ANZ Royal Bank (Cambodia) LTD.

Mao Tse Tung Blvd Branch

Construction New Building June 2008

SECTION 03380

PRESTRESSING FOR CONCRETE STRUCTURES

PART 1 GENERAL

1.01 SECTION INCLUDES

A. The basic and minimum standards for materials, components and procedures for the
application of prestressing forces to pretension and post-tensioned concrete members
for viaducts, bridges, and other structures.

1.02 RELATED SECTIONS

A. Section 03060 – Concrete Properties

B. Section 03070 – Concrete Batching and Mixing

C. Section 03080 – Concrete Transportation and Placing

D. Section 03100 – Concrete Formwork and Finishes.

E. Section 03200 – Concrete Reinforcement.

F. Section 03250 – Concrete Accessories.

G. Section 03300 – Cast-In-Place Concrete.

H. Section 03370 – Concrete Curing.

I. Section 03400 – Precast Concrete

1.03 REFERENCES

A. American Concrete Institute (ACI)

1. ACI 209 – Prediction of creep, Shrinkage, and Temperature Effects in Concrete
Structures.
2. ACI 301 – Specifications for Structural Concrete for Buildings.
3. ACI 318 – Building Code Requirements for Structural Concrete.
4. ACI 341 – Seismic Analysis & Design of Concrete Bridge Systems.
5. ACI 343 – Analysis and Design of Reinforced Concrete Bridge Structure.
6. ACI 345 – Guide for Concrete Highway Bridge Deck Construction.

B. American Society for Testing and Materials

1. ASTM A416 – Standard Specification for Steel Strand, Uncoated Seven – Wire
for Prestressed Concrete.
2. ASTM A421 – Standard Specification for Uncoated Stress Relieved Steel Wire
for Prestressed Concrete.

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3. ASTM A722 – Standard Specification for Uncoated High – Strength of Steel Bar
for Prestressed Concrete.
4. ASTM C109 – Standard Test Method for Compressive Strength of Hydraulic
Cement Mortars (Using 2 in or (50 mm) Cube Speciments).
5. ASTM C150 – Standard Specification for Portland Cement.
6. ASTM C494 – Standard Specification for Chemical Admixtures for Concrete.
7. ASTM C827 – Standard Test Method for Change in Height at Early Ages of Cy-
lindrical Speciments form Cementitious Mixtures.
8. ASTM C953 – Standard Test Method for Time of Setting of Grouts for Preplaced
Aggregate Concrete in the Laboratory.

C. British Standards Institution

1. British Standards Institution 812 – Testing Aggregates

D. Precast/Prestressed Concrete Institute

1. PCI MNL-116 – Manual for quality Control for Plants and Production of Precast
and Prestressed Concrete Products.

1.04 SUBMITTALS AND RECORDS TO BE RETAINED

A. Methods statements

B. Drawings

1. Shop Drawings – Include the following:

a. Description of equipment to be used and procedure for constructing pre-
stressed concrete members.
b. Ductwork and method of holding ducts in position, tendon or bar sizes, splic-
ing of bars, unit weights, materials and stress grade, jack clearances and pro-
cedures, stressing sequence, initial tensioning forces, pressure gauge or load
cell for determining loads, calculated friction and elastic shortening losses
and tendon or bar elongation, anchorage details and anchorage slippage
losses, bonding and grouting procedures, mild steel placement, provisions for
camber and clearances and concrete dimensions.
c. Details of procedures for yard and site, handling, transporting, storing and
erecting. If necessary, furnish design calculations. Show embedded items
including, but not limited to, inserts, anchors, couplings fittings, vent hole
openings and anchorage pockets. Show method of tendon support for post-
tensioned systems during tendon placing operations.
d. Complete details and substantiating calculations of method and materials
proposed for use in prestressing operations, including additions or rearrange-
ment of reinforcing steel from that shown. Calculate, details and show indi-
vidual tendon layout and anchorage arrangement to satisfy design require-
ments and to avoid interference. Coordinate with embedded items Changes
or rearrangement of details shown permitted only with approval. Ensure that
spacing of tendon is sufficient for full encasement of each tendon in concrete.
Plan sequence of installation to minimize fitting problem of various compo-
nents embedded in prestressed member. Show camber computations.

