£1Of:« = \ittal Record Trans! Job : Contract No. CV/2000/09 Infrastructure for Penny’s Bay Development Our Ref, Contract 1 Issue to: Mr. C. L. Choi - China State Date 1PT02095/TL0077.03 23-Jun-03, 25 JUN 2003 ce: PBU (w/o) i CVE (wio) fica tre sot my i 1 1 { dear Sir, a : las find enclosed the following ‘No.of z ‘Document Reference / 1 Copies Deseription Drawing No. (Revision) nee 1 | Method Statement Prestessing & Grouting 1PT02095/PPPT/S00S (Rev. 0) 19-4un-03 ! i jus: For Approval ev acs sie Approval : (Please contact the undersigned regarding content of shove documents, if required) | ‘Name Position Si Date ‘Contact No. a7 ay Pascal Burtet, Project Manager | 23-Jun-03 2983-6261 Transmital By Name Position Siguanre Dae Contact No Sylvia Sun Secretary Ez 23.tun-03 | 298346261 Please confirm receipt and vem tis page 7 Ms. Sylva Sun (Fax No. 2085 C530) Received By Signature / Company Pie 7 Chop on pete Weylo "INFRASTRUCTURE FOR PENNY’S BAY ICG 41PT02095 ‘CONTRACT 1 (Contractor: cH CHINA STATE CONSTRUCTION ENGRC.(HONG KONG )LTD 7 [ames Tino Bi for [ba —— Ped PROJECT: BAY DEVELOPEMENT INFRASTRUCTURE FOR PENNY’S 2 < s CONTRACT 1 o TITLE : CONTROLLED Ct PY Method Statement PRESTRESSING AND GROUTING DOCUMENT NO.: a FOR APPROVAL 1PT02095 PP PT/5005 rev.0 teviewed: Dat 2 _ Par 14-06-02 Fava [ie of? | pen FAY | ao/oulox 5 To ionea Ar neg? { 7 7 rieinoat engineer sey anager aoe Ok ere Pras pe (9,6.03 Fevwegs( Pe foifo3. peer Poe: is ee Pes Fe FE Technics Engineer A— Produation Manager Prvjectitandger Copyright Reserved ‘Tals document s the property of VSL and must not be copied, reproduced, duplicated nor disclosed totaly or partially to any Third Party, nor used in any manner whatsoever without prior writen consent of VSL. Form0006-0 created 07-01-2008, TOTAL PAGE = CF 442+ ‘INFRASTRUCTURE FOR PENNY’S BAY IG - 1PT02095 * CONTRACT 1 4 Objective This document describes the procedures related to the prestressing works that includes the installation of anchorage, ducting, threading of tendons, stressing of tendons and grouting of tendons. Those works apply to all the spans of Bridge A erected by Overhead Girder. The erection of the bridge starts from Grid 4 (South Abutment) towards Grid 1 (North Abutment). The Road P2 Bridge A is a continuous twin bridge over 3 ‘spans with the span length 35.00 — 31.00 — 36.00 m. Deck 1 and deck 2 consist each of 40 nos of precast segments. ‘Some drawings are attached in the appendix for easy reference. Risk Assessment is also attached in the appendix. = Prestressing System 2.1 VSL Post-Tensioning System VSL Post-Tensioning System Type EC will be used in the project, which consists of: - Anchorage (Casting): Type 5-31Sc for tendon 6-19 and Type 5-48Sc for tendon 6-37, - Anchor Block: Type E6-19 for tendon 6-19 and type E8-37 for tendon 6-37. - Wedges: VSL Wedges 0.6” Super - Strand: Diameter 0.6” Super (15.7mm), 7 wires, complies with BS5896:1980. Minimum Breaking Load 265 KN. - Duct: Corrugated galvanized steel duct. OD/ID 107/100mm for EC 6-19 and ODAD 137/130mm for EC 6-37. 2.2 Equipment Stressing of Tendon. VSL Stressing Jacks will be used: - Type ZPE-480 for EC 6-19 - Type ZPE -1000 for EC 6-31 Pressure Gauge Hydraulic Pump. Strand Installation: Form0006-0 ereated 07-01-2003,«Penny Bay Contract 1, MS Prestressing and Grouting I ©, iy Calibration Procedure 1. Increase the pressure and record the reading of the jack gauge and load cell's digital reading at every 10 MPa increment of the reference gauge reading until the working capacity of the jack is reached. Release the jack pressure and repeat step i for two more times. 3. The Operator shall record the calibration data on the Jack Calibration Certificate (Form No. CA-01) ertificate 1. The StoreMorkshop Supervisor or the Operator shall complete the Jack Calibration Certificate (Form No. CA-01) by calculating the following: a. Average measured load and jack gauge readings of the three runs b. Linear equation between the measured load and jack gauge readings by linear regression method 2. The Jack Calibration Certificate (Form No. CA-01) shall be checked by the Quality Assurance Manager/Engineer and signed by the witness if any Calibration Report The report shall include: 4. Calibration report of the load cells. 2. Calibration report of the calibrated jacks (ZPE-460 and ZPE1000). 4 Installation of Anchorage The Installaticn the Anchorage shall be done by Others at the Segment Casting Yard 4.1 Material 1. VSL Anchorage (Casting) Type 5-31Sc and 5-48Sc. 2. Fixation Bolt and Nut. 3. Bursting Steel Reinforcement. © Copytight Reserved ‘This document must net be copies, repreduced, cuplcated nor dlsclosed totally or partially to any Thid Party nar used in ‘any purpose other than originally Intended without pror witten permission of VSL Hang Kong os (is Peavy BAYS Presresng ung £008 DOC enreatne+ Penny Bay Contract 1, MS Prestressing and Grouting IW ©, Yj 4. Empty ducts across segment joints shall be securely fixed and have their profile maintained at the end shutter for the matching of next stage duct connection The open end of the duct shall be covered with plastic sheet to prevent ingress. of conerete grout, dirt and debris. 