TALK ON MATERIAL & WORKMANSHIP

FOR POST-TENSIONING WORKS

Part 1: MATERIAL FOR POST-TENSIONING WORKS

Ir. Dr. LOW HF PhD.Eng (Monash)

PEPC, MIEM, C.Eng MIStructE, MIEAust, CPEng, Singapore
MIES, APEC Eng, ASEAN Eng

22 Apr 202 1
PRESTRESSED CONCRETE
APPLICATIONS

2
HOW PRESTRESSED CONCRETE WORKS

In Reinforced Concrete (RC)

design, steel bars are provided at
the tension zone to intersect the
cracks
In Prestressed Concrete (PC)
design, external forces are applied
to pre-compress the tension zone
before loading.

IES Talk on Material & Workmanship for Post-Tensioning Works 3

METHOD OF APPLYING PRESTRESSING FORCE

Pre-tensioning:
Placing of concrete
around reinforcing
tendons that have
been stressed to the
desired force

Post-tensioning:
Stressing tendons only
after concrete has
hardened by casting in
void formers during
concreting.

IES Talk on Material & Workmanship for Post-Tensioning Works 4

COMPONENTS OF POST-
TENSIONING WORKS

 PC Strands
 Post Tension Anchorage
 Sheath/ Duct
 Grout
 Apparatus

IES Talk on Material & Workmanship for Post-Tensioning Works 5

PC Strand
 Bonded vs. Unbonded System

 Bare strands for bonded system (cement grouted)

IES Talk on Material & Workmanship for Post-Tensioning Works 6

PC Strand Properties
 7-wire strand is commonly used

 It consists of a central core (king wire) around

which 6 wires are spun in one layer.

 Designation

eg. EN10138-3-Y1860S7-15,7
BS5896-Y1860S7-12.7
IES Talk on Material & Workmanship for Post-Tensioning Works 7
PC Strand Properties
 Properties of PC Strands in accordance to
BS5896 / prEN 10138
BS5896/ prEN 10138
Common Dia. (mm) 12.9 15.2 15.7 Tolerance
Ultimate Tensile Stress 1860 1860 1860 Min= 1860
(MPa)
Specified Max Force, 186 259 279 Min= Fm
Fm (kN) Max= 1.15Fm
Nominal Area, mm2 100 139 150
Weight (kg/m) 0.785 1.086 1.172 ±2%
Total Elongation at 3.5% 3.5% 3.5% Min 3.5%
Max Force (Agt)

IES Talk on Material & Workmanship for Post-Tensioning Works 8

PC Strand Properties
 The characteristic value 0.1% proof force, Fp0.1 is taken as 88% of the
specified max force, Fm. The test value of 0.1% proof force must be ≥
this characteristic value.
 Force Ratio, σ (max force, fm,max divided by the value of 0.1% proof load
of the test) must not be less than 1.07 but not more than 1.17

Max Force,
fm, max

0.1% Proof
Force

 Low Relaxation Steel

The term relaxation describes the reduction of the
existing stress at a constantly applied material strain

IES Talk on Material & Workmanship for Post-Tensioning Works 9

PC Strand Test & Protection
• Each coil of PC strand delivered to site comes with a mill
cert indicating the weight, grade, coil ref. no. etc.
• Minimum 3 samples sent for test at the beginning of the
project
• Random sampling shall be carried out on materials
delivered to site at a frequency of testing of once in every
40 tones of PC strands (about 12 coils).

Corrosion Inhibitor that has

no deleterious effect to
strands and concrete, and
not affected the bonding

10
PC Strand Tensile Test
 Using the proper grips to
prevent slippage
 Strand tensioned until breakage
 Breaking load, yield/proof load,
max elongation, modulus E,
sectional area

IES Talk on Material & Workmanship for Post-Tensioning Works 11

PC Strand Tensile Test

IES Talk on Material & Workmanship for Post-Tensioning Works 12

 Evaluation of
Test Results
and A unit of
Inspection
Testing Route

IES Talk on Material & Workmanship for Post-Tensioning Works 13

Component of Internal Post-
Tensioned Tendons

IES Talk on Material & Workmanship for Post-Tensioning Works 14

Post-Tension Anchorage
Multi Strand Anchorage
Slab Flat Anchorage
Coupling Anchorage

Single Strand Anchorage

IES Talk on Material & Workmanship for Post-Tensioning Works 15

Post-tensioning Anchorage
 Beam Multi Strand Anchorage GI Ducts
Bearing Plate
Casting

