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tr-6 CONSTRUCTION
(i)
I t.6.8 Post-Tcnsioning sl l-8
(ii)
SECTTON II. PRESTNESSIN.G FOR STRUCTURES
11.1 DESCRIPTION
This Work shall consist of thc construction of all prestressed concretc structut€q
inciuaingcasting, tensioning grouting, ttoragc, transporting and launching; all thc
lineq lcvcl, grades, dimensions and crss-scctions as shorrn on thc Drawinp aod
u dirccted by the S.O.
tt.z Crencrrl Reoulrcments For Ssfct
Thc Oontractor shall be cntirely responsible for thc safe srccution of tcnrioning
operations. Specialist precautions against accidcnt shatl be taken whcn *orking
with or ncar tcndons which have bcen tensioned or are in thc process of being
teruioned.
The typcs of prestressing shall be to the details as shorvn on thc Drawings. They
shall be either one or both of the follotringl tj?esr-
11.4 II{ATERIAI,S
1) High tensile steel wire and seraen wire stecl strand shall comply with the
requirements of BS 5896.
2') Nincteen wirc stecl strand shall comply with requirements of BS 4757.
3) High tcnsile alloy stcct ban shall comply with thc requirements of BSi
441,5.
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Prestressing tcndorn shall be clean and fiec lrom pitting loosc rust and t<xrsc
scale at thc timc of incorporation in the Work.
The Conlractor shall submil rcsults of rclaxation lcsts lor thc approval of the S.O.
The C.ontractor shall also supply in thc forms, as requircd by the S.O.,
manufacture's certificates of tests on samples taken from cach parcel of stecl to
be use. Where dirccted by the S.O., tbe Contractor shall arrange for samples of
the stcel intended for use in thc Work to be testcd at an approved independent
testing laboratory. If such samples fail to comply with thc relevant Srandards,
notwithstanding any prwious acceptance on the manufacture's test crrtificate, that
steel represented by the sample may be rejccted by the S.O and shall require its
removal from Site.
Materials and workmanship for concretc shall comply with all thc clauses on
concrete for structures of Sectioo 9 of this Specification, except in such respects
as they may be modified by the provisions of the remainder of this Section.
All sheaths sball be either as described on lhe Drawings or of the form, gauge
and dimensions appropriate to the prestressing system employed, subject to the
approval of the S.O. The sheaths sball be able to withstand the pressure due to
the height of the concrcte during concreting.
Where sheaths are used, the number of joints shall be kept to a practicable
minimum and each joint adcquately sealed against the ingress of any material.
Joints in adjacent sheaths shall be staggered by at least 3@mm.
Sheaths shall also be kept free of any matter detrimental to the bond between the
sheath and the concrete cxcept for the material sealing a sheath joint. The
internal and external surfaces ofsheath shall be clcan and free from pitting, loose
rusl and loose scale at the time of incorporation in the Work-
When duct formcrs arc used, they shall bc coated with a relcase agent only with
thc approval of thc S.O, Duct formers shall not be cxtracted until the concrete
has hardcned sufficiently to prevcnt it being damaged.
Thc cnds of all ducs or shcaths shall tre sealcd and protectcd until the tcndon
is threaded through and the stressing opcratfulns arc commenced.
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I 1.4.5 Ancbortges
All anchoragc dcviccs shall withstand a force of not less than95%o oltlp' spccitied
minimum ultimatc tcnsile strength of the tendon without damage from excessirre
deformation tlr draw-in.
AJI anchorage devices shall be free from rust, pitting, blorr-holes and shall bc in
accordance with the manufacture's specified tolerance.
Unlcss otherwise directed or agreed as a result of grouting trials, the grout shall:
(b) have a watcr:cement ratio as low as possible consistent nitb tbe neccssary
workability and under no circumstanccs shall the water:cemcnt ratio
excecd 0.45:
Watcr shall be addcd. to the mixer first, then tbe cement. When these are
thoroughly mixed, tbc admixture, if any shall be added. The grout shall be mixed
for a minimum of 2 minutes and until a uniform consistency is obtained, before
grouting commenccs. Mixing shall not be done by hand.
The compressive strength of 100mm cubes made of the grout shall exceed
17N/sq.rnm at 7 days. Cubes shall be cured in a rnoist atmosphere for the fint24
hours, and subsequentlY in water.
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11.5. EOUIPMENT
ll.5.l Moulds
Tbc Contractor shall supply and maintain an adequate number of moulds fior thc
casting of prestrcssed Elrudtures. The moulds shall bc manulacturcd from stecl
forms, and shall be rigidly stitlcncd to prevena any distortion. Wherc nesessary,
the mould shall allow for the incorporation of form vibrators of approved
capacity.