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e. Stress/stain curve of tendons and bars. Show amount of slip normally ex-
pected in seating anchorage devices as opposed to that assumed in design cal-
culations. Show friction wobble coefficient and friction curvature coefficient
expected from tendons and bars and duct material. Show complete stress di-
agram for each tendon.
f. Erection diagrams and details of connections to other work.
g. Details and design calculations for size and thickness of anchor plates and
corresponding reinforcement necessary for each system to guarantee safe
transfer of forces into end block. Show amount, size and arrangement of such
reinforcement to be installed at anchorage zone and along path of tendons to
prevent bursting and splitting concrete members when subjected to prestress-
ing forces.
2. Working Drawings:
a. Complete Working Drawings and necessary calculations for and falsework.
b. Include compensation for deflection as necessary to construct structures to
lines and grades shown.
c. Consider loads, forces and stresses to be imposed during casting and post-
tensioning elements of structure.

C. Certification

1. Certified mill reports on the prestressing steel showing, for each size of strand to
be used in the work, physical, chemical and stress/strain test properties including
modulus of elasticity and stating guaranteed minimum ultimate tensile and yields
strength.
2. Certified test reports on three individual test preformed on anchorage as specified
in the following criteria:
a. Static tests Stressing anchorage shall develop at least 95 percent of the mini-
mum specified ultimate strength of the prestressing steel without exceeding
anticipated set. The total elongation under ultimate load of the tendon shall
not be less than 2% measured in a minimum gauge length of 3,000 mm. The
tendon assembly shall be tested in such a manner as to allow accurate deter-
mination of the yield strength, ultimate strength and percent elongation of the
complete tendon to insure compliance with this Specification. The specimen
used for the static test need not be one that has been subjected to dynamic
loading.
b. Dynamic testes shall be performed on representative specimens. The tendons
shall withstand, without failure, 500,000 cycles from 60% to 66% of the min-
imum specified ultimate strength, and also 500,000 cycles from 40% - 80% of
the minimum specified ultimate strength. The test tendons shall duplicate the
behavior of the full size tendon and generally shall not have less than 10% of
the capacity of the full size tendon.
3. Tendons:
a. Certificates for each five reels or coils or fraction thereof.
b. Submit certificates prior to delivery of tendons to job site.
c. Applicable certificates to accompany each shipment of tendons.
4. Hydraulic jacks: Cerfitied calibration curves for each hydraulic jack.
5. Certified test reports: Concrete tests.

D. Documentation
1. Specified calculations.
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2. Records of tendon elongation promptly upon completion of pre and/or post-

tensioning of each member.

1.05 QUALITY ASSURANCE

A. Qualification of Fabricator and Installer:

1. Prestressing work shall be performed by personnel with proven experience in pro-
duction of prestressed concrete products.
2. Post-tensioning shall be under the immediate control and supervision on person-
nel with proven experience in this type of procedure.
3. Control of post-tensioning operations shall be exercised to ensure full compliance
with the requirements indicated on the Working Drawings.
4. Submit name, qualifications and evidence of recent experience of staff on previ-
ous work comparable to that specified above to the Designer.

B. Allowable Tolerances:
1. Fabricate prestressed concrete members to the tolerances specified in the refer-
enced PCI standard.

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1.06 DELIVERY, STORAGE, AND HANDLING

A. Prestressing Steel:
1. Protect prestressing steel against physical damage and rust or other results of cor-
rosion at all times form manufacture to grouting or encasing in concrete. Physi-
cally damaged prestressing steel shall be rejected. Rust or other corrosion shall be
a cause for rejection. Avoid mechanically damaging, work hardening or heating
prestressing tendons while handling.
2. Package prestressing steel in containers or shipping forms for protection against
physical damage and corrosion during shipping and storage. Place corrosion in-
hibitor and rust preventive in package or form or use corrosion-inhibiting carrier-
type packaging material. All prestressing tendons shall be stored clear of the
ground and protected from the weather, from plashes from any other materials,
and from plashes from the cutting operation of an oxy-acetylene torch, or arc-
welding process in the vicinity. In no circumstances shall prestressing tendons af-
ter manufacture be subjected to any welding operation, or on site heat treatment or
metallic coating such as galvanizing. This does not preclude cutting as specified
below.

B. Prestressing Tendons - Cutting.

1. All cutting of wire, strand or bar shall be carried out using a high speed abrasive
cutting wheel, friction saw or other mechanical method or. In post-tensioning
systems, the cutting action shall be hot less than one diameter form the anchor,
and the temperature of the tendon adjacent ot the anchor shall not be greater than
200 ْC.