Anchor Head

PE Transition
Tube
Strands Held by
Wedges

IES Talk on Material & Workmanship for Post-Tensioning Works 16

POST TENSIONING SYSTEMS

IES Talk on Material & Workmanship for Post-Tensioning Works 17

 Post-tensioning Anchorage
 Slab Flat Anchorage

Bearing Plate
Casting
Barrels

GI Ducts

Strands Held by
Wedges

IES Talk on Material & Workmanship for Post-Tensioning Works 18

Tendon Anchorage Spec.
 All tendon anchorages shall comply with the requirements of
BS EN 13391.
 Post Tension Anchorage Proprietary System;
eg. Freyssinet, VSL, BBR, Utracon etc. of which they will
guarantee the performance of the anchorage systems.
 Test certs on the anchorage system by the suppliers and the
performance warranty.

IES Talk on Material & Workmanship for Post-Tensioning Works 19

Ducts
 Ducts are commonly formed from corrugated hot-dipped
galvanised steel strips on special tube-former machines.
 Ribbed sheet metal ducts provide high rigidity that can
withstand being embedded in concrete without deformation.
 Duct corrugation provides excellent bond behaviour between
tendon and concrete.
 Provide a fair secondary corrosion protection to the strands;
primary protection is provided by the alkalinity of grout and
concrete

IES Talk on Material & Workmanship for Post-Tensioning Works 20

Sheath/ Duct Spec.
BONDED POST-TENSION TENDONS

 Ducts must be large enough to

allow the threading of PC strands
and to facilitate grouting.
 The inside cross-sectional area of
the duct to be at least 2.5 times
the net area of the strand tendon
 For galvanized metal strips, metal
thickness shall be 0.30mm ~
0.60mm

EXTERNAL PRESTRESSING TENDONS

 External prestressing shall use smooth High Density Polyethylene (HDPE) sheath
 Pipe material shall be in accordance to ASTM Specification D1248 with standard
density ≥ 941 kg/m3.
 Minimum wall thickness shall be at least the avearge OD of the pipe divided by 17,
or 4mm whichever greater.
 No joint shall be allowed at saddle or deviator locations
IES Talk on Material & Workmanship for Post-Tensioning Works 21
Grout Specification
 The properties of grout shall satisfy the requirements of BS EN 447
 Grout is composed of cement and water with accepted admixtures.
Cement shall comply with BS EN 197-1 Type CEM 1 (Portland Cement)
and the mixing water for concrete shall comply with BS EN 1008.
 The water/cement ratio shall not exceed 0.4.
 Admixtures used shall comply with BS EN 934-1 to 6, including
plasticizing agents, viscosity modifying agents and shrinkage
compensating agents
 Compressive strength of grout in accordance to BS EN 445 shall not be
less than 30N/mm2 at 28 days, or 27N/mm2 at 7 days if it is proposed
to estimate the likely 28 day strength at 7 days.

IES Talk on Material & Workmanship for Post-Tensioning Works 22

Grout Properties
Fluidity
• Grout shall have sufficient fluidity for each of pumping,
and if appropriate, for the penetration of the grout into
the strand but sufficiently low to expel the air in the duct

IES Talk on Material & Workmanship for Post-Tensioning Works 23

Grout Properties
Bleeding
• Bleeding of the grout shall be sufficiently low to prevent
excessive segregation and sedimentation of the grout materials.
• Admixtures are used to modify the viscosity and not increased
by reducing the water/cement ratio
• Bleeding shall be measured by either one of the following
methods given in BS EN 445 based on the requirements below:

IES Talk on Material & Workmanship for Post-Tensioning Works 24

Grout Properties
Volume Change
• The volume change is measured as a difference in percentage of the volume of
grout between the start and the end of the test by wicked-induced method in
accordance to BS EN 445
• The volume change of the grout at rest for 24 h shall be within the range of - 1 %
and + 5 %

Liquid Density
• Grouting shall continue until the fluidity of the
grout flowing from the outlets is the same as
the grout being injected, to within the limits
specified in BS EN 447.
• The grout taken at the outlet at the end of
the tendon shall not exhibit variation in liquid
density in excess of 3% compared with grout
taken at the mixer

