Development of Six Lane Chittoor-Thatchur Highway from

km 0.000 to km 43.800 on Hybrid Annuity Mode under

Bharatmala Pariyojana, in the state of Andhra Pradesh and
Tamil Nadu (Package-I).

CONTENTS

Sl. Content
No

1 PRESTRESSING WORKS

2 METHOD STATEMENT FOR PRESTRESSING WORKS

3 METHOD STATEMENT FOR GROUTING OF PSC GIRDER

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Development of Six Lane Chittoor-Thatchur Highway from km 0.000 to
km 43.800 on Hybrid Annuity Mode under Bharatmala Pariyojana, in
the state of Andhra Pradesh and Tamil Nadu (Package-I).

1. PRESTRESSING WORKS

A) Scope: -

The scope of work in post tensioning of superstructure as per section 1800 of

MoRTH, which consists of following operations at site:

1) Cutting of H.T Strand, laying and profiling of tendons.

2) Stressing of tendons.

3) Grouting of tendons.
These are dealt in detail in the following sections in this method statement.

B) Equipment’s & Accessories

Equipment's and Accessories Required for Stressing

1) Hydraulic Jacks
2) Hydraulic Pumps
3) Bearing plate

4) Permanent wedges

5) Master wedges

6) Calibrated pressure gauges

7) High-pressure hose pipes

8) Low-pressure hose pipes

9) Abrasion cutter

2. METHOD STATEMENT FOR PRESTRESSING WORKS

A. Uncoiling of Strand:-

The operation will be carried out on elevated platform to prevent contact with
earth / mud. The strand will be uncoiled very carefully since the end of the coil
has the tendency to fly with a jerk. The elevated platform on which the coil is
placed is termed as coil dispenser with supporting frames to avoid jerking of the
strand end.

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Development of Six Lane Chittoor-Thatchur Highway from km 0.000 to
km 43.800 on Hybrid Annuity Mode under Bharatmala Pariyojana, in
the state of Andhra Pradesh and Tamil Nadu (Package-I).

B. Cutting of Strands and Identification: -

The uncoiled strands will be laid on the elevated platform and cut to the required
length as given in the drawings including the jacking length required at the time
of stressing. The cutting of strands will be done by abrasive cutter only.

C. Insertion of Anchor Head:-

1) After concreting, preparations will be made for stressing. The stressing

operation will be carried out after the concrete attains the required
compressive strength as given in approved drawing.

2) The strands should be free from dust, grease, and oil stains.

3) The threading method adopted is the ‘Push-Through' method. In this

method the H.T Strands are individually or a few no’s inserted in the duct.

4) The anchor head is cleaned well (to remove anti corrosive oil which was
applied before dispatch). The taper holes should be free from dust and oil
stains.

5) The H.T Strands will be inserted one by one into the anchor head, and they
will be secured firmly by wedges.

D. STRESSING OPERATIONS FOR TENDONS:-

1) Stressing of Tendons will be carried out after the concrete attains the required
strength. Before stressing the following points will be checked mentioned
below.

a) Calculate the maximum pressure required as per the jack details and
apply correction factors depending on the calibration certificate of the
pressure gauge and the jack.

b) Note the stressing sequence of the tendons as per drawing. This is

recorded in the stressing format.

c) The wedges will be cleaned to remove dust or oil traces from the threads
of the wedges.

d) The grip lengths of the H.T Strands will be cleaned to remove dirt or oil
traces.
3|Page
Development of Six Lane Chittoor-Thatchur Highway from km 0.000 to
km 43.800 on Hybrid Annuity Mode under Bharatmala Pariyojana, in
the state of Andhra Pradesh and Tamil Nadu (Package-I).

2) The wedges will be inserted on to the Strands and assembled by a wedge-

seating tool to seat properly on the tapered holes of the anchor heads.

3) The hydraulic jack with wedge seating (collar plate) device will be
assembled over the Anchor Head.
4) The hydraulic jack and wedge-seating device will be connected to a hydraulic
pump by high and low-pressure hoses.

5) The stress operations will begin after aligning the hydraulic jack and an
initial force will be given to remove any slackness in the tendon. Ram
movement will be noted from this stage. The pressure will be increased
slowly in stages up to the maximum required pressure. Ram movement will
be noted for each increment of pressure.

6) Zero correction will be calculated by drawing a graph from the pressure

and elongation readings recorded so far. The total elongation will be
observed from these readings.

7) If elongation values correspond with calculated values (within tolerance),

the wedges will be locked by wedge seating device. The draw-in of the
wedges (slip) at both the stressing ends will be measured.

8) After wedges locking, the jack will be released and shifted to another tendon
as per stressing sequence. All observations will be recorded in the Stressing
Report.

3. METHOD STATEMENT FOR GROUTING OF PSC GIRDER

A. Grouting Procedures as per appendix 1800/111 MoRTH 5th Revision: -

A. The purpose of Grouting is to provide permanent protection to the post- tension

tendon against corrosion and to develop a bond between the prestressing Strand
and the surrounding concrete.

B. Equipment’s & Accessories: -

1) Pressure grouting pump.

2) Agitator
3) Mixing Drum

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Development of Six Lane Chittoor-Thatchur Highway from km 0.000 to
km 43.800 on Hybrid Annuity Mode under Bharatmala Pariyojana, in
the state of Andhra Pradesh and Tamil Nadu (Package-I).

4) Grout caps
5) Marsh cone
6) Thermometer
7) Cube moulds
C. Materials Required for Grouting: -

▪ Cement grout will be prepared at site by mixing cement, water, Ice and
Cebex 100/200 or similar as per the approved mix design.

D. Pre-Grouting Operations: -

▪ The protruding Strands will be cut with a Abrasion cutter.

▪ A Grout Cap will be fixed to the anchor head by fasteners.

▪ The tendon duct will be washed well with water and then this water will be
flushed by compressed air.

E. Grouting Operations: -

▪ After 24 hours completion of stressing of the tendon, grouting will be

commenced.

▪ The mixing of the grout will be done in the mixing drum as per the mix design,
the grout will be agitated thoroughly by agitator. The temperature of grout
will be maintained at 25 degrees Celsius by adding Ice to the water.

▪ Grout temperature maintained as required will be injected into the tendon

in a continuous manner without any interruption.

▪ The consistency of mixed grout from the mixing drum will be checked
before commencement of grouting.
▪ Grouting will be started with a low pressure of injection. As the grout fills
up and flows forward, the pressure will be increased and allows flow of grout
through outlet until required consistency come out.
▪ At this stage, pumping will be stopped. The outlet will be closed, and the
pumping will be resumed. The pressure will be increased and we will be
allowed to build 3 to 5 Kg / Sq. Cm. This pressure will be maintained for about
1 min.

▪ After this the inlet will be closed and grout pipe will be shifted to another tendon.

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