C. Protection
1. Use corrosion inhibitor, which has no deleterious effect on steel, concrete, or bond
strength of steel to concrete.
2. Replace or restore to original condition damaged packaging or forms.
3. Clearly mark shipping package or form with statement that package contains high
strength prestressing steel, and caution that care be used in handling. Show type,
kind, amount and placement date of corrosion inhibitor used. Include safety rec-
ommendations and instructions for use.
4. When prestressing steel for post-tensioning is installed in members prior to plac-
ing and curing concrete, provide protection against rust of other corrosion, until
grouted, by means of corrosion inhibitor placed in ducts or applied to steel in the
duct.

D. Members:
1. Handle, store and transport completed members and member components so as to
prevent damage.
2. Maintain beams in upright position.

PART 2 PRODUCTS

2.01 MATERIALS

A. Concrete
1. Section 03060 Grade 40, unless otherwise specified
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B. Grout:
1. Materials for grout: Cement to comply with ASTM C150

C. Concrete Formwork and Finishes: Section 03100

D. Concrete Reinforcement: Section 03200

E. Concrete Accessories: Section 03250

F. Tendons, Anchorage, Couplers and Ducts:

1. Pretensioning tendons:
a. Strands: ASTM A416, low-relaxation strand with 15.3 mm in diameter or
smaller.
b. Wire: ASTM A421
2. Post-tensioning tendons:
a. Strand as specified or shown for pretensioning either in single-strand units or
in multiple-parallel-strand units, with wedge-type anchorages.
b. Button heads to be cold formed symmetrically about axes of wires so that
button develops minimum guaranteed ultimate tensile strength of wire. Use
of cold-forming process that causes indentations in wire is prohibited.
c. Prestressing bars:
(i) Fabricated and processed equal or better than as specified in ASTM
A722.
(ii) High tensile strength hot rolled alloy steel, individually cold stretched
and thermally stress relieved to ensure uniform stress/strain characteris-
tics and to obtain yield strength not less than 85% of required minimum
quaranteed ultimate tensile strength
(iii) The minimum requirements shall be specified ASTM A722
d. High-strength, thermally stress-relieved, large steel cables with socketed ends
fitted with anchorage nuts on peripheries of sockets and meeting required
breaking strength, yield strength, elongation composition and other pertinent
requirements may be used. Oil-tempered wires are prohibited.
3. Anchorage and couplers:
a. Steel anchorage and couplers shall be compatible with a particular installa-
tion. Anchorage devices shall hold prestressing steel at load producing stress
of not less than 95% of specified minimum ultimate tensile strength of pre-
stressing steel. Anchorage with cut threads or notches are prohibited on pre-
stressing steel. Fabricate stressing anchorage to provide adjustable seating
loss. Ensure that each anchorage is capable of lift-off, detensioning and re-
tensioning tendon at any time prior to grouting.
4. Ducts:
a. Galvanized ferrous metal.
b. Strong enough to retain shape and resist damage during construction.
c. Capable of preventing entrance of cement paste and water from concrete
d. Incapable of causing electrolytic action or deterioration in concrete.
e. When grouting is necessary, ensure that:
(i) Inside diameter of duct is at least 6 mm larger than bar o strand tendons
or, in the cause of parallel-wire cable tendons, that inside area of duct is
at least 100% larger than area of tendon.

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(ii) Ducts shall have grout holes/air vents at each end and at high points
(crests) in the duct profile and elsewhere as specified.
f. Grout and vent hole connections to duct made with metallic structural fasten-
ers. Connections to be mortar-tight taped as necessary. Provide grout holes
with means to inject grout. Provide positive shutoff valves.
g. All ducts shall be free from water and thoroughly clean before grouting. All
surplus water from flushing shall be removed by compressed air injection.
All anchorage shall be sealed or fitted with grouting connections.
G. Corrosion Inhibitor: Water-soluble oil.