IES Talk on Material & Workmanship for Post-Tensioning Works 25

Grout Test Frequency

IES Talk on Material & Workmanship for Post-Tensioning Works 26

Tensioning Apparatus
 The force in the tendons during tensioning shall be measured by direct-reading
load cells or obtained indirectly from gauges fitted in the hydraulic system to
determine the pressure in the jacks.
 Force measurement shall be required to an accuracy of 2%; if gauge is used to
determine the jacking force, it shall be selected so as to be used at between 40%
and 80% of its full capacity when full stressing.
 All tensioning apparatus and gauges shall be calibrated by an approved laboratory,
no more than 4 weeks old at the time the equipment is brought to site. If
required by QPS, intermediate tests on equipment will be required.
 Tendon extension measurements shall be required to an accuracy of 1mm

IES Talk on Material & Workmanship for Post-Tensioning Works 27

Grouting Equipment

• The grout mixer shall be of the high speed type such that
it is capable of at least 1000 rpm with a full batch of grout.
After mixing, the gout shall be kept in slow continuous
agitation, until it is ready to be pumped into the duct.

• Grout vent tubes shall be at least 500mm long, have a

minimum internal diameter of 20mm with threaded
connection to the duct at the lower end and to the grout
pump at the upper end.
IES Talk on Material & Workmanship for Post-Tensioning Works 28
TALK ON MATERIAL & WORKMANSHIP
FOR POST-TENSIONING WORKS

Part 2: WORKMANSHIP FOR POST-TENSIONING WORKS

Ir. Dr. LOW HF PhD.Eng (Monash)

PEPC, MIEM, C.Eng MIStructE, MIEAust, CPEng, Singapore
MIES, APEC Eng, ASEAN Eng

22 Apr 202 29
POST-TENSIONING WORKS
AT SITE
 PT Specialist’s Submissions
 Develop Site Supervision Plan
 Cable Installation
 Inspection Prior to Concreting
 Inspection Prior to Stressing
 Stressing Operation
 Stressing Record
 Analyzing Cable Elongations
 Inspection Prior to Grouting
* Contingency Plan
IES Talk on Material & Workmanship for Post-Tensioning Works 30
SPECIALIST’s SUBMISSION
 Prestress Shop Drawings
 Elongation Calculation
 Bursting Links Design
 Method Statements for Prestressing Works
 Inspection Checklists and QA/QC Forms
 Calibration Certs for Jacks and Gauges
 Contingency Plans

IES Talk on Material & Workmanship for Post-Tensioning Works 31

CHECKLIST & GUIDELINES
FOR SITE SUPERVISION PLAN

 Material Preparation & Testing –

sampling of strand and grout

 Preparation for Concreting

 Check Stressing Equipment

 Tendon Stressing and Elongation

Calculations

 Preparation for Grouting

 Contingency Plans

IES Talk on Material & Workmanship for Post-Tensioning Works 32

MATERIAL
PREPARATION
Carry out Material Testing
 PC Strand testing
 Grout trial mix and
testing

Prepare Strand Cutting List

 Strands length and
markings are shown
 Strands installed is
traceable to Coil
Number and material
properties

IES Talk on Material & Workmanship for Post-Tensioning Works 33

PC STRAND PROTECTION
AND HANDLING AT SITE
• All prestressing steel and its assembles shall be stored clear of
ground under a waterproof shelter, and protected from damage and
deterioration from exposure or other causes
• Strands must be protected from exposure to deleterious
substances, or subject to splashes from the cutting operation of an
oxy-acetylene torch or arch-welding process in the vicinity which
may reduce its strength or ductility or bond characteristic in the
permanent works
• Strands with a light brown coating of rust are acceptable provided
no flaking or pitting that will reduce its strength

• All cutting of wire, strand or bar shall

be carried out using a high-speed
abrasive cutting wheel, friction saw
or other mechanical methods
(cutting by oxy-acetylene torch is strictly
prohibited)

IES Talk on Material & Workmanship for Post-Tensioning Works 34

Cables Installation
 Reinforcement along entire length including end blocks must be
completed before cables installation could begin.
 Tendon profiles in the shop drawings shall show locating dimensions
for each of the tendons at 600mm centers or less. The ducts shall
be firmly fixed to, or supported from the steel reinforcement within
the forms at 600mm center or less.
 The tolerance in the location of the duct shall be 3mm from the
true position.

IES Talk on Material & Workmanship for Post-Tensioning Works 35

Cables Installation
 Open ends of bottom flange links to be opened vertically instead of
closed “X cross” at locations where tendon profiles are obstructed.