The tensioninS apparatus shall also mect to the following general requirements:-
(a) The means of attachment of the tcndon to thc jack or tersioning devicc
shall be safe and secure.
(b) Where two or morc wires or strandr arc strcssed simultancously, thcy
shall be approximately of equal lcngth bcturccn anchorage poins at the
datum of load and extension mcasurem€nl The degree of variation shall
be small comparcd with cxpected cxtension.
(c) The tensioning apparatus shall be such that a controlted total forcc is
imposed gradually and no dangerous secondary strcsses arc induced in the
tendons, ancborage or @ncrcle.
(d) Thc force in the tendons during tensioning shall bc mcasured by dircct-
reading load cells or obtained indirectly from gauges fittsd in tbc
hydraulic spten to dctermine the presure in the jacls. Facilitics shall be
provfrled for thc measuremcnt of the cxtension of the tendon and any
mor€ment of thc tcndon in the gripping dsvic€c. The load-measuring
device'shalf be calibrated to an accuracy within x2Vo and checked at
intervals as appropriatc to thc approval of the S.O.
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1153 Groutlm Eaulpment
Thc eguipment shall have a sensibly constant delivery pressure not exceeding
lN/sq.mm. All piping to the grout pump shatl havc a minimum of bends, valves
and cbangcs in diameter.
All bullles to the pump shall be fitted with 1.18m sieve straincrs. The prgssure
gauges sball be calibrated before they arc first used in the Works and thereafter
if required by the S.O. All equipmcnt, especially piping, shall be thoroughty
washed through rvith clean water after every series ofoperations and at the end
ofusc for each day. The interval between washings shall not exceed 3 hours. The
equipment shall be capable of maintaining Pressure on completely grouted ducts
and shall be fitted with a valve that can be locked off without loss of pressure in
the duct.
11.6 CONSTRUCTION
Cables shall be assembled with the individual wires or strands ly'ing parallel to the
cable axis, and they shall be bound with strong adhesive tape or wire to maintain
them parallel during handling. Spaccrs shall be provided where shown on the
Drawings or as dirccted by the S.O.
Sheaths shall bc assembled from lengths not less than 3 metres except where
makc-up lcngths are required; cotrplen shall be screwed home fully. Sheaths shall
bc screwcd into the back of anchorages, adaptors being used, whcre required. All
joints shall be scaled by binding with approved waterproof adhesive tape.
The methods of inserting cables and sheaths, handling and placing of completed
cablcs shall be to the manufacture's instructions and to the approval of the S'O.
Shcathing puncturcd or clamaged in any way shall be made good to the approval
of thc S.O. Should the damage bc extcnsivc, complcte replacement at the
C-ontractor's expensc shall bc required.
Sheaths shall bc supported at points not more than 9ffimm apart. Thc C,ontractor
shall provide such additional supports as arc nccessary and for cradles for
supprlrting the shcaths on thc rcinforccmcnt. The sheaths shall be fixcd into
position so as to avoid displaccmcnt during placing of conctete, vibration or by
workmcn or construction traf{ic.
Should the Cnntractor proposcs to thread cablc.s into ducts after concrctc has
bccn plaed had scl, rhc S.O. will rcquirc to bc satisficd that cablcs can in fact
bc pullcd through thc ducLs.
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All ducts shall be chcckcd for bk*kages duc to entry o[grout or damage during
placing and the C.<rntractor shall be rcsponsible for remedial measures. During
concret"ing and within 24 hours after concreting, thc Contractor shall demonstrate
that all cables alrcatly in shcaths beforc concrcting arc still completcly free to
movc.
Cables shall be carelully aligncd to the hcights and lines shown on the Drawingp
and shall not deviate therelrom by more than 3mm at any point.
Beforc concreting, the lines and levels of all sheaths shall be subject to the
approval of the S.O.
Sheaths shall be checkcd for leakages to the satisfaction of the S.O, before
coocreting.
All wires or strands stressed at the same time shall be taken from the same
parcel. Each cable shall be tagged with its number and the coil grumber or
numbers of the steel used.
Tendons shall not be welded within the length to be tensioned. Tendon shall be
sawn or cropped unless other methods of cutting are agrced by the S.O.
Tendons shall be built into the Works strictly in accordance with the system which
is being employed.
