges, etc…
7. Provide the post tensioning shop drawing for approval by the A/E.
8. Coordinate the final position of the tendons with the final plumbing sleeve
locations as shown on the ME shop drawings. Cross check as built
equipment loads against the design assumptions, and amend the design
where necessary. The amended design will be submitted to A/E, and to the
Statutory Authorities if warranted.
9. Conduct and supervise all post tensioning installation works and specialist
post tensioning operations in accordance with the approved design, codes,
specifications, and rules of good practice.
10. Conduct a strict inspection regime of the installed elements and provide sign
off the post tensioning elements before casting, to the acceptance of the A/E.
11. Provide a set of as built drawings for the post tensioning works after
completion of the works.

C. Require main contractor to perform the following.

1. Provide the required labor for installation of the post tensioning works.
2. Provide and install the materials which are not deemed to be specialist items,
such as form work, concrete, conventional steel, to the approval of the A/E.
3. Provide conventional reinforcement shop drawings in accordance with the
approved design drawings, and to the acceptance of the A/E.
4. Provide specialist material such as duct chairs and grout to the approved
specifications and Specialist Contractor’s instructions, and to the acceptance
of the A/E.
5. Any other relevant service as referenced in Sections 031100, 031500,
032000, 033000, 033500.

1.5 SUBMITTALS

A. General: Refer to Section 01 33 00 – Submittal Procedures, for submittal

requirements and procedures.

B. Post tensioning design calculations: a report describing the design assumptions and
containing the design calculations shall be submitted for review and approval by the
lead structural consultant.

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C. Undertaking letter confirming that the post tensioning works have been adequately
designed.

D. Post tensioning design drawings: Sepias of other photographic reproductions of the

structural drawings are not allowed as a base for the design drawings and shall be
cause for re-submittal. The design drawings shall be consistent with the design
calculations, and comply with international drawing standards. Submit the following
to the lead structural consultant for review and approval:

1. Formwork drawings of all elements showing slab thicknesses, pour

sequence, position of infill strips, casting delay required for infill strip.
2. Dimensioned tendon drawings showing the location of the tendons in the
horizontal plane, number of strands per tendons, theoretical extensions of the
tendons, jacking force.
3. Conventional reinforcement drawings and typical details sufficient to enable
the main contractor to produce the conventional reinforcement shop
drawings.

E. Post tensioning shop drawings: Sepias of other photographic reproductions of the

structural drawings are not allowed as a base for the shop drawings and shall be
cause for resubmittal. The shop drawings shall be consistent with the design
drawings and calculations, and comply with international drawing standards. Submit
the following to A/E for fabrication and placement:

1. Tendon profile drawings showing chairs, chair height, location of support

steel, and other information regarding tendon support method.
2. End anchorage details.

F. Deviations: Should proposed materials and methods deviate from those shown on
drawings or specifications, submit calculations justifying the materials and methods
proposed.

G. Changes: Do not incorporate proposed changes into the fabrication and placement
details unless approved in writing. Do not make changes in details after approval.

H. Mill Tests: Submit certified mill test results and typical stress strain curves.

I. System approval: submit the necessary certificates showing that the proposed post
tensioning system is being provided by a reputable international firm, and has been
checked against the relevant Euronorms or ASTM standards.

J. Calibration: Submit certified calibration test curves and results for stressing system.

K. Qualification Data: Submit data verifying qualification of specialty firm and

supervisor including references.

L. Standards: Submit letter stating that specialist firm has in their possession and will
have on the jobsite copies of referenced standards and that management and
foreman are knowledgeable about provisions that relate to this project.

M. Method statement: submit a method statement describing all operations related to

the post tensioning work.

N. Measurement of Elongations: Submit narrative and details showing means of

measuring elongations, tolerances for measurement, and procedure to be followed
for extension approval.

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O. Installation records: records of the tendon installation for each slab shall be kept,
and shall include: strand source and cast number, anchorage batch number, wedge
batch number, duct batch number, and location of the respective products in the
slab if more then one batch number is used, names of the supervisor and foremen
responsible for the works.

