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Post Tension Slab System. Method of installation, Stressing and
grouting.

METHOD STATEMENT TYPE OF CONCRETE

Post Tension Slab System. Method

of installation, Stressing and
grouting.
 Civil Engineers  13 August 2020 0

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Construction of Post Tension Slab

System.

Post tension slab system is one of important concrete slab

systems that reduce the percentage of steel reinforcement.
Post-tension is a method of reinforcing concrete with a
high strength steel strands, typically referred as Tendons.

MATERIALS.
Strands:
We have several types of strand, but a common type is
Strand 12.7 mm/15.2 mm-Grade 270,1860 Mpa lower
relaxation.

G.I Flat Duct:

Strands will insert inside these ducts. The duct shall
sufficiently robust and tough to resist the rigors of the
placing and compaction of the concrete without suffering
damage, nor deformation. The duct are to remain mortar-
tight along their entire length and at splice points.
 Ducts have several types and dimension but the most duct
used in construction dimension is:
20 mm x 90 mm -Smooth.
20 mm x 70 mm -Smooth. 
20 mm x 43 mm -Smooth.

G.I Round Duct.

Used in multi strands case. Diameter for G.I round duct
start from 40 mm to 160 mm.

Live Anchorage:
Live anchorages suitable for traditional internal post-
tension using tendons made up of high-strength steel
strands and should be as per NFA-35-045 or EN- 10138
standard.
Each anchorage device shall be capable of safely
transmitting a force not less that the ultimate strength of
the tendon without over stressing the concrete.

Wedges 13 mm / 15 mm.

Grout Vent Pipe. 

Pocket Former.

Duct Support Chairs.

The figure below show all material will use in post-

tension slab system.

Post-tension slab system Plants & Special

Tools:
Stressing Jacks:
Mono-Jack:

Mono-strand tendons: Are often used in buildings, where

each tendon is a single strand, usually comprising 2 to 5
strands, In deck slabs or similar applications.

Multi-Jack:

Multi-strand post- tension tendons are usually stressed as

an entire group, using very large custom-made jacks. This
ensures that all strands are tensioned together and avoids
the risk of trapping an individual strand. 

Stressing Pump:

Onion Jack:
Used in tendons less than (30) m to create an onion shape
at the end of these strand by spreading and separating the
wires.

Dispensers:
Device used for manual insertion of strands into cable
ducts.

Stapler:
Used for attaching duct chairs with Form-work when
concreting.

Grout set (Mixer & Pump):

Used to mix cement, water, and admixtures for grouting to
assure the mixture is not containing lumps or any air
bubbles during injection into the ducts.

INSTALLATION.
Cutting & Preparation of the Strand:
Cutting list to be prepared from the shop drawing for each
tendon considering the stressing lengths are 300 mm for
single live end stressing and 600 mm for double live ends.
The area of cutting should away free pedestrians and
vehicles.
Display the Safety Sign Board that states Work in Progress.
Arrange the Dispenser, coil, electric connection, grinder, and
strip cutter.
Loading the strand to the strand dispenser.
Mark the lengths of the strands as per the cutting list, pull
and cut the strands to the correct marked length.

Make the dead end by using the onion jack for the tendons
that have single live end.
The size of the dead end to be 80 mm so that the concrete
can bond with the dead end.
Bundle the strands and tag it with the length, number of
strands and tendon number.
Every Coil is having a tag which states the coil No. the
below to be fill form which indicates which coil was
installed in which Tendon.

Slab installation:
Once the slab form-work is ready and has a safe access
and safe edges to work, the bottom mesh has been fixed;
the material should be lifted in the correct racks or boxes.
All item should be shifted by a crane which must be
supervised by the Rigger.
Mark the side shutter with the location of anchors and dead
ends.

Drill and cut the shutter at marking locations.

Fix the polystyrene blocks and anchor to the side shutter.
Starting in the long direction, Insert the duct into the
anchor

Keep joining the ducts together always inserting the male

into the female until you reach the required length of the
tendon.
The tagged strand should be unrolled, and hand pushed
throughout the Tendon, If there is one live end the strand
should be pushed from the dead end side first.
Complete the same for all tendons in one direction.
Place the anti-bursting steel at the anchor.
Start the marking of the chair sizes on the ducts as per the
approved drawings.
Align the tendon finally as per the marking on the shutter
and start pinning
(by staple gun).

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Make sure to spread the dead-end wires 10 cm apart and

tie them with a steel
Bar supported by the chairs. Make sure again the anti-
bursting before finalizing the dead-end distribution.
Repeat the same procedure for other tendons and continue
till completion of the slab.
Fix top steel wherever and only when duct profiling has
been completed.
Once the top steel is completed, the grout vents should be
fixed in the anchor
Holes and the dead ends.
If tendons are longer than 30 m fix intermediate vents by
puncturing the duct
And inserting the vent. 

Make sure the Pan Boxes have been fixed in the required
alignment and height.
Make sure the additional rebar is fixed around the pan box
as per the details.
Fill up the installation check list prior to handover the slab
installation undertaking.

CONCRETING:
The concreting operation for a post tensioned floor is very
similar to that for a  reinforced floor, the contractor must be
aware of the following:
Ducts can be easily damaged during concreting; this would
cause problems in the stressing and grouting operations.
Anchorages and tendons must not get displaced during
concreting; Vibrations should not be allowed to contact the
tendons.
The concrete behind and around the anchorages is well
compacted. 

STRESSING:
Stressing of the tendons is the central and most important
operations of the post tensioning process.
Prior starting the Stressing, the following needs to be
checked.

Make sure the required quantity of required sizes of

Stressing blocks and wedges are available at the site.
Make sure the required equipment is on site i.e. stressing