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Technical Report No. 72

Durable Post-tensioned
Concrete Structures
Report of a Concrete Society Working Party

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Durable post-tensioned concrete

structures

Contents

Preface vi

List of figures vii

List of tables vii

1. Introduction 1

1.1 General background 1

1.2 Technical background 2

1.2.1 Post-tensioned bridges 2

1.2.2 Post-tensioned buildings 4

1.3 Summary of progress 4

1.4 Summary of key provisions 5

1.4.1 Design and detailing 6

1.4.2 Duct and grouting systems 6

1.4.3 Grout materials 7

1.4.4 Certification of post-tensioning operations and training 8

1.4.5 Testing 9

Recommendations for durable post-tensioned

concrete bridges 11

2. Factors affecting durability 13

2.1 Corrosion of prestressing steel 13

2.2 Materials and components 14

2.3 Construction quality 14

2.4 Expansion joints 14

2.5 Construction joints 14

 2.6 Cracking 15

2.7 Duct and anchorage layout 15

2.8 Precast segmental construction and joint type 16

2.9 Proximity to seawater 16

2.10 Road salts, waterproofing and drainage 16

2.11 Access for inspection and maintenance 16

3. Available protective measures 18

3.1 Design strategy -

multi-layer protection 18

3.2 The structure as a whole 19

3.2.1 General 19

3.2.2 Bridge deck waterproofing systems 19

3.2.3 Coatings 20

3.2.4 Drainage 21

3.3 Individual structural elements 21

3.4 Prestressing components 22

3.4.1 Prestressing tendons 22

3.4.2 Ducts 23

3.4.3 Anchorage location 25

3.4.4 Anchorage details 29

4. Grouted bonded post-tensioned construction for bridges 30

4.1 Grouts and grouting 30

4.2 Vents and grout injection 31

4.3 Recommended protection systems 31

4.3.1 Prestressing system 33

4.3.2 The deck and its elements 34

4.3.3 Possible additional measures for exceptional structures 34

5. External unbonded post-tensioned construction for bridges 35

5.1 Advantages and disadvantages 35

5.2 Background 35

5.3 Structural design and basic performance requirements 36

5.4 Available protective measures 37

5.5 Detailing 37

5.6 Tendon systems 38

5.7 De-tensioning and replacement of external tendons 41

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6. Segmental construction 44

6.1 Multi-layer protection 44

6.2 Anchorage location and detailing 45

7. Void grouting 47

7.1 Overview 47

7.2 Aims of void grouting 48

7.3 Condition of bridge stock and potential demand 49

7.4 Inspection records 49

7.5 Grouting materials 50

7.6 Grouting equipment and methods 50

7.7 Determining the void characteristics 51

7.8 Flushing with water 52

7.9 Effect of existing defects 52

7.10 Specification for grouting 53

7.11 Trials 54

7.12 Quality control 54

8. Test methods for grouted post-tensioned concrete bridges 56

8.1 Introduction 56

8.2 Range of tests considered 56

8.3 The need for testing 56

8.4 Test methods appropriate in particular circumstances 58

8.4.1 Type approval at pre-contract stage (duct systems, grout materials

and procedures) 58

8.4.2 Trial grouting within a contract (geometry, materials and procedures) 59

8.4.3 Duct assembly verification before main grouting 59

8.4.4 Duct integrity after concreting or assembly of precast units, but

before main grouting 60

8.4.5 Grout stiffness test of main grouting 60

8.4.6 Automated quality control testing of main grouting 61_

8.4.7 Survey of existing grout conditions before regrouting 61

iii
 Recommendations for durable post-tensioned
concrete buildings 63

9. Durable post-tensioned concrete buildings 65

9.1 Factors affecting durability 65

9.2 Materials and components 66

9.3 Construction quality 66

9.4 Expansion joints 66

9.5 Construction joints 66

9.6 Cracking 67

9.7 Ducts and anchorage layouts 67

9.8 Proximity to seawater 69

9.9 Road salts 69

9.10 Access for inspection and maintenance 69

10. Available protective measures 70

10.1 The structure as a whole 70

10.2 Individual structural elements 70

10.3 Prestressing components 70

10.3.1 Prestressing tendons 70

10.3.2 Ducts 70

10.3.3 Anchorages 71

11. Grouted bonded post-tensioned construction for buildings 73

11.1 Grouts and grouting 73

11.2 Vents and grout injection 74

11.3 Recommended protection systems for buildings 74

11.3.1 General 74

11.3.2 Prestressing system 75

11.3.3 The slab 75

11.3.4 Possible additional measures 75

11.4 Void grouting 76

11.5 Test methods for grouted post-tensioned buildings 76

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12. Unbonded post-tensioned construction for buildings 77

12.1 Introduction 77

12.2 Recommended protection systems for buildings 7_7

12.2.1 General 77

12.2.2 Prestressing system 78

12.2.3 The slab 79

12.2.4 Possible additional measures 79

Recommendations for specifications for

durable post-tensioned concrete 8i

13. Recommendations for specifications for duct and grouting systems for
post-tensioned tendons 83

13.1 Introduction 83

13.2 Guidance on the project specification 83_

13.2.1 Trials 84

13.2.2 Grout materials 85_

13.2.3 Ducting for bridges and other aggressive environments 85_
13.2.4 Ducting for internal elements of buildings 86

13.2.5 Vents 86

13.2.6 Testing 87

13.2.7 Grouting 88

14. Contractor's quality scheme requirements 9fJ

14.1 Introduction 90
14.2 Basic quality system elements 90_
14.3 Product requirements 92_
14.4 Certification 94

References 95

Appendix A. Test methods 99

A1 Leaktightness tests for duct systems 99

A2 Grout stiffness tests 100

A3 Void sensors 101

A4 Duct pressure sensors 102

A5 Automated quality control systems 102

A6 Volume of voids before regrouting 104