P. Stressing records: records of the stressing of the stressing of each slab shall be
kept and shall include: date of stressing, strength and age of concrete cubes,
minimum age of concrete at transfer, equipment calibration date, serial numbers of
gauges and jacks, theoretical extension, actual extension and stressing force,
names of the supervisor and foremen responsible for the works.

Q. Grouting records: records of the grouting of the stressing of each slab shall be kept
and shall include: materials used including batch numbers, grout properties
including temperatures, ambient temperature and weather conditions, date and time
under which grouting operations were carried out, details of any interruptions and
any problems encountered during the grouting process e.g. blockages or loss of
grout or loss of pressure, names of the supervisor and foremen responsible for the
works.

R. Health and safety: submit a health and safety plan addressing all necessary
precautions which need to be taken in order to create a safe working environment
during and after tendon installation operations.

1.6 INSTRUCTION

A. The Specialist Contractor will give the main contractor's personnel instruction in
placing the tendons and use of stressing equipment. The Specialist Contractor’s
qualified personnel shall be present on site whenever an operation relevant to the
post tensioning installation is ongoing, and supervise the post-tensioning work at all
times. The supervisor shall be on present on site for all major operations, which
includes but is not limited to checking and signoff of the slab, stressing and grouting.

PART 2 - PRODUCTS

2.1 POST-TENSIONING TENDONS AND ACCESSORIES

A. Strand shall comply with the following specification:

1. Uncoated, seven-wire stress-relieved steel strand meeting requirements of

ASTM A416, Grade 270, Low-Relaxation.
or
Uncoated, seven-wire stress-relieved steel strand meeting requirements of
BS 5896 / Eurocode prEN 10138, Super Strand, Relaxation class 2.

B. All hardware of the proposed post-tensioning system shall be manufactured by a

reputable international firm and certified according to international standards. All
hardware shall be part of the same recognized system; mixing elements of various
systems shall not be allowed.

C. All equipment used on site shall be compatible with the proposed system.

D. It shall be allowed to choose a bonded or unbonded system

E. If an unbonded system is used:

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1. Fabricated coated tendons shall be shop coated with coating compound to

prevent bond, reduce friction and resist corrosion. The tendon shall be
encased in slippage sheathing to further assure prevention of bond and
maintain the element in proper diameter.
2. Tendon coating compound: Tendon wire shall be completely shop coated
with a non-volatile, low friction mineral oil base grease with a rust preventing
additive. This coating material shall have a relatively uniform viscosity under
temperature ranges of -200 to 1200 degree F.
3. The coating of unbonded tendons strand shall be either high density
polyethylene or polypropylene. PVC shall not be used. The coating thickness
shall be at least 1.0mm. Friction values shall be confirmed by the
manufacturer.
4. The coating shall be capable of maintaining the group of wires tightly bundled
and containing the wire coating compound during shipment, placing and
concreting. It shall also prevent the admission on concrete and mortar during
concreting operations.

F. If a bonded system is used then:

1. The duct shall be either smooth galvanized steel with a minimum wall
thickness of 0.35mm, corrugated galvanized steel with a minimum wall
thickness of 0.3mm or polyethylene or polypropylene with a minimum wall
thickness of 0.2mm. PVC shall not be used. The ducting shall be sufficiently
robust to avoid denting or damage on site.
2. Ducting shall prevent the entrance of paste from the concrete and shall not
cause harmful electrolytic action or any deterioration of the tendon or tendon
components. The internal cross area of the duct shall be at least twice the net
area of the tendon’s prestressing steel. Ducting shall have some profiling to
be capable of transmitting forces from grout to surrounding concrete.

2.2 GROUT

A. This part is only relevant for a bonded system.

B. The properties of grout, made with materials, plant and personnel proposed for use
on site shall be assessed for suitability for the intended purpose sufficiently in
advance of grouting operations to enable adjustments to be made to the materials
plant or personnel.