5. Fix the grout vents at all “low” and "high" points at intervals of not exceeding 15m along the tendon duct. The location of joint sheaths to the joints in adjacent sheaths shall be staggered by at least 300mm. 6. Grout inlet or outlet hole is provided at each anchorage for connection of the grout hoses 7. Empty ducts at Segment Joints next to an insitu cast stitch shall be provided with a 300mm long “screwed” coupler of the next size to allow coupling on site (SEE OTHER SKETCH ON THE NEXT PAGE) © Copyright Reserved ‘This document must not be copied, reproduced, duplicated nor disclosed totally or pa sy purpose other than originally intended without prior watlen permission of VSL Hor yt any Third Pay norvsedin = 5 ong ‘8 PENNY BAAS Presesing Gray 28 06 ‘raePenny Bay Contract 1, MS Prestressing and Grouting IW © iy 6 Threading of Tendons 6.1. Equipment 1. VSL Strand Pushing Machine. 2. Electric disk cutter. 6.2 Material 1. 15.7 mm diameter low relaxation 7-wire super strands (class 2) conforming to BS5896-1980. 2. Prestressing tendons from each batch shall not be installed until testing of the batch has been completed. 6.3 Method 1. All strands of the tendons of a respective construction stage (1* and 2™ stage) shall be threaded into the ducts after erection of segments, temporary prestressing and casting of the insitu stitches of a respective stage. 2. Position the strand pusher on top of bridge deck. Strand will be directed to each tendon with a flexible PE or corrugated guide tube. 3. Install a coil of strand in the supporting bri-pack (strand dispenser) and place it at about 5 metres from the pushing machine. Pull the strand from the centre of the coil 4. Feed the strand through the strand-pushing machine and thread the strand into the duct. 5.When the length of strand has reached the other end of the duct, cut the strand at a suitable length from the face of the anchorage to allow for the stressing operation. The last strand from each coil will be discarded if the length is not sufficient, no joint on strand is allowed 6. Continue to feed strand one by one into the duct until the required number of strands is threaded into the duct. For future calculation purposes record the coil nos. of strands that form the tendon. 7. Temporary protects the protruding strands with plastic sheet if the tendon will not be stressed within two weeks © Copyright Reserved ‘This dacument must not be copied, reproduced, duplicated nor dsciosed totally or pally to any Third Party nor used in q any purpose other then originaly intended whout prior writen permission of VSL. Hong Kong. Penny Bay Contract 1, MS Prestressing and Grouting I ©, Yj 10, 11. Apply initial load to the tendon, normally 10% of design load to take up the slack of the strands within the tendon. Measurements of the strand and stroke of the jack at the initial loading stage are recorded. Apply the ‘load to the tendon in four or five increments up to the final design load, taking extensions of the tendon at each load increment. Reset is needed whenever the jack comes near to its end of stroke. When the design load has been reached, transfer the load to the structure by gradually releasing the jack to nominal load. Take extension measurements again to check the actual “draw-in". Release the jack completely and remove it from the tendon. Stressing report is to be recorded by VSL foreman and checked by the Project Engineer. If the measured extension for the whole structure is within +/-5% (within +/-10% for individual tendons) of the adjusted theoretical extension, cropping of strands shall be commenced and the anchor heads are rendered with cement mortar to seal wedge cavities. If the measured extension is less than 95% of the adjusted theoretical extension. The prestressing force shall be increased until 95% of the adjusted theoretical extension is achieved except that the prestressing force shall not exceed 80% UTS of the tendon. The Engineer shall be informed immediately for solution, if the above procedures item 8 and item 9 fail to produce an average extension variation of +1-5%, Actual draw-in is equal to Sp-&} and shall not be greater than 6mm. Where Sp = Measured jack Stroke Difference at design jacking force and nominal jacking force. E, = Calculated Elastic extension of tendon within the jack If actual draw-in is greater than 6mm, the excessive amount will be pull out to compensate the loss due to the draw-in. Stressing Report ‘The stressing report will record the details of the tendon being stressed and the extension measurement. The report will also show the measured extension of the tendon and the variance from the theoretical extension. Sample of stressing report (multi-strand and mono-strand) is attached for reference. © Copyright Reserved This document must not be copied, reproduced, duplicated nor dsciosed totally 0” partially to any Third Party nor used in g any purpose other than orginally intended without prior witen permission of VSL Hong KongPenny Bay Contract 1, MS Prestressing and Grouting IN © yf 3. All tendons shall be tested with air for leakage before commencing of grouting If the air test is failed, water test shall be used to locate the leakage, 4. Close all vent pipes, except the inlet, of a tendon and fill the tendon up with air through the grout inlet pipe. Install a pressure gauge and a T-valve in front of the grout inlet pipe for pressure monitoring 5. _ Increase the air pressure to 0.3Mpa (3 bars) and maintain for approx. 2 minutes to observe any drop of pressure. 6. If there is a drop of pressure, repeat the test with water to identify the location of leakage and make good of it. . Repeat the tests until no further leakage is observed. 8. Blow each tendon with oil free compressed air to remove any. surplus of water, which may remain after the leakage test. Grouting 1. The water supply for grouting should be continuous with adequate pressure. 