IES Talk on Material & Workmanship for Post-Tensioning Works 36

Cables Installation
 Bursting links installed at Stressing and Dead Ends of cables
 Anchorages fixed to end piece mould

IES Talk on Material & Workmanship for Post-Tensioning Works 37

Inspection Prior to Concreting
Site Personnel should make sure:
 Nos. of strand per tendon to follow shop drawings
 Tendon profiles are done as per shop drawings
 Bursting steels are installed
 Grout tubes are installed and sealed correctly
 Anchors and ducts are tied securely before casting
 Ducting joints are properly taped or sealed
 Dead end/ flower ends are properly sealed

Sample of Checklist

IES Talk on Material & Workmanship for Post-Tensioning Works 38

Closing of Steel Mould
 After inspection, steel mould closed
 Concreting of beam

IES Talk on Material & Workmanship for Post-Tensioning Works 39

 Tendon Stressing
Site Personnel should make sure:
• No member shall be stressed until the concrete has attained the minimum age at
which control test cubes have reached the specified strength for transfer. It
may take 3 to 4 days to achieve this, depending on the design mix of concrete.
• Tendons shall be tensioned to the specified max force gradually, and in the
sequences, given in the drawings.
• Calibration certificates of stressing jack and pressure gauges are submitted
prior to stressing
• Extension readings shall commence after 10% of the load has been applied in
order to ensure that the datum is set after slack has been taken up.
• The cable extension from 0 to 1000psi shall be extrapolated to obtain the total
extension.
• The strands at the non-stressing end shall be marked with chalk or other
means so that any movement of strands relative to each other can be observed.
The draw-in at the non-stressing end shall be measured so that the
appropriate allowance can be made in the measured extension.
• The total extension is to be compared with the theoretical extension to get the %
difference. IES Talk on Material & Workmanship for Post-Tensioning Works 40
Stressing
• Anchor head and wedges are installed onto each bearing plate
• Jack is hung to thread through the strand bundle to bear onto
the anchor head.
• Hydraulic hoses connect to the jack and pump
• The jack piston move outwards and stress the strands

IES Talk on Material & Workmanship for Post-Tensioning Works 41

Stressing
• Extension measured
using steel ruler or
tape
• Upon full jacking
force, the strands are
locked off with the
wedges

Calculation of % of Elongation:
Elongactual – Elongtheory x 100%
Elongtheory
Tolerance = ± 5% for individual tendon
= ± 2% for total force in member
IES Talk on Material & Workmanship for Post-Tensioning Works 42
Stressing
Record
 Record pressure and
extension every
1000psi
 If the tendon elongation
is too long, the jack
stroke needs to be
retrieved and stress
again

IES Talk on Material & Workmanship for Post-Tensioning Works 43

Actual Cable Extension Vs
Calculated Cable Extension

Q: Why do we compare the actual cable extension to

the calculated extension?
A: This provides a check on the accuracy of the
assumption made for the frictional losses at the
design stage. It is part of the quality control
measures.

Q: What’s the theory behind this comparison?

IES Talk on Material & Workmanship for Post-Tensioning Works 44

Typical Stress – Strain Curve for PC Strand

178.7kN (Yield Point)

137.8kN (75% Pj with no frictional losses)

***Within Elastic Range,

Tendon Force α Elongation***

0.72

IES Talk on Material & Workmanship for Post-Tensioning Works 45

Tolerance for Actual Cable Extension
VS Calculated Extension

 According to EC2, the code allows ±5% tolerance.

 If the elongation of tendons are within the allowable
limit, can proceed to crop and grout the tendons
 If there is any shortfall, get the specialist to propose
remedial action. Remedial action and results shall
be submitted for review and approval.

IES Talk on Material & Workmanship for Post-Tensioning Works 46

 NEGATIVE TENDON ELONGATION
X 103
 Let’s say, the designer requires 1230kN
force per cable for his bridge design. From
L=30m the extension calculation, he’d expect an
L’ << L, let’s say 12m elongation of 0.63% or 189mm for a 30m
beam
 Let’s say, after stressing, the extension
recorded is only 175mm or short fall by -
7.4%.
 Due to the fact that, the elongation a force
for elastic range, shorter extension implies
a lower force in the cable. The bridge may
not be able to achieve the design stresses
with this lower prestressing force. Thus,
Designer requires 1230kN force corrective action shall be taken.
Sample of load-elongation curve if  Possible Causes of Negative Extension or
blockage of ducts. Full jacking force will
Only 1130kN force
be achieved with short elongation short fall:
◦ Actual frictional losses are more than
Calculated Extension

the designer’s assumption

Actual Elongation

◦ More Seriously, blockage of ducts

 Possible Corrective Measures
◦ Stress higher, but not more than 80%
UTS
◦ Reduce friction by water soluble oil
Actual 0.58% or 175mm
◦ Remove blockage of ducts