C. Grout shall consist of pre-bagged material requiring only the addition of a measured
amount of water and shall comply with the following requirements:

1. Fluidity: > 10 secs and < 25secs.

2. Bleed: < 0.3%
3. Volume change < 5%
4. Strength > 27MPa @ 7 days (100mm cubes)
5. Sieve test: grout should contain no lumps (sieve aperture =
1.5mm)
6. w/c ratio: < 0.35
7. Grout temperature: > 5°C and < 30°C

D. Grout shall be batched to an accuracy of +/- 2% for dry materials and +/- 1% for
mixing water.

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E. The suitability of grout prior to the works shall be tested with 3 tests of all items
mentioned under C. The acceptability of each batch of grout during the works shall
be tested with 2 tests of all items mentioned under C.

2.3 NON SPECIALIST MATERIALS

A. All non specialist materials shall comply with the provisions of Sections 031100,
031500, 032000, 033000, 033500.

PART 3 - EXECUTION

3.1 DESIGN

A. The design of the Specialist Contractor shall comply with all relevant design
standards. Design assumptions and details of design software shall be submitted to
the lead structural designer for review and approval prior to commencement of
design work.

B. The design will use the same gravity loading as assumed by the lead structural
designer for the design of the overall structure. The slab will be designed for the
worst load combination and load distribution.

C. The design shall incorporate any provisions which may be required for the overall
stability as established by the lead structural consultant. These requirements may
be communicated by the Main Consultant as additional reinforcement or as an
additional design force.

D. The design will be done in such a way that all reasonable care has been taken to
avoid early age shrinkage / thermal cracking. This may will include but not be limited
to the provision of pour strips, additional bonded reinforcement, evaluating the need
for early age stressing.

E. The design shall be produced in a timely manner to allow sufficient time for the lead
structural consultant to review and comment. The design will be submitted
sufficiently ahead of time as not to delay any Statutory Approvals.

3.2 INFILL STRIPS

A. The Specialist Contractor shall propose positions for infill strips in accordance with
the design and stressing access requirements, and in accordance with the Main
Contractors proposed construction sequence, for approval by the Lead Structural
Consultant.

B. Care shall be taken to avoid the safety hazards associated with stacked infill strips.
Infill strips shall be staggered wherever practical. Residual risk shall be recorded
and communicated to the Main Contractor.

C. Casting of the infill strips will not occur before the time specified in the design
drawings.

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3.3 FORMWORK

A. Comply with applicable provisions of Section 031100, Concrete Formwork and as

specified.

B. It shall be assessed whether the formwork needs to be designed for any additional
loads due to the shifting of self weight during stressing.

C. Secure stressing assemblies at tendon terminals to the formwork designed to

maintain tendon in a fixed position during concreting.

D. The Specialist Contractor and the Main Contractor shall be required to determine
the deshuttering time and provide adequate backpropping calculations. The
deshuttering and backpropping calculations shall be submitted to the Main
Consultant.

E. Do not remove forms until stressing operation is complete and elongations are
approved.

3.4 HANDLING AND PLACING OF TENDONS

A. Have the complete tendons shipped coiled and fastened on shipping racks to
protect tendons from damage during transit and storage at the job site. Protect from
excessive corrosion and keep free of deleterious substances during shipping.

B. Deliver, store, and handle strands and coils to prevent rust, soiling, bending and
damage. Coils shall be stored and strands handled in a dedicated area on site,
which will be clearly marked. Only properly trained staff shall be allowed to
manipulate the coils and cut the strand, and appropriate safety precautions shall be
taken at all time.

C. Strands shall be cut to length using mechanical means only.

D. Tendons shall be fixed on chairs supported by the formwork. The position of the
tendons, chair locations and chair height shall be marked on the soffit of the slab
with an indelible marker.

E. Tendons supports shall not be more then 1 m apart.

F. The primary tendon profile points (high and low points) shall be installed to an
accuracy of 5mm vertically. The profile between the high and low points shall
describe a smooth double parabolic profile in accordance with the design
assumptions. Abrupt changes in profile shall not be permitted.