2. Upon receipt approval of the stressing result, protruding strands outside the anchor block are cut at a distance of 16mm (1 x diameter of strand) approximately measured from the surface of the anchor block. 3. Seal up the anchor head with dry packed cement mortar to prevent grout leakage through the wedges 24 hours before grouting 4, Attach grout inlet and outlet pipes to the casting 5. The tendons shall be blown with compressed air to check for blockage. The vent pipe is checked and labelled for identification during grouting. If the test 6. Mixing Procedure shall be as follow: - Grout is to be mixed with VSL grout mixer / pump, which is a blade type centre agitated machine. - Discharge the required volume of water into the grout mixer. - Tum on the grout pump and add in the pre-determined amount of Pozzolith 300 R and then Rheomac GF320 into the mixing tank. Continue mixing for 1% to 2 minutes. - Add in cement, bag by bag, to the mixing tank. Continue mixing until the grout mix is consistent Grout shall be used after approx. 30 minutes of mixing 8. A 1.18mm size strainer shall be provided in the path of the grout circulation in order to catch cement lump, if any. 9. Grout is pumped through the inlet pipe from the lower end of the structure. The grout flows out from the vents should be checked until no air bubble and the consistency is similar to that in the mixer before closing off the vents. The © Copyright Reserved “This document must not be copied, reproduced, duplicated nor cislosed totally or partly to any Third Party ner used in tt ‘any purpose other than originally intended without prior writen permission of VSL Mong KongPenny Bay Contract 1, MS Prestressing and Grouting 104 VEST pipe AT Leo Ane Hig Poy em poe t Peeper Tevet © | Beadd LAYouT | y ace © Copyrnt Resered ‘nis document must nl be copied. epaduces, cuplated nor dctosed totaly or pata o any Thiré Party or used mary purpose cher than orginal tended without por ren permission ot VSL HongKong 13Penny Bay Contract 1, MS Prestressing and Grouting I ©, iy 7. Grouting 7.1 Plastic gloves and dust mask should be worn when handling cement and grout 7.2 Protective eye goggles should be worn when cutting of strands and inspecting of grout outlet pipe under pressure. © Copyright Reserved “This document must not be copied, reproduced, duplicated nor disclosed totally or patialy to any Third Party nor used in 6 ‘any purpose other than orginally intended without prior wien permission of VSL Hong KongVSL Hong Kong Limited Strand Threading Record Project Engineer Ca Project: Structure : Location : Sheet No. : Date ‘Tendon No. Size Heat No. Coil No. No. of Strand [FamNos Pio [Revsion 0 Pages“LYSL Hong Kong Limited Tendon Stressing Report for Multi-Strand Prec [ieee bes ne) Ea ANA eR a 7 fewen ps:VS pd -s04 PERSONAL PROTECTIVE EQUIPMENT ISSUE RECORD FOR DIRECT EMPLOYEES L.D.No. Name of employee Staff No. Department SHRM ICO IE GSD R EEG OO SHO GHD BOE Ho SDoEna biolnrrsribesreliiersretabeninie: I hereby acknowledge the receipt of the following protective equipment and agree to use the protective equipment as is necessary for my own safety and for the compliance with the statutory requirements. The use of the protective equipment has been explained and demonstrated. Protective Equipment “Application * Date issued ‘Signature T Safety Helmet Within the project site boundary : Chin Strap Together with safety belmet | (Optional) | Safety 7 Shoe Within the boundary | Eye Goggle Cutting with machine driven Bw abrasive tool NO, Inspecting grout outlet pipe ap la under pressure | Gloves Handling material and | equipment a Dust Mask / Filters Handling cement, breaking concrete or in dusty are. Working at height may fll for morethan2m Working in noisy zone where | hearing protection is spenified_| Safety Belt / Hamess Breathing Apparatus Working in confined Others : | *Note :- The application of the protective equipment is not limited to the environment/activities as stated above. They may be and should be used in environment where personal safety may be endangered. Document No. = VSLHKISP/GLIOOI | Form No. ‘VSLHK-001-01 [Revision No. : c ACALCULATIONS OF STRESSING REPORT 1. Calculation of Modified Expected Extension Matt = PR where ALI AIEL El Al = 12 a2 = aL AED EB AQ = PL 13 all = AlEL Bo ee OED ‘Therefore AL2= AL} x ALEL AIE Calculation of Stressing Report 2.1. Elastic shortening of strand over jack length Ae stressing force x length of ix AB total area of stand x E value of sand 22 Totalextension = Y+Z where Z = xP PIP) 2.3 Actual extension = total extension - elastic shortening of strand over j 2.4% variation of extension . (cctue] extension - modified expected extension modified expected extension 25° Drewsin Wedges draw-in theoretical extension 1.95 x 10° Nimm™ 100 mm? modified theoretical extension actual E value from mill certificate of the respective heat and coil of strand actual cross-sectional area from mill certificate of the respective heat and coil of strand Y = Cumulative measured extension Z = Initial incremental measurement FP = Final pressure IP = Initial pressure 4 length - Far end slip in (if any) x 100% stroke difference at lock off pressure - elastic shortening of strand over jack length re teSS RHEOMAC GF320 Formerly Flowcable Admixture for anchor grouting DESCRIPTION Rohomac Gr320 is 2 powder admixture, which when mixed in specified quentities with cement and water yields a shrinkage compensated, thixotropic, pumpable grout. The admixture iso has