Expected 0.63% or 189mm

IES Talk on Material & Workmanship for Post-Tensioning Works 47

 POSITIVE TENDON ELONGATION
X 103  Let’s say, the designer requires 1093kN
force per cable for his design. From the
extension calculation, he’d expect an
L=30m
elongation of 0.56% or 168mm for a 30m
beam
 Let’s say, after stressing, the extension
recorded is 180mm or longer by +7.1%.
 Due to the fact that, the elongation α force
for elastic range, longer elongation implies a
higher force in the cable. Most of the cases,
higher force is beneficial for beam design,
provided the behavior of the tendons are
acceptable.
Actual force = 1210kN force  Possible Causes of Positive Extension:
◦ Actual friction losses are less than the
Designer requires 1093kN force designer’s assumption
Non linear behavior, may be due
◦ More serious case would be tendon
Calculated Elongation

slippage at dead end

Actual Elongation

to breakage of some strands in

the bundle; forcing other strands
to take more load and yield
Non linear behavior, most likely
due to slippage of dead end
Expected 0.56% or 168mm
Actual 0.60% or 180mm
◦ Or some of the strands in a bundle
snaps and thus forcing other strands to
take more load until yielding.
 Possible Corrective Measures
◦ If the load-elongation curve for the
actual stressing shows linear and elastic.
Acceptable based on engineering
judgement.
◦ Detension and re-stress.

IES Talk on Material & Workmanship for Post-Tensioning Works 48

Inspection Prior to Grouting
Site Personnel should make sure:
 Trial mix of grout has been done earlier and the design mix
has complied the requirements.
 Stressing records are within allowable limits and acceptable
 Grouting shall be carried out not more than 14 days after
installation. In case that longer period of exposure of
unprotected tendons in the duct is expected due to delay
during the course of construction, temporary protection
measure should be taken.
Grouting important for Tendon Corrosion & Durability:

IES Talk on Material & Workmanship for Post-Tensioning Works 49

Grouting
• The ducts are blown clean from debris with dry compressed air
• Sufficient material shall be batched to ensure complete grouting of a duct and
making due allowance for overflow.
• Mixing shall be carried out mechanically with suitable equipment to obtain a
homogeneous and stable grout with plastic properties in accordance to BS
EN 447.
• Grout shall be used within 30 minutes of mixing

IES Talk on Material & Workmanship for Post-Tensioning Works 50

Grouting

IES Talk on Material & Workmanship for Post-Tensioning Works 51

Contingency Plan for Stressing
Works
1. If a few strands in a tendon snapped DURING stressing, stop
stressing the tendon. Investigate and report to engineer for further
action. Remedy could be by stressing remaining strands and other
tendons to higher forces to compensate for the loss.
2. If a few wires in a strand snapped during stressing, stop stressing the
tendon. Investigate and consider possibility of stressing remaining
strands and other tendons to higher forces. Report to engineer for
further action.
3. If a few strands in a tendon snapped AFTER locked off, check
whether the snapped portion is beyond the wedges. Check whether
the wedges are evenly seated on the anchor block. Report to
engineer for further action.
4. If concrete bursts during stressing, stop the operation immediately
and slowly de-tension whatever remaining forces in the tendons.
Remove the loose concrete (most of the case is due to honey comb
at the anchorage area) and replace all the bursting links and cast back
with non-shrink concrete.
IES Talk on Material & Workmanship for Post-Tensioning Works 52
 Contingency Plan for
Grouting Works
1. Adequate water shall be supplied in the event of breakdown in
grouting operation.
2. Water shall be pumped through the grout vents to flush out the
cement grout which is still unset.
3. Next, flush out the residual water in the tendon using compressed
air. Resume grouting operation.
4. In the event of a blockage in the tendon, it is necessary to establish
the location of the blockage. This is done by repetitive drilling
holes and blowing air into the tendon. Next, hack the concrete at
the location to remove the blockage. Then resume grouting.

IES Talk on Material & Workmanship for Post-Tensioning Works 53

 MY CONTACT EMAIL:
lowhf@osdconsultants.com.my
References:
admin@onesmart.com.sg
• Eurocodes
• BS5896: 2012/ pr EN 10138
• LTA Material & Workmanship Specification for Civil & Structural Works
(Doc: E/GD/09/104/A2)
• Guide book for Site Supervision Plan (ver. 2019) by BCA/IES/ACES