G. Tendon positions shall be coordinated in advance with slab cutouts, in order to

avoid major tendon deviations on site. Individual tendons can be shifted sideways
up to 400mm in order to avoid obstacles, as long as maximum allowable tendon
spacing is maintained. If a tendon is shifted the revised position shall be marked on
the slab soffit and on the as built drawings.

H. Tendons shall be kept straight, unless the curvature has been considered in the
design. Special provisions shall be taken to minimize friction on curved tendons.

I. Do not nick, bend, or damage in any way the tendons, coupler hardware, and
anchorages during heading or prestressing of tendons. Repair tears, holes, and
other damages in the ducting by re-wrapping before concreting begins.

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J. If required, and where approved, couple the prestressing tendons to develop

continuity with a capacity equal to at least 95 percent of the specified tensile
strength of the tendons. The coupler shall be detailed to transfer the post-tensioning
force through the coupler without creating bending moments in the tendon. Coupler
hardware shall be clean and free of deleterious substances.

K. Construct anchorages to develop 95 percent of the specified tensile strength of the

tendons, both individually and as a group, without slippage, distortion or other
changes that will allow loss of stress. The anchorage shall be detailed to transfer
the post-tensioning force to the concrete without creating bending moments in the
tendon. Anchorage hardware shall be clean and free of deleterious substances.

L. In case of the use of an unbonded system vents shall be fixed at entry and exit
points and at intervals not more than 25m. Vents shall extend approximately 500mm
above the slab surface, and shall be fixed so that concrete ingress is avoided.

M. If the slab contains areas with an excessive number of MEP conduits this shall be
brought to the attention of the A/E. The A/E may then instruct the main contractor to
remove or relocate the conduits, or to provide additional reinforcement to
compensate for the voids in the slab. These decisions will be taken in collaboration
with the Specialist Contractor.

3.5 OBSERVATION

A. Do not begin concreting of prestressed members until placement of tendons and

conventional reinforcement has been observed and approved by the Specialist
Contractor’s supervisor, by the A/E and by the relevant Statutory Authority.

3.6 PLACING OF CONCRTE

A. The Specialist Contractor’s supervisor, or a qualified replacement approved by the

A/E, shall be present during all concrete placing.

B. Place concrete in such a manner as to ensure alignment of post-tensioning tendons

and conventional reinforcement remains unchanged.

C. Provide uniform compaction of concrete, especially around anchorages.

D. Prior to concrete placing the Main Contractor and the Specialist Contractor shall
determine the procedures to be followed in case casting is interrupted by an
unforeseen event. These procedures may include predetermined locations and
details for possible construction joints, provisions for back up equipment. The
procedures shall be approved by the A/E. In case of an interruption the procedures
will be jointly put in place by the A/E, Main Contractor and Specialist Contractor.

E. No construction joint shall be formed without prior approval by the Specialist

Contractor’s supervisor and by the A/E

3.7 STRESSING EQUIPMENT

A. All stressing equipment used on site shall be registered and all relevant certificates
for the equipment shall be held on the site. No new equipment shall be brought to
the site without prior record and certification.

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B. Stressing jacks and their load measuring system shall have a certified calibration
within 3 months of first use and at maximum 3 month intervals. The stressing
equipment shall be capable of establishing a tendon load to an accuracy of +/- 2%.

C. In order to insure proper calibration is maintained, exercise care in handling of

stressing equipment.

3.8 PRESTRESSING

A. All labor involved in the stressing of the tendons will have been trained specifically
for this task, and shall be aware of the safety risks. The Main Contractor in
coordination with the Specialist Contractor shall implement all necessary
precautions for safe working during and after stressing operations. The Specialist
Consultant’s supervisor shall be present on site during stressing.

B. Concrete Strength: Do not begin tensioning operation until test of field cured
concrete cubes indicate the concrete in the members has attained a satisfactory
compressive strength, as shown on the design drawings. The main contractor shall
arrange and pay for testing field cured cubes to verify strength for stressing as
specified under concrete work. The A/E shall be notified before any stressing
operations take place.