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PART 3 EXECUTION

3.01 COMPONENTS

A. Concrete

1. Mixing and placing.

a. Mix concrete shall be as specified in Section 03070, with the following addi-
tion requirements:
(i) Do not use admixtures containing chlorides, fluorides or nitrates.
(ii) Use more than one admixture only when compatible with each other.
When used, add separately during batching sequence.
b. Placement of concrete: Section 03300
2. Concrete Protection for Reinforcement: Section 03200
3. Compaction of Concrete:
a. Compact concrete by means of internal, external of surface vibrators and as
follows:
(i) Use internal vibrators on sections that are sufficiently large to admit
them.
(ii) Use external vibrators on smaller sections and sections produced by
extrusion of slip-form method.
(iii) Surface or screed vibrators may be used for flat slabs.
4. Patching
a. Thoroughly celan and hammerpack holes left by tie rods, strand hold-down
devices or other temporary inserts withstiff dry mortar made with same type
of sand and cement used in concrete. In areas of tensile stress, bond hole
patches with epoxy resin.
b. Members with honeycombs of such depth as to expose tendons shall not be
used.
c. Where honeycombed areas are to be repaired, remove loose material and cut
area back until coarse aggregate breaks under chipping: coat area with layer
of epoxy bonding agent and patch with grout matching existing concrete col-
or and strength.
5. Curing: Section 03370
6. Finishes:
a. Types of concrete finishing: As shown and specified on the Design Drawings.

B. Forms
1. Ensure that joints are smooth and tight to prevent leakage of mortar. Maintain ac-
curate alignment of forms during casting operations. Check form alignment and
grade for each casting.
2. Make provisions in form anchorage system for anticipated differential movement
of beds and forms during casting and curing operations. In details of forms, ties,
inserts, bulkheads and other accessories, details forms and anchor them so that
differential movement cannot occur or loosen them so that movement can occur
without damage to member or forms. Ensure that bearing devices supporting pre-
stressed member are free to rotate and that expansion bearings are free to translate
during post-tensioning operation.
3. Clean beds and forms thoroughly before casting. Do not allow coatings used for
form releasing to accumulate in bottoms of forms. For members to be cured by
artificial heat, provide for ventilation of void forms.
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4. Treat surface in contact with concrete with effective form release agent.
5. Prevent contamination of tendons by form release agent, mud, grease or other det-
rimental substances.
6. Provide bolting fittings and welding plates for embedment in prestressed members
to allow later attachment of conduits, pipes boxes and similar items.

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C. Ducts
1. Where ducts are used, the number of joints shall be kept to a practicable mm and
each joint adequately sealed against the ingress of nay material. Joints in adjacent
duct shall be staggered by at least 300 mm. Ducts shall be accurately located and
maintained in position both vertically and horizontally as shown on the Working
Drawings. Unless otherwise described the tolerance in the location of the center-
line of the duct shall be 5 mm.
2. Ducts shall be kept free of any matter detrimental to the bond between the duct
and the grout and, except for material sealing a duct joint, between the duct and
the concrete.
3. Ducts shall be supported at points not greater than 800 mm centers. Extractable
cores shall be coated with a release agent. Cores shall not be extracted until the
concrete has hardened sufficiently to prevent it being damaged.
4. All ducts shall be checked for blockages due to entry of grout or damage during
concrete placing.
5. The ends of all ducts shall be respectively sealed and protected until the tendons
are treaded through and the stressing operations are commenced. Minimum 10-
mm diameter vent shall be provided at all high and low points on the cable pro-
files.

D. Anchorage
1. Anchor cones, blocks and plates shall be positioned and maintained during con-
creting so that the centerline of the duct passes axially through the anchorage as-
sembly. All bearing surfaces of the anchorage shall be clean prior to concreting
and tensioning.
2. Propriety anchorage shall be handled and used strictly as specified in the manu-
facturer instructions and recommendations.

E. Jacks
1. Load measuring devices shall be calibrated to ± 2% and checked at intervals de-
termined by the Designer.
2. Prestressing equipment and components shall be appropriate for the system in use,
as specified in the instructions or recommendations of the manufacturer or licen-
see of the system.
3. Equip each jack used to stress tendons with pressure gauge or load cell to deter-
mine jacking stress.
4. When pressure gauge is used, provide accurate, easily readable dial at least 150
mm in diameter. Calibrate each jack and its gauge as a unit with cylinder exten-
sion in approximate position in which it shall be at final jacking force. Provide
certified calibration chart as specified.
5. When inconsistencies occur between measured elongation and jack gauge read-
ing, recalibrate gauge. Consistency within five percent shall be satisfactory.
6. When a load cell is used, calibrate and provide with and indicator by means of
which the prestressing force in the tendon may be determined. Ensure that the
range of the load cell is such that the lower 10 percent of the manufacturer’s rated
capacity shall not be used in determining the jacking stress.
F. Tendons
1. Prestressing operations shall be carried out under the direction of an experienced
and competent supervisor and all personnel operating the stressing equipment
shall have been properly trained in its use.