Cables shall not be kinked or twisted and individual wires or strands shall be
readily identifiable at each end of the member. No strand which has become
unravelled shall be used in the Works.
Where tendons are coupled, care shall be taken that the couplers are clean and
free from grit. High tensile steel bars shall be jointed by an approved high
efficiency coupler which shall dcvelop not less than 95Vo of the specified
minimum ultimate strength of the tendon. Coupler shall be provided where shown
on the Drawings.
Particular carc shall bc takcn in placing aod compacting thc concrctc around the
anch<lragcs.
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The working surfuce.s of all anchorages shall be clearn<l prior to tensioning.
rToPnerary ancnorages $nall Dc nanoteo ans us€o srncuy tn aoooroEnce wrm tbc
Manufacture's instructions and recommendations and to thc appro*al of the
s.o.
Wires and strands shall be in coils of sufficiently large diameters to ensure that
the wires and strands pay off reasonably straight.
All cutting of u'ire, strand or bar shall be carried out using a high-speed abrasive
cutting wheel, friction saw or any mechanical method approved by tbe S.O.
In post-tensioning syotem, the cutting action shall be not less than one diameter
from thc anchor.
tl.6.7 P4etensionlnq
Whcrc prctensioning methods are used, the tension shall be fully maintained by
some positive means during the period between tensioning and transfer. When
concrete has reachcd the age at which tests cubes taken from it bad attained the
specific transler strengtb, the stress shall be transferred gradually, without
severancc of the tcndon, to minimise shock. Ttre tendons shall then be trimmed
back fiush to thc face of the concrete. The tendons shall bc protected against rust
by apptying neat epoxy rcsin of a suitabte quality or an epoxy mortar to the ends
of thc tcndons. Thc mcthod of apptication and the thickness of the protcctive
coating shall be to thc satislaction of the S.O.
Whcn tcndons are dcscribcd on the Drawing as debonded from the concretc, they
shall be covered with sleeves of P.V.C. or othcr matcrial approvcd by the S.O'
The ends of the slccvcs shall bc tapcd to thc tcndons to prcvent the ingress of
concrclc.
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Further provbiorn for thc hn, t!"€s of tcndon aligpmcnts are ar follou,rr
a) Stnhbt tcndom
In the long-line method of prctcrsioning sullicient localor platcs shall be
distributed througbout thc length of the bcd to etrsur€ that rhc wircs or
strand$ are maintained in their proFr pcition during coocrcting Wherc
a number of units are made in linc, thcy shall bc frce to slidc in the
direction of their length and thrs permit transfer of the prcstressing force
to thc concrete along thc whole line.
b) Dellected lendons
For singlc tendon, the deflector in contact with thc tendon shall hanc a
radius of not lcss than 5 timcs the tcndon diameter for wire or l0 times
thc tcndon diameter for strand, and the total angle of deflection shall not
excecd 15" .
11.6.8 Posl-lensionine
Where wires, strands or bars in a tendon are not strcssed simultaneous, the usc
o[ spaccn shall bc in accordance with the recommendations of the s]stem
manufacturc and approvcd by thc S.O.
For dcflectcd tcndons, the de0ector in contact. with the tendon shall, wherc
possiblc have a radius of not less than 50 times the diameter of tbe tendon, and
thc total anglc of deflcction shatl not excccd l5o . lffhcre the radius is less than
50 timcs the diamctcr of the tcndon and tlrs anglc deflection exceeds l5o , the
loss of strength of the tendon shall be determined by test and due allorrance made.
fmmcdiatcly bcforc tensioning, thc Contractor shall prow that all tcndoos arc
frec to move in thcir shcaths or ducls and that mcmbcn arefrcc to accnmmodrtc
ths horirrntal and vertical rnovcmcnts duc to lhe application of prcrtrcss-
su{|
Consrelc shall not bc rtrcsscd until it har rcachcd at least the age at whicb tr+o
teil sub6 taken lrom it attain thc spccilicd transfer strength.
The tcst cubcs shall bc made and tested in accordance with MS 26 but shall be
cured in similar conditions to the concrete to wbich they relate. Notwithstanding
Section 9 of this Specification, tbc Contractor shatl cast a minimum of 9 cubec for
each day of concrcting for prestressed structures.
The Contractor shall establish the datum point for measuring extension and jack
prcssure to the satisfaction of thc S.O. Thc movement of the jack ram will not be
taken as tbe atension of the tendons.
The order in which lcndons shall be tensioned shall be in accordance with the
Drawingp or as directed by the S.O.