efficient water reducing properties that help to maintain a low water cement ratio of approximately 0.25 and hence Imparts high strength to the grout. RECOMENDED FOR Rheomac GF320 Is recommended in situations where steel anchors (e.g. rock anchors) and cables (e.g prestressed cables) are required to be firmly anchored or routed, and protected from corrosive attack of subsoil water, It is ideal for overhead anchoring due to its thixotropic properties. Applications include both pre~ routed and post-grouted anchors and cables such as: + tube bolt anchoring. ‘© roof stitching in mines and tunnels using wire ropes. ‘grouting of pre-stressed anchors in rock and soll contact grouting, grouting of cable ducts, FEATURES AND BENEFITS Shrinkage Continues to retain filed compensated volume. Efficient anchoring, Thixotropic Grout does not flow out of overhead holes. Pumpable Advantage in deep hole or cable duct grouting. Dense micro Resists water ingress. structure Protects steel High early and Early load transfer. final strength Long open time Sufficient ime to allow grout penetration even in difficult circumstances. PERFORMANCE DATA Compressive strength (Typical with wie : 0.25 @ 20°C) 8 hours > 3 Nimmé tday > 30 Nimmt 28 cays > 7O.NImm® \ ERIE Master Builders Technologies PROPERTIES ‘Supply form powder Colour Storage 210-60°C. Solubilty in water low Chloride content <0. APPLICATION Material Condition Cement : For optimum performer, alvays use fresh Portland cement, since the 1esctlvity of cement is reduced with ageing, Mixing Mechanical mixing is necessary. high speed (approx. 1500 rpm} mixer is recommender! Use Rheomac GF320 at a dose of 3-6% by weight of cement and mix water at approxinitely 25 L per 100 kg coment {.. wle of 0.25). Note : finely ground cement nornall’ requires @ higher quantity of water. Place approximately 23 L of waies i the mixer and add 5 kg of Rheomac GF320. Keepiny tre mixer running add 100 kg of cement slowly and snix for 3 minutes (5 minutes if 8 slow speed mixer 's employed), until a llumpfree homogenous mix is obisined. If required add more water (from the remaining = |.) until the required consistency is reached, Placing Place the mixed grout using @ roirnai grouting pump (@ ‘small, worm or piston pump). Atways use a stiff PVC hose to place the grout. Pre-grouted anchors Introduce the PVC hose to the end of the hole and start pumping. While pumping, pull tin hose back gredully, allowing the grout to completeiy ‘il the volume of the hole. Pace the grout slowly and continuously. install the anchor carefully into the yrouted hole so as to displace the grout to fil the annvius around the anchor completely. Mildly agitate the anchor to release any ‘entrapped alr around the anchor. Hold the anchor in postion using a suitable device, until the grout attains initial set. Post grouted anchors, tube anchors Connect the PVC hose to the anchor and install the anchor in the hole. Start pumping and continue unt the grout starts issuing out between the rock arid the bearing plate. Curing Curing wil not be required as the grout normally is completely enciosed. s. -POZZOLITH 300-R Polymer admixture for Improving conerets, meals and exceeds AS 1478, ASTM C 494 and BS 5075 requirements DESCRIPTION POZZOLITH 300-R Is a ready-to-use liqule admbure for making better, more uniform and more predictable high qually con- crete. It retards the setting time to feciltale placing and finishing. it meets and exceeds AS 1478, ASTM C 494 Type B and D admixtures and BS 5075 Part | requirement. RECOMMENDED FOR ' all types of concrete where retardation of set and improved performance (par- tloularty improved pumpabilty) are re- quired «Improving pumped conerets, shotetete (wet mix) and conventionally placed concrete «Improving plain, reinforced, precast, prestressed, light weight or standard ‘weight concrete «use with alr-entraining agents ap- proved under SAA, ASTM, AASHTO and BS 5075 specilications when alr- entrained concrete Is specified. (MET approved alr-entraining admixture ME- VR Is recommended for use with POZ- ZOLITH 300-8 admixture) FEATURES/BENEFITS «mild to extended retartiation «reduce permeability 4 Improve watertightness 4 superlor finishing characteristics for slabwork and off-form surfaces «reduce water content for a given workabalty «Increase compressive, flexural and bond strengths easler placement Improve workability reduce segregation greater durabiity greater pumpabllty Increase resistance of alr entraliied conctete fo damage due to freezing, thawing and scaling from de-lelhg salls. PERFORMANCE In comparison to plain concrete, a mix containing POZZOLITH 300-A develaps higher early and ultimate strengths, POZZOLITH 300-R exceeds the strength requirements of AS 1478, ASTM C 494, AASHTO M 194, CRD C87 and BS 5075 specications. bosac: POZZOLITH ‘300-A Is tecommended for Use at a dosage rate of 300 +/- 50 mi per 100 kg of cement for mast concrete mbes using average concrete Ingredients, but It | appreclated that variations In the Job conditions and concrete materials employed may make usage rates outside the recommended range desired. Consult your local MBT fleld repre- sentative who Is avallable to assist you In determining the dosage rate for best per- formance ln your work PACKAGING 206 litre drums or bulk delivery, NOTE “For additional Information on POZZOLITH 300-A or on its use In developing a con- “crete mix with special peformance char- acterlstics, contact your local MBT fleld fepresentatlve, or the Technical Service: Department, MBT, . S S x x = x x x “Grout connection casting Wedges corse f Dimensions: 5 : 735 % a5 100 3. 