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2. All wires strands or bars stressed in one operation shall be taken, where possible,
from which the coil numbers of the steel used can be identified. Cables shall not
be kinked or twisted. Individual wires and strands for which extensions are to be
measured shall be readily identifiable at each end of the member. No strand that
has become unraveled shall be used.

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3. The tensioning apparatus shall meet the following general requirements:

a. The means of attachment of the tendon to the jack or tensioning device shall
be safe and secure.
b. Where two or more wires of strands are stressed simultaneously, they shall
be approximately of equal length between anchorage points at the datum of
load and extension measurement. The degree of variation shall be small
compared with the expected extension.
c. The tensioning apparatus shall be such that a controlled total force is imposed
gradually and no dangerous secondary stresses are induced in the tendons,
anchorage, or concrete.
d. The force in the tendons during tensioning shall be measured by direct read-
ing load cells or obtained indirectly form gauges fitted in the hydraulic sys-
tem to determine pressure in the jacks. Facilities shall be provided for the
measurement of the extension of the tendon and of nay movement of the ten-
don in the gripping devices. The load-measuring device shall be calibrated to
and accuracy within 2% and checked at frequent intervals. Elongation of the
tendon shall be measured to accuracy within 2% or 2 mm, whichever is the
lesser.
e. The tensioning equipment shall be calibrated before the tensioning peration
and subsequently at frequent intervals.
4. Placement and Tensioning of Tendons for Prestressing:
a. Prior to stringing tendons, inspect bottom of forms for cleanliness and accu-
racy of alignment.
b. String tendons singly or in multiples.
c. Splicing of wires or strands is prohibited.
d. Cut length of each tendon between tendon vise and tendon coil.
e. Do not string tendons incorporation points previously gripped by tendon vises
or wedges within lengths to be stressed. Do not use notched, nicked, pitted,
rusted or otherwise damaged tendons.
f. Provide tendon vises of wedges capable of anchorage stressing loads posi-
tively with a minimum of differential slippage. Have vises or wedges
cleaned, lubricated and inspected between each use.
g. Discard grips which become visibly worn or distorted or which allow exces-
sive slippage. Furnish full set of cleaned and inspected tendon vises or
wedges before commencing each stressing operation. Ensure that vises and
wedges are free of rust and physical damage.
h. Position tendons to specifications and detailed dimensions show on the Shop
Drawings. Prevent sagging and kinking of tendons. Support tendons as nec-
essary to maintain proper position and prevent vertical and horizontal move-
ment during pouring of concrete. Permissible deviations from profile shown
on Shop Drawings as follows:

Depth of Member Permissible Deviation

Less than 250 mm 3 mm
250 mm or more 6 mm

i. After straight wire tendons have been positioned, apply initial force to each
tendon to eliminate slack and to provide uniform initial stress condition in all
tendons prior to final stressing. Initial force shall be applied only by pressure
jacks equipped with proper gauging system for measuring initial force.

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j. Do no weld or make grounds for welding equipment on forms or on steel in

member after prestressing steel has been installed.
k. Maintain records of elongation and tension applied to each tendon.
l. Use load cells to calibrate load-measuring devices and to check initial force
on at least 10% of tendons.
m. Regardless of method used, measure initial load within tolerance of 23 kg or
2% of tendons whichever is larger.
n. Do not use elongation measurements as measure of initial stress.
o. Perform final stressing as shown on Shop Drawings.
p. When prestressing bars less than 9,000 mm long ar eused, measure elonga-
tion by means of dial indicators.