C. Early age stressing shall be done whenever there is a risk of early age cracking.
The main contractor shall ensure that stressing access to the sides of the slab is
granted in a timely manner, in order to avoid any delays in early age stressing.

D. The final force shall be imparted as soon as the concrete attains transfer strength.

E. The stressing operation shall be conducted as recommended by the manufacturer

of the prestressing materials, and in compliance with approved shop drawings.

F. Tendons will generally not be stressed to more than 75% of their ultimate strength.
Individual tendons may be stressed up to 80% in order to compensate for a shortfall
in force.

G. Records of the elongation and of the tension applied to each tendon shall be kept
and submit to the A/E promptly upon the completion of the post-tensioning of each
member. The records shall be reviewed by the A/E and by the specialist
consultant’s design team.

H. Site extensions of individual tendons shall not deviate more then +/- 15% from the
theoretical extensions. The average extension of all tendons within a tributary shall
not deviate more than +/- 6% from the average theoretical extension. These
averages will exclude the extensions of any unprofiled (straight) tendons.

If a trend is observed on site of a large number of extensions deviating from the

theoretical values as described under point H, than the stressing of the slab shall be
completed for a reduced force sufficient to avoid early age cracking. All further
concrete placing and stressing shall be halted until a reasonable explanation for the
occurrence has been found, and appropriate design checks have been performed.

I. In the event of any failures of tendons or concrete occurring during stressing, the
A/E shall be informed immediately. All stressing shall be halted until it has been
established that proceeding will not have any adverse effect on the safety on site or
integrity of the structure. In case of failure the specialist contractor shall propose
mitigative works and / or design justifications for the approval of the A/E, which will
establish that the occurrence has no adverse effect on the integrity of the structure.
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J. Do not begin cutting of stressed tendon tails, sealing of anchorages or grouting of

tendons until receipt of written approval of elongation reports by A/E.

3.9 TREATMENT OF ANCHORAGE COMPONENTS

A. Anchorage components must be sealed against the ingress of water or aggressive

agents likely to cause corrosion of steel or anchorages.

B. After the application of an epoxy bonding agent, the pockets shall be filled with
grout as follows:

1. Interior exposure in service: Cement grout.

2. Exterior exposure in service: Non-shrink, non-metallic grout.
3. Match color and texture of adjacent concrete where exposed to view in
completed structure.

C. Data sheets and method statements for anchorage sealing shall be submitted to the
A/E.

D. For bonded tendons the method of sealing shall be capable of resisting the
specified grout pressure.

3.10 GROUTING EQUIPMENT

A. This section is only relevant for bonded tendons.

B. Grouting equipment shall consist of a mixer, a storage reservoir and pump with all
necessary connecting hoses, valves, measuring devices for water, dry materials
and testing equipment. Gauges for monitoring grout injection pressure shall be
maintained in serviceable condition; when there is any doubt about a gauge’s
serviceability, it shall be checked against a calibrated gauge. Water supply reservoir
shall be calibrated each time the grout mixing equipment is moved.

C. The mixing equipment shall be capable of producing a grout of a homogeneous

consistency and shall be capable of providing a continuous supply to the injection
equipment. The capacity of the equipment shall be such that the duct can be filled
and vented without interruption and at the required rate of injection. The injection
equipment shall be capable of continuous operation and shall include a system of
recirculation the grout while grouting is not in progress. The equipment shall be
fitted with suitable devices or adjusted to limit the maximal delivery pressure or shall
be equipped with a pressure gauge at the pump and, if necessary, at the injection
point to allow constant monitoring of grout pressure with the aim of avoiding excess
pressure.

D. All piping to the grout pump shall have a minimum number of bents, valves and
changes in diameter and shall incorporate a sampling tee with locking off valve.