35 165 fa 40 | 8 100. 65 125 el eae 25 #0 450, 160. | 420 F980 Bao |e 208 70 “380 z0 145 200 LBS} sa. ‘200 ad 200 215 180 402 "290 Be | 27 ans s 220 $00 178 107 350 Ey 5st 518, 400 230 300 i7s 407 250 [6 2.0) sero] en 107 250 220, 200 nr 2308, I! sa] abo ae 220 40 27 saree | 908 5-48. 430. 1227 290 340 a8. “437, 865, 5.55 495) | iso 320 340 250 142 oa a as a 30 70 cs 28 5 6-4 105 60 410 400 85 54 125: Se er 28 60 150 4180 120 ree | 180 YEO] e2 ze] 78 180 210 145 ar 200 2S) | ‘e19 316, 22 220 300 175 107 250 Ze 6-22, “318. 400 230 300. 475. 107 5 250 £ES-} ear, 370 tie 250 ‘320 200 417. 205 2} es 390 ie 270 340 217 127 325 er 430 42 00 340 235 187 205 re 485 145 220 240 250 142 400 Dimensions in mm Tiled is odicaton Bmrensione ar vai oc: 29 Nominal coneretesengh a 28 day: 35 Pe (ube, 28 MPa (onde Maximum presvassing force may Be appied when concrete reaches 2 MPa (cube) or 20 MPa (cling), Max prestressing force i 75% of rin. london breaking oad (temporary oversressing fo 80%),Stressing The unique feature of the VSL Post-Tensioning system lias in Its special procedure for locking the wedges. The wedges always remain in contact with the strands during the stressing operation. As the pressure in the jack is released, the wedges automatically [ack in the conical holes of the anchor head. Seating of wedges Grouting \VSL grouting equipment includes mixer and pump in one unit. Grouting Is usually carried out as soon as possible alter stressing. SNe SKO:Kile 23 [o}io} [alo sole VNOILWAIS 0057 igtooo, 14raarsi PEE TavisANOAWT ONISS3UIS Ie ania osuneyy| 2 oo= ve a brecatoy (sos papen) worsen ara aumeusis) Uuosiag waredwio> aed pauyuooyaleueyy Apje5 ” : wonsog 4a pondwo>| es ee ee t}o cle sag lee ay 009 pre mug i alee re 899 9 pn ay 12310 son x a 00s aragseocouat cou Sap qo se ued yo} uses Ais peers Sven a0. 19 yf {ROAM LWAWSSASSV HSRE(or wae ue wt jase easiness oy EOD HR oy ‘tupnosp pon Fyetereeed Sie sRiodnt LNaWssassy SRI =nay EA Hes eee ez Pi ie mS pny oun po 7 i tin wna LAMM Mie] + LD suet te| eons i peste ovement alg |g |g rat om nn tno ogee a i Hg nes nm par fe iu a + [a [Bomosn peony coue/st/9 M34 Wioam Luanssassv xsrt sons nanareovoiar ‘eneen pa Buteoriea Se ot =o(ot ra th yon ses TS Ta S00 /91/9 siomey ye, M94 sRioday Luawssassv nentPenny Bay Contract 1, MS Prestressing and Grouting K © YJ APPENDIX — E RISK ASSESSMENT 1. Assessing interior of span as a possible confined space. 2. Risk Assessment : Methos Statement ~ Prestressing and Grouting. © Copyright Reserved This document must not be copied, reproduced, duplicated nor disclosed totally or partially to any Third Party nor sed in any purpose other than orginally Intended without prior written permission of VSL Hong Kong 3BLd/dd/5602014 tan0r1a7darseoro.as 90 0) ECOASWHOHONY 6L~ ‘994 SNOT WNOILVATIaConcrete over according =) {9 apolablestancare } \ ae a wears i | fo zea wo |) s00 es 200, | 10 zee ia) | tao ZETA ooo. | 20 Beate si: | 0 2peat0 xo. | 20 aes | ox | 350 peeawoci, | 20 | 700 | iso" [aes | “ano zesaa' | aa | rise | aon |e | ae zero’ | so. | isso | ato [are | aes zreiooo | a6 | jan | am |. 70° | a0, zeeiaso | eo. | tao | caso [amo |. ore Type | (ZPE-23 FJ) Type Il (ZPE-19) Type ill (ZPE-500) Dimensions mm sg PEST Pesg] ane [SRPED | ETA AES TONE] Pe 0] EET PE] DOE SOU PET ERE Oe PE [Re cei aa MEIRSTIE pang ce A re Length (men)| 790] 720, 15. | 600 60 520 | 1000. |. 1465."|" 1200 Diameter m]-—196—. 140. a0" | 2a ais a5 [580500] 750 Siroke im) 200 “280 250 “80 0 100 —|-200f~150—| “200. Piston area em) a7-19_ 50.08 726.4 [ 205.8 mer 304.5 | 946 | Teer | T0008 Espaciy @n) [250] 300 22. | 1084 2000 4960 | 5000. | 7500 10000 (oon [ane | sd soo. [se ed seo. | s56._[ sor) ssa. Wwaght_—fg) [128 [oF 7a 8 35 5 [ose | 00a Used fer tamm |S] Et 3258 Bie bee [$22]. ah Se os tence ypeg w54' | i sot [-8a1 | ss7_| sss sedfor ts mm | 6A | $2 36 bie | 618 | ea] eat osnisnairityped "| 63 Sea eis fioeadPenny Bay Contract 1, MS Prestressing and Grouting JIOr APPENDIX — D BROCHURE AND SKETCH VSL Type Ec Anchorage VSL Jacks for type Ec Ane! Typical VSL Stressing Jack Installation Drawing 1PT02095/PP/PT/000/-01 Anchorage Details Drawing 1PT02095/PP/PT/0007-02 Anchorage Details Drawing 1PT02095/PP/PT/0101-01 Prestressing Layout (Reviewed by VSL) Drawing 1PT02095/PP/PT/000'-02 Prestressing Layout (Reviewed by VSL) Drawing 1PT02095/PP/PT/0007-03 Prestressing Layout (Reviewed by VSL) Drawing 1PT02095/PP/PT/000/-04 Prestressing Layout (Reviewed by VSL) ©MPNOARONS © Copyight Reserves ‘hls document mst nat be copie, reproduced, culate nor dictsed ttl or partly to any This Party nor 38 Jed in any purpose ote than orginal intended wot proruniten pemason of VSL Hong KongPA EQUIPMENT ' Mixing : High speed grout mixer ar heavy duty siow speed dril fitted with 2 grout stirrer. Placing, : Worm or Piston type pump. CLEANING Use water to clear tools and equipment before the grout hardens, ESTIMATING : ATA 100 kg of cemer ! sixed with 25 L of water and 5 kg of Rheomac GF32d elds epproximataly 60 L. ‘Therefore material requiremant will be 0,083 kg per litre of grout needed. PACKAGING Rheomac GF320 : supplied in 18 kg bags. SHELF LIFE Rheomac GF220 :an be stored in unopened original bags for 12 morn, if kept dry and at even temperature, Do not use the pr-duct if the bag Is damaged, or has been open for over a month, STATEMENT OF Master Buliders Technologies PRECAUTION Health : Rheomac GF320 is alkaline like normal cement ‘and can cause skin