3.02 PRETENSIONING:

A. Where pretensioning methods are used, the tension shall be fully maintained by
some positive means during the period between tensioning and transfer. The
transfer of stress shall take place showily to minimize shock.
1. Straight tendons
a. In the long-line method of pretensioning, sufficient locator plates shall
be distributed throughout the length of the bed to ensure that the wires
or strands are maintained in their proper position during concreting.
Where a number of units are made in line, they shall be free to slide in
the direction of their length and thus permit transfer of the prestressing
force to the concrete along the whole line. In the individual mould sys-
tem, the moulds shall be sufficiently rigid to provide the reaction to the
prestressing force without distortion.
2. Deflected tendons:
a. Where deflected tendons are used in pretensioned members the mecha-
nisms for holding down or holding up tendons shall ensure that the part
in contact with the tendon is free to move in the line of the tendon so
that friction losses are nullified. If, however, a system is used that de-
velops a frictional force, any frictional forces developed shall be de-
termined and due allowance made in the calculation of the prestressing
force.
b. For single tendons, the deflection in contact with the tendon shall bave
a radius of not less than 5 times the tendon diameter for wire or 10
times the tendon diameter for strand, and the total angle of deflection
shall not exceed 15 degrees. The transfeer of the pre-stressing force to
the concrete shall be effected in conjunction with the release of hold-
down and hold-up forces so that any resulting tensile stresses in the
concrete do not exceed permissible limits. Unless otherwise described,
the concrete shall not be stressed until it has reached at least the age at
which two test cylinders shall be cured in similar conditions to the con-
crete to which they relate. The Contractor shall cast and test sufficient
cylinders to demonstrate that the required strength of the concrete at
transfer has been reached.
3. Debonded tendons:
a. Where tendons are required by the design to be debonded from the
concrete, they shall be covered with sleeves of PVC or other material
shown on the Shop Drawings. The ends of the sleeves shall be taped to
the tendon to prevent the ingress of grout. Joints in sleeves shall be se-
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curely taped to prevent penetration of the sleeve by concrete or lai-

tance, and ends of sleeves shall be protected after the stressing and
grouting operations. Joints in adjacent sleeves hsall be spaced at least
300 apart.
b. Tendon Vises for Pretensioning:
(i) Use tendon vises for pretensioning capable of anchoring tendon
positively without slippage after seating.
(ii) Have steel cases for tendon vises proof tested by manufacturer
to at least 95% of guaranteed minimum tensile stress of pre-
stressing steel.
(iii) Maintain chucks in serviceable condition. Discard chucks that
become visibly worn or show evidence of allowing post-seating
slippage of tendon.

3.03 POST-TENSIONING:

A. Arrangements of tendons. Where wires, strands, or bars in tendon are not stressed si-
multaneously, the use of spacers shall be as specified in the recommendations of the
system manufacturer.

B. Deflected tendons. The deflector in contact with the tendon shall have a radius of not
less than 50 times the diameter of the tendon, and the total angle of the deflection shall
not exceed 15 degrees.

C. Tensioning procedure:
1. Immediately before tensioning, prove that all tendons are free to move in the
ducts, unless the geometry of the ducts makes this in practicable, between jacking
points and that members are free to accommodate the horizontal and vertical
movements due to the application of prestress. Tensioning shall be a carried out
in such a manner that the stress in the tendons increases at a gradual and steady
rate. Tensioning shall not be carried out at a temperature below zero.
2. Unless otherwise described, the concrete shall not be stressed until it has reached
at least the age at which two test cubes taken form it attain the specified transfer
strength. The test cubes shall be cured in similar conditions to the concrete to
which the relate. East and test sufficient cubes to demonstrate that the required
strength of the concrete at transfer has been reached.
3. Ensure that those carrying out the stressing are provided with the particulars of the
required tendon loads, order of stressing and extensions. Allowance shall be
made during stressing for the friction in the jack and in the anchorage, although he
former is not necessary when using load cells, and for draw-in of the tendon dur-
ing anchoring. Stressing shall continue until the required extension and tendon
load is reached. The extension shall allow for any draw in at the non-jacking end,
but measurement shall not commence until any slack in the tendon has been taken
up. After the tendons have been decreased gradually and steadily so as to avoid
shock to the tendon or the anchorage.
4. Perform sequence and staging of post-tensioning as specified on the Shop Draw-
ings. Perform special techniques, such as over jacking with following reduction
of load or jacking form both ends of the tendon, as specified on the Shop Draw-
ings.

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5. Stress post-tensioned prestressing steel by means of hydraulic jacks equipped with