3.11 GROUTING

A. This section is only relevant for bonded tendons.

B. All labor involved in grouting will have been trained specifically for this task, and
shall be aware of the safety risks.

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C. Prior to the start of any grouting works a procedure for corrective action in the event
of a blockage or a breakdown shall be established.

D. The ducts shall be kept free from contamination at all stages from storage to
installation and shall be thoroughly clean before grouting. Ducts should be blown
through with oil free compressed air prior to grouting (not water).

E. Grout injection shall be continuous at an agreed rate and shall be slow enough to
avoid segregation of grout. Grouting of ducts shall be expected to leave no void
which has a radial dimension greater then 5% of the duct size.

F. The method of injecting grout shall ensure filling of the duct and complete
surrounding of the steel. Grout shall be vented from each intermediate (when
installed) and exit vent until it is of the same consistency as that of the injected
grout. This may be judged by visual inspection but, in the event of disagreement
fluidity testing may be carried out. All vented grout shall be disregarded.

G. All vents shall be closed one after another on the direction of the flow. The injection
tubes shall then be sealed off under a nominal pressure of 0.1 MPa.

H. If any damage to the structure occurs during grouting, then the grouting shall be
stopped immediately and the A/E notified. All grouting shall be halted until it has
been established that proceeding will not have any adverse effect on the safety on
site or integrity of the structure. In case of failure the specialist contractor shall
propose mitigative works and / or design justifications for the approval of the A/E,
which will establish that the occurrence has no adverse effect on the integrity of the
structure.

I. The level of grout in the injection and the vent tubes shall be inspected after the
grout has set. If the level of competent grout has fallen below the required final level
or the material is degraded due to bleed water or air or segregation or there is other
evidence of inadequate protection, all defective grout shall de removed from the
vent and topping up shall be carried out.

J. The filled ducts shall be protected to the satisfaction of the A/E to ensure that there
is not damage to the grout after injection of the grout due to shock or vibration for 24
hours after injection of the grout. The slab shall also not experience any change in
loading during this 24 hour period.

K. Two days after grouting the level of grout in the injection and vent tubes shall be
inspected and reported in the grout level has fallen below the top of the slab.
Remedial measures shall be taken in this event.

L. On completion of grouting, grout vents shall be cut off to slab level and positively
sealed to ensure that the encapsulation of the tendons is complete.

3.12 PATCHING

A. Thoroughly clean holes left by tie rods, strand hold-down devices, or other
temporary inserts. Repair same as required for anchorages.

B. Members with honeycomb in areas of such depth as to expose tendons will be

examined by A/E for structural adequacy. Where structural adequacy is deemed
unsatisfactory, the member or work will be rejected.

C. When honeycomb areas are to be repaired, remove loose material and cut back
area until the coarse aggregate will break under chipping. Saturate the area; allow
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SECTION 03 38 00 Post Tensioned Concrete Page 13 of 14
Proposed Marassi Park - Plot 99
Marassi Al Bahrain, Kingdom of Bahrain January 2020

to approach a condition of surface dryness. Then apply a thin coat of epoxy

adhesive bonding agent as specified in Section 033000, cast-in-place concrete and
repair with non-metallic, non-shrink grout and cure as required. The method to be
used shall meet the approval of the A/E.

D. If any cracking is spotted in any of the post tensioned members the A/E will be
notified immediately. Appropriate action on site will immediately be taken to ensure
structural safety. The A/E will instruct the Specialist Contractor to submit a report
which demonstrates the reason for the occurrence of the cracking, describes any
mitigative measures which need to be taken, and demonstrates the cracking shall
not adversely effect the performance of the structure, to the satisfaction of the A/E.
Where impairment of structural adequacy is apparent, the member or work will be
rejected.

E. Any parching and repair works will be jointly done by the Main Contractor and
Specialist Contractor. Before commencement of the site it will be agreed between
Main Contractor and Specialist Contractor how the responsibility for any eventual
patching work will be split between the two parties. This agreement will be
presented to the Clients Representative and A/E for approval.

END OF SECTION 03 38 00

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