irritations to persons with sensitive skin, Wear gloves and masks while handling the product. Take all precautions normally taken while handling cement. Fire : Rheomac GF320 is not flammable OTHER USEFUL PRODUCTS A range of high performance Meyco SA series sprayed concrete accelerating admixtures for applications. Meyco TCC activators : A range of specialty admbcures to be used in combination with certain selected MBT superplasticisers in shotcreting, for imparting such properties as instant slump loss, pumpabilty and total hydration. Rheobuild : A range of high performance super Plasticisers to produce Rheoplastic concrete. Rheocem : A range of superfine coments for pressure grouting of micro cracks in concrete, rocks and soll. Masterfiow : range of shrinkage compensated, free flowing grouts - cementitious and resin based - with exceptional strengths, for precision grouting of both dynamically loaded and static machinery and equipment. ‘The Technieal infomation and application advice aven In Bis MBT publication are based on Wie present stats OF fur best scientific and practical knovtedge. As the information herein fs of a general nature no aesumplon can be made 2s to @ products sultabilty for @ paricular use or application and no warrenty as to is accuracy, reliability or competeness either expressed or imped is n other than those required by law. The user, is sesponsible for checking the sullatlty of products for their Intanded use NOTE Master Builders Technologies (HK) Ltd. 20/F EW International Tower 422-124 Texaco Road Tsuen Wan, N. T. Hong Kong, Tel : (852) 2407 4281 Fax : (852) 2406 7391 Field service where provided, does not constitu supervisor responsibly, Suggestions made by MBT alter ‘rally or in wring may be followed, modified or rejected by the owner, enginear or contractor since they, and ot MBT are responsible for carying out procedures appropiate fo specie appl (ison)Penny Bay Contract 1, MS Prestressing and Grouting I ©, is APPENDIX — C PARTICULARS OF GROUT MIX 1. Technical Information of RHEOMAC GF320 2. Technical Information of Pozzolith 300 R © Copyright Reserved This document must not be copied, reproduced, duplicated nor disclosed totally or partially to any Thre Party nor y used in any purpose other than orginally intended without pror witen permission of VSL Hong Kong 24Penny Bay Contract 1, MS Prestressing and Grouting ser APPENDIX —B CALCULATION OF STRESSING REPORT (© Copyright Reserved TBs oer mt not be copie epadunddulintadnox aioe iyo part amy Ta Party no useein an aly intended witout pror writen penmission of VSL Hom‘VSL Hong Kong L: i sO ay Tendon Grouting Report . ee as i Aa im Zz I [ DESIG ARG. SSeS ae A esteomeiahe nies ea ise Taumaen > SAMPLING \* f } pater [eee pee oa ae eras Ea iin ean T= eae eeY (VSL Hong Kong Limited 4Q4F Jack Calibration Certificate ‘ : Jack No. Certificate No. Indicator No. : ‘Jack Gauge No Lond Cell No: ‘Load Cell Accuracy : Reference Gauge No ‘Temperature : Date of Calibration : ack Calibration Be Acceptance Criteria : Load cell accuracy shall be within # 2% Reference ‘Load Cell Reading “ack Gauge Reeding Gauge Reading any ‘ra) =] lee fe | | ae | ee ay 7 2 3 ics 1 2 3 ical in Calibrated by : | Witnessed by : IName of Representative : Checked by Company ee | [Fame Ch [Revi 7Penny Bay Contract 1, MS Prestressing and Grouting Ki © iy APPENDIX —A PROFORMA REPORT FORM Strand Threading Record (Form PT-01) Jack Calibration Certificate (Form CA-01) Tendon Stressing Report (Form PT-04) Tendon Grouting Report (Form PT-08) Personal Protective Equipment Issue (Form VSLHK- 001-01) ARoOn a © Copyright Reserved “This document must not be copied, reproduced, duplicated ner used in any purpose other than original intended without prior wi 1 totally or patialy to any Third Party nor emission of VSL Hong KongPenny Bay Contract 1, MS Prestressing and Grouting I@ iy 10 Safety 1. The Project Engineer shall act as a safety coordinator on site for post- tensioning works. 2. Appropriate personal protective equipment (such as safety helmet, safety boots, etc.) shall be issued to all VSL's site workers and properly recorded. 3. Any safety harzard and accident shall be reported to the Safety Officer of the Main Contractor as soon as possible. 4. Lifting of Material and Equipment a. Each item of lifting equipment shall have a valid test certificate. b. Items to be lifted shall be suspended from designated lifting points or at points such that the item being lifted is in a balanced condition, c. No person shall stand or work under the load being lifted. Care should be taken to ensure the stacked pile of strand coils is stable. 5. Tendon Installation a. The working area for strand threading shall be identified as an exclusion zone where only VSL's personnel and the representatives of the Engineer and Contractor are allowed to enter. b. The strand pusher and dispensing coil shall be positioned in line with the tendon. When this is not possible, a guide pipe (corrugated duct or PE pipe) may be used to guide the strand between the strand dispenser and pushing machine c. Protective eye goggles should be worn when cutting the strand with a disc cutter. 