accurately calibrated, easily readable hydraulic pressure gauges or load cells to
permit reading stress in prestressing steel throughout stressing operation.
6. Keep full records of all tensioning operations including the measured elongation,
pressure-gauge or load-cell readings and the amount of draw in at each anchorage
for each tendon at all stages and submit records as specified. Make readings of
elongation to within 0.8 mm when dial indicators are used, reading accuracy to be
accordingly higher.
7. At the time of stressing first member of each type, check stresses in individual
tendons and verify calculated frictional losses and seating losses to establish post-
tensioning procedure and ensure uniform results.
8. When friction losses in post-tensioning tendon exceed calculated friction losses
shown, relieve tendons of stress, lubricate with water-soluble oil and retention.
9. Anchor prestressing steel at initial stresses (transfer) calculated to result in final
force shown. Initial stress not to exceed 70% of minimum ultimated tensile
strength of prestressing steel at any point of tendon.
10. During jacking of prestressing steel, do not exceed 80% of the minimum guaran-
teed ultimate tensile strength of tendon.
11. Pretension members:
Stress immediately prior to transfer –
Low-relaxation strands ….. 0.75 f’s
Stress-relaxation strands ….. 0.70 f’s
Post-tensioned members:
Stress immediately after seating –
At anchorage ….. 0.70 f’s
At the end of the seating loss zone .83 f*y
Tensionign to 0.90f*y for short periods of time prior to seating may be per-
mitted to offset seating and friction losses provided the stress at the anchorage
dose not exceed the above value.
Stress at service load after losses …… .80 f*y
12. Make accurate measurements of anchorage slippage losses at time of anchoring
first tendon of each type of member and compare with assumed slippage losses.
In case of deviation, detension tendon: repeat tensioning.
13. When necessary, make adjustments to post-tensioning procedure to obtain re-
quired stresses.
14. Immediately after concreting, check ducts for obstructions by drawing cleaning
device through them, by blowing through and by movement of tendon. Immedi-
ately prior to installation of tendons in ducts, demonstrate to the Contractor QA
Manager that ducts are free of water, debris and other obstructions.
15. Tendons shall not be welded within the length to be tensioned. Cropping of ten-
dons by burning shall not be permitted. Tendons shall not be cut less than 3 days
after grouting.
16. The prestressing tendons shall be protected in their permanent positions from both
mechanical damage and corrosion.

3.04 GROUTING

A. Immediately prior to grouting, clean ducts of foreign materials and remove corrosion
inhibitor by thoroughly flushing duct with water and dry by blowing. Unless pre-
stressing steel is adequately protected form corrosion, complete grouting operation
within 28 days after concrete is placed around ducts but not later than 10 days after
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stressing, flush the ducts with compressed air to ensure no blocking of the grout vents.
Complete grouting operation within 10 days after all tendons of that span are stressed
to the full load.

B. The mixing equipment shall produce a grout of homogeneous consistency and shall be
capable of providing a continuous supply to the injection equipment. The injection
equipment shall be capable of continuous operation with little variation of pressure
and shall include a system for recirculating the grout while actual grouting is not in
progress. Compressed air shall not be used. The equipment shall have a constant de-
livery pressure not exceeding 1 N/mm2. All piping to the grout pump shall have a
minimum of bends, valves, and changes in diameter. All baffles t the pumps shall be
fitted with sieve strainers. All equipment, especially piping, shall be thoroughly
washed through with clean water after every series of operations and at the end of use
each day. The equipment shall be capable of maintaining pressure on completely
grouted ducts and shall be fitted with a valve that can lock off without loss of pressure
in the duct. During the grouting operation the Contractor shall provide adequate flush-
ing-out plant to facilitate complete removal of the grout in the event of a breakdown of
the grouting equipment or other disruption before the grouting operation has been
completed.

C. Mix grout as specified by the manufacturer, as tested or for 1-1/2 minutes in high-
speed mechanical mixer or until the mix is of a uniform consistency; pass through
strainer into pumping equipment which has provision for recirculation. Begin pump-
ing grout as soon as possible after mixing. Pumping may be continued as long as
grout retains proper consistency.
1. Use grout consisting mainly of cement and water unless gross inside area of duct
exceeds five times tendon area, in which case fine sand may be added.
2. Admixtures which contain chlorides, nitrates, sulfates, sulfides or which are gas
producing shall not be used. Admixtures shall be at least as specified in ASTM
C494.
3. Base proportions of materials on results of tests made on grout to achieve the fol-
lowing:
a. Water content: Minimum necessary for proper placement.
b. Water-cement ratio: Limited to maximum of 0.45 by weight.
c. Minimum seven-day compressive strength: 17 N/mm2 for 50 mm cuges
nolded, cured and tested at least as specified in ASTM C109.
d. Shrinkage to be minimum 0% early height at final set when tet according to
ASTM C827 and C953.
e. Cholride/sulphat content limits shall compliance to British Standards Institu-
tion 812 part 117

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D. The grout shall be of the same grade as the concrete, of non-shrinkage type and shall
comply with the requirements of ASTM C150. Strength to meet the specified concrete
strength, shrinkage to be minimum 0% early height at final set, when tested according
to ASTM C827 and C953 chloride/sulphate content limits and associated QC testing,
e.g. Marsh flow and S.G limits as the testing frequencies for these QC test, to ensure
compliance to these limits.