Stressing shall be cirrried out at a smooth and even rate. The maximum permitted
loads in the tendons will not normally be more than 80Vo their ultimate strength
but the actual tension to be applied shall in all cases be as agreed with the S,O.
Strcssing from one end only will be permitted only where indicated on the
Drawings. All othcr tendons shall be stressed tom both ends simultaneously.
Whcn stressilg from ooe end only the pull-in at tbe end remote from the jack
shall be accuratcly measured aod the appropriate'allowance madc in the
measured extcnsion at the jacking end..
The forces in the tendons shall be determined either by means of jack pressure
gauge reading or by approved load cells, and shall be checked against the
measured cxtensions of thc tendons.
Allorvance shall be made for slip of the tendon during anchoring in accotdancc
with the manufacturer's recommendations. The actual slip shall be rer:ordcd for
each individual u'ire or strand, and wberc this excceds the amounl for which
allowance has been made the tcnsioning procedure shall be carried out afresh,
i[ Dscssary with a new tendon, at the Crntractor's expense.
After anchoring, tbe jack force shall be decreased gradually and evenly without
shock to tbe anchorage, steel or concrete.
If it is nccessary to croP thp tendons to enable the ducts to be Srouted, this shall
be delayed as long as practicable up to the time of grouling. In all other cases,
unless agccd otherwisc by the S.O., tcndons shall not be cropped tess than 3 dap
aftcr grouting.
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The Contractor shall kecp full record of all tcnsioning operations including the
measured extcnsions, pre$sure gauge or load ccll rcadings and amount of pull-in
at each anchoragc. Copies o[ thcsc records shall bc verified on Site by the
Contractor snd the S.O. immcdiately aftcr cach tensioning.
Grouting trials shall be undertaken when required by the S.O. and all grouting
wbrls shall be carried out in the presence of the S.O.
Ducts formed without sheathing shall be filled with water at least one hour before
grouting. Sheathcd ducts shall not be filled witb water unless required by tbe S.O.
Where ducts have been fillcd with water, it shall be blown out by compressor air.
All anchorage shall be sealed before grouting.
Ducts shall be gr<rured a$ soon as practicable after the tendons in them have been
stressed and the S.O.'s permission to commence has been obtained. Grout shall
bc injected in one continuous operation and allowed to ilow from the vents until
the consistency is equivalent to that being injected.
Ttrc maximum pcrmitted grout prcssure at ttle point of injccti<ln inlet shall be 1.0 ,
N/sq.mm. Whenever the pumping pressure excecds 1.0 N/sq.mm and thc one-way
grout flow cannot bc maintaioed, the ducts shall be immediately ilushed clean
with watcr and the obstruction clcared.
Vents shall be scaled consccutively in the direction of flow and the injection tuhe
sealed undei prcssure until lhe grout has set. Tbe filled ducts shall be protccted {
to thc .salisfaction of thc S.O.to cnriure that thcy arc not subjected to sbock or
vibration for onc day. Two days aftcr grouting, lhe level of grout in the injectio
and vcnts tubcs shall be inspccted and made good if ncccssary"
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Thc Contractor shall kecp full records of grouting inctuding the date each duct
was groutcd, the proportions of the grout and any approvcd admixtures uvd, the
pressure, details of any interruptions and topping up rcquircd. Copies of thcse
records shall be supplied to the S.O. within thrcc dap of grouting.
Whcrc thcre are blockagcs, thc Cr:ntractor shall providc lacilities and attcndance
lor ttre radiographic testing of ducts.
11.7.1 Genenl
The precast prestressed beams shall be designed to carry the deck formwork and
insitu concrete without propping during the construction of the deck. Should the
C-ontractor choose to make any adjustments to the quantity and disposition of
the prestressing tendons he shall submit his proposals to the S.O. for approval-
Although the design of the proposed adjustmena shall be checked, it'shall not
rclieve the Contractor of his responsibility for the design.
Thc precast concrete construction shall comply with Scctitln 9 of the Specification
on C,oncrete for Structures, excePl in such resPects as they may be modified by
the provisions of the remainder of this Section.
1r-7.2 StoraeQ
When members are stored, they shall be firmly supported at such bearing
positions to ensure that strqcs induced io them are always less than the
perm issible design stresses.
Members shall be lifted or supported only at the points described on the Drawing
and shall be handled and placcd without impact.
The Contractor shall submit to the S.O. for his approval, the method and
sequence he intends to adopt, for launching or lifting of the precast beams. The
Contractor shall be responsiblc to provide all neccssary equipment and rnachinery
for the launching and lifting of the heams.
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