6. Tendon Stressing a.The working area for stressing shall be identified as exclusion zone where only VSL's personnel and the representatives of the Engineer and Contractor are allowed to enter. b.A warning sign shall be erected at the stressing and non-stressing ends whenever stressing is in progress. c. When site personnel are working beyond an exclusion zone, a plywood board shall be provided beyond the tendon both at the stressing and non-stressing ends to prevent flying away of strands in case of strand breakage. © Copyright Reserved ; “This document must not be copied, reproduced, duplicated nor disclosed totaly or partly to any Thit Party narused in 4 ‘any purpose other than originally intended without prar written permission of VSL Hang KongPenny Bay Contract 1, MS Prestressing and Grouting waste grout shall be collected in buckets and discharged to the location designated by the Main Contractor. 10.Grouting of each tendon should be carried out in one continuous operation. If grouting is interrupted for more than one and half-hours, the tendon shall be flushed with water and cleaned with compressed air before resuming the grouting operation 11.As the last grout vent is closed off, the grout pressure is maintained at 0.5Mpa (6 bars) for about 5 minute. Then the injection vent shall be closed under pressure, 12.All grout hoses and vent pipes shail be cut flush to the concrete surface and removed 24 hours after grouting. The grout vents should be checked and topped up. 13. Anchorage recesses shall be back filled by Main Contractor using concrete, preferably using the same grade of concrete of the structure. 14. Testing of bleeding and free expansion of grout mix shall be in accordance with Clause 7.06 of General Specification For Building. 15. Testing of grout cubes shall be in accordance with Clauses 7.08 of General Specification For Building, 9 Proposed Method Statement for Grout Trial 1. Erect formwork and fix nominal steel reinforcement for the trial beam as per the layout below. (By others) 2. Fix anchorage, duct and grout vent on the trial beam in accordance with the method statement. (By VSL) Conerete the trial beam with say 30/20 concrete. (By others) Thread 19 nos. of 15.7mm strand into the tendon duct, pull tight with chain block and wedge with jaws. (By VSL) 5. Cut the end of strand and seal the anchor head in accordance with the method statement. (By VSL) 6. Grout the trial tendon in accordance with the method statement submitted. (By VSL) 7. Cut off the trial tendon in sections as directed by the Engineer for inspection. (By others) 8 Remove the trial beam after inspection. (By others) © Copyright Reserved “his document must not be copie, reproduced, duplicated nor csclosed totally or partially to any Thre Party nor used in ‘any purpese other than orginally intended without prior written permission of VSL. Hong KengPenny Bay Contract 1, MS Prestressing and Grouting I © iy 8 — Grouting of Tendons 8.1 Equipment Grout Plant (COLOMONO 10 Grout Pump). 8.2 Material Grout mix shall be as follow Material Proportion a) Ordinary Portland cement (Champion Brand) b) WIC ratio 7 0.33 ¢) Flowcable/RHEOMAC GF320 3% by weight of cement 4) Pozzolith 300-R 4 mlkg of cement 8.3 General 1, After approval of the stressing report, VSL shall ciop the strands to about 1 strand diameter from the anchorage. The anchor heads will be rendered with cement mortar to seal wedge cavities. After air and water test, the duct is then grouted. The recess will finally be filled up with concrete or covered by an approved method. A min, of 25mm cover to a cropped end of prestressing strand shall be provided. 2. As the general rule, all the tendons of a respective construction stage shall be grouted at the same time as soon as possible after completion of the stressing but not later than two months after stressing. 3. To prevent the filled tendon ducts from loss of grout pressure, the inlet and outlet grout vent hoses are "double bent" at the end of the grouting operation. 4. If for any reason the grouting operation is interrupted for more than one and a half hours the duct shall immediately be flushed out with water and blown dry with compressed air and re-grouted as soon as possible. 5. Adequate stand-by water flushing lines shall be available at all times when grouting is in progress. 8.4 Method ir and Water Testing of Tendons 1. Upon receipt approval of the stressing result, protruding strand outside the anchor block are cut and sealed up with cement mortar. 2. Install grout inlet and outlet pipes on each anchorage. © Copyright Reserved This document must not be copie, reproduces, duplicated nor disclosed totally or partially to any Third Paty nor used in 10 ‘ny purpose other than original intended without prior witten permission of VSL Hong KongPenny Bay Contract 1, MS Prestressing and Grouting : I ©, iy 7 Stressing of Tendons 71 Equipment 1. VSL Stressing Jacks (ZPE-460 / ZPE-1000 2. Electric operated Hydraulic Pump. 3. Pressure Gauge. 7.2 Material 1. Appropriate types of VSL Anchor Blocks. 2. VSL 0.6" Wedges (Super). 7.3. General - _ Stressing will be carried out under the instruction of the Main Contractor. 2. Check the validity of the jack calibration certificate. Jacks shall be calibrated before sending to the job site for stressing operation. The jack shall be recalibrated every 6 months. 