E. Do not retemper grout.

F. Injection shall be continuous, and it shall be slow enough to avoid producing segrega-
tion of the grout. The method of injecting grout shall ensure complete filling of the
ducts and complete surrounding of the steel. Inject grout into ducts and anchorage fit-
tings. Continue flow until grout of consistency equivalent to that injected flows from
vent openings without presence of air in bubbles. Ensure that there is enough grout in
supply bin to prevent suction of air. The injection tubes shall then be sealed of under
pressure until the grout has set. The filled ducts shall not be subjected to shock or vi-
bration within 1 day of grouting. Not less than 2 days after grouting, the level of grout
in the injection and vent tubes shall be inspected and made good if necessary.
a. The pressure gauges shall be calibrated before they are first used and the calibra-
tion shall be checked at intervals by a licensed laboratory as determined by the
Contractor.

G. Close vent openings progressively in direction of flow. After vent openings are
closed, raise grouting pressure to 0.7 N/mm2 minimum and plug injection hole. The
Contractor shall keep full and accurate records of grouting including the date each duct
was grouted, the proportion of the grout and any admixtures used, the pressure, details
of any interruptions and topping up required.

H. In the vent of blockage or interruption of grouting, remove grout from duct by flushing
with water. Provide water pump in standby condition.

I. Adequate standby water flushing equipment shall be available at all times when grout-
ing is in progress. This equipment shall be in addition to the grouting equipment and
should be capable of working from a separate power source. The water flushing
equipment shall have sufficient capacity to flush out any partially grouted cables,
when necessary, due to blockage or breakdown of the grouting equipment.

J. Prevent water trapped in ungrouted ducts from freezing.

K. Maintain temperature of concrete around grouted tendons at 7 or higher for at least

three days after grouting.

3.05 STRESS TRNASFER

A. Perform stress transfer to pre or post-tensioned member only after concrete strength, as
demonstrated by test cylinders, is at least equal with the transfer strength specified.

B. Minimum transfer strengths of concrete:

a. Concentrically stressed members: 200 kg/cm2
b. Eccentrically stressed members: 240 kg/cm2
c. Bridge beams or other members in which camber must be minimized: 280 kg/cm2
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d. Post-tensioning members: 280 kg/cm2 or as shown

C. If precast concrete has been moist heat cured, perform detensioning immediately fol-
lowing the curing period and while concrete is still warm and moist.

D. In detensioning operations, release tension so as to minimize eccentricity between re-

sultant of prestressing forces and the vertical centroidal axis of member and so as to
minimize sudden of shock loading. Limit maximum eccentricity about vertical cen-
troidal axis to one strand.

E. Prior to detensioning, remove or loosen forms, ties, inserts, hold-downs or other de-
vices that would restrict longitudinal movement of members along bed.

3.06 TESTING OF PRESTRESSED MEMBERS

A. When directed by the Engineer one or more beams shall be subjected to a loading test.
The Contractor shall obtain a prior approval of the Engineer to the detailed arrange-
ments for the testing. A beam which is to undergo test shall be supported at its design
points of bearing and the upward deflection due to the prestressing force measured rel-
ative to a line joining these points.

B. Equal loads shall then be applied at the third points in ten equal increments, the total
being sustained for 5 minute. The beam shall then be unloaded.

C. The midspan deflection relative to the reference line shall be measured for each incre-
ment of load. The load deflection curve plotted from these values must show no appre-
ciable variation from a straight line. The Drawings shall show, or the Engineer shall
direct, the loads to be applied and the corresponding deflections which must not be ex-
ceeded.

D. Any beam which fails to satisfy the Engineer under the prescribed test shall be rejected
and all other beams cast in the same line as the rejected beam shall also be rejected un-
less tested at the Contractor’s expanse and found satisfactory.

E. The Contractor shall supply to the Engineer record sheets of the tests showing date of
test, loads, deflections, and load deflection curves, calculated values of “E”, and the
strength of the concrete at release as indicated by the relevant cube test results.

F. The tests are to be carried out on units selected by and in the presence of the Engineer
after he has agreed the method of testing and form of records. The cost of such tests
and records shall be included in the unit prices.

END OF SECTION

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