3. The stressing force and stressing sequence of each tendon shall be followed as specified in the working drawings 4, At the Anchor Block, strands are painted along a reference line prior to stressing, for checking of any possible wedge slippage during stressing and after the wedges are draw-in Sample of the stressing report is attached Stressing jacks will be handled by chain blocks and slings through the reserved holes within the deck and through the lifting devices at stressing platform outside the deck 7.4 Method a Fix the end block and the wedges onto the strands behind the anchorage guide. ie Install Jack at the stressing end of the tendon. Connect the hydraulic pump and the pressure gauge to the jack. © Copyright Reser ‘This document must not be copied, reproduced, dupicted nor disclosed totaly or partially to eny Thiel Paty nor used in 3 any purpose other than orginally inteniec without prior writen permission of VSL Hong KongPenny Bay Contract 1, MS Prestressing and Grouting . I © yj Plostic Extension Tube ic Grout Vent with Cpmpressiple __— Plastic Extension a (9 20mm) ic Grout Vent sible gosket eee Procedure © Copyright Reserved Ts decor uot be copied vou pha nox Sod ety parity any The Party nausea Gi ‘any purpose other than originally intended witht prior writen permission of VSL. Hong KonPenny Bay Contract 1, MS Prestressing and Grouting : I ©, Yj 4.2 Method 1. Fix the anchorage onto the formwork by using bolts and nuts. Ensure the grout inlet is oriented at the top of casting and properly sealed with mastic tape or similar to prevent ingress of grout during concreting 2. The anchorage shall be fixed perpendicularly to the tendon’ axes either onto the end shutter or the recess formwork as detailed in the working drawings. The edge of the casting shall be sealed to prevent ingress of grout during concreting 3. Fix bursting reinforcement, as per the working drawings, behind the anchorage. 4. Strip the formwork after the concrete has been places and achieved an appropriate strength 5. Check and clean the bearing surface of the anchorage by removing any cement slurry adhered to it during concreting 5 Duct Fixing 5.1 Material 1. Ducts shall be galvanized corrugated steel sheathing. a), Ducts will be delivered in the length required for the precast segment. b). The ducts can be joined by 200 mm long outside "screwed" couplers and the joints are sealed using waterproof tapes 2. Grout vents shall be "Limpet' type 3. Grout tubes shall be polyethylene tube of 20 mm ID and 24mm OD. 5.2 Method The following operations will be carried out in the Segment Precasting Yard : 1. Setout and marked the tendon profile on the formwork/reinforcement in accordance with the vertical and horizontal profiles specified on the working drawings. 2. Fix the duct supporting bars to segment reinforcement at the correct level to form the required duct profiles. Supporting bars shall be no more than 600mm center to center. 3. Fix and secure the empty ducts onto the duct supporting bars at 600mm center or at spacing specified on the working drawings. ‘any purpose other than crginally intended witheut prior written permission of VSL Hong KongPenny Bay Contract 1, MS Prestressing and Grouting . I © Yj - Bri-pack (strand dispenser) - Strand Pushing Machine. Grouting: - Grout Mixer Pump. 3 Calibration of Stressing Jacks The valid calibration certificate of the jacks shall be obtained before stressing operation can be commenced, otherwise the calibration of the jacks shall be performed with the following procedure. 3.1. Equipment 1. VSL ZPE-480/ZPE-1000 hydraulic prestressing jacks connecting with pressure gauges. Electrically driven hydraulic pump. Master pressure gauge. 19 pieces for ZPE-460 and 37 pieces for ZPE-1000 of diameter 15.7 mm super strands for VSL jack 5. Load cells with Serial No.720 3.2 General The purpose of this procedure is to ensure that each hydraulic jack to be used on project site is calibrated to ensure the accuracy of measurement. 3.3. Method Pre-calibration Preparation The Store/Workshop Supervisor shall identify the jack to be calibrated and ensure the load cell to be used has the valid calibration certificate (within 2 years). © Copyright Resored “hls document rust nt be copied, epecuced, copa nor disclose italy or parayo ary The Party orusedin ‘any purpose other than criginaly intended without prior written permission af VEL Hong KongPenny Bay Contract 1, MS Prestressing and Grouting J2. iy TABLE OF CONTENT Content 1. Objective (1) 2. Prestressing System (1) 3. Calibration of Jacks <2) 4. Installation of Anchorage (Casting) 73) 5. Duet Fixing <4) 6. Threading of Tendons 6) 7. Stressing of Tendons (3) 8. Grouting of Tendons C70) 9. Proposed Method Statement for Grout Trial (72). 1 0. Safety (4) Appendix —A (Proforma Report Form) (7) 1. Strand Threading Record 2. Jack Calibration Certificate 3. Tendon Stressing Report for Multi Strand 4, Tendon Grouting Report 5. Personal Protective Equipment Issue Record. Appendix — B (Calculation of Stressing Report) (22) Appendix - C (Particular of Grout Mix) 4) 1. Technical Information of RHEOMAC GF320 2, Technical Information of Pozzolith 300 R Appendix —D (Brochures and Sketches) (2 ) VSL Type Ec Anchorage VSL Jacks for type Ec Anchorage Typical VSL Stressing Jack Installation Drawing 1PT02095/PP/PT/O007-01 Anchorage Details Drawing 1PTO2095/PP/PT/0007-02 Anchorage Details Drawing 1PTO20S5/PP/PT/O101-01 _Prestressing Layout (Reviewed by VSL) Drawing 1PTO2095/PP/PT/0007-02 _Prestressing Layout (Reviewed by VSL) Drawing 1PTO2095/PP/PT/0007-03 _Prestressing Layout (Reviewed by VSL) Drawing 1PTO2095/PP/PT/0007-04 —_Prestressing Layout (Reviewed by VSL) Appendix - E (Risk Assessment) (3é J 1. Assessing interior of span as a possible confined space. 2. Risk Assessment : Methos Statement — Prestressing and Grouting © Copyright Reserved ‘This document's the property of VSL and must rot be copied, reproduced, dupicated not disclosed totaly or partially to ary Third Party, nor used in any manner whalsoever without prior wltlen consent of VSL. ( i)