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SABS 1200 G F - 1 9 8 4

SOUTH AFRICAN BUREAU OF STANDARDS

S'l'ANDAR13 I ZEE S P E CI F ICAT1ON

for

C I V I L ENGINEERING CONSTRUCTION

GF : PRESTRESSED CONCRETE

A p p r o v e d by t h e
CODNCIL O F THE
SOUTH AFRICAN
BUREAU O F ST'ANDAFDS
on 6 J u n e 1984

O b t a i n a b l e from the
S A BUIiEAU O F STANDARDS
Pri-vate B a g X191

Pretoria
0001 R e p u b l i c of South A f r i c a .

Telegrams : C o m p a r a t o r , Pretoria
Telex : 3-626-SA
P u b l i s h e d and p r i n t e d i n t h e R e p u b l i c of South A f r i c a by t h e
South A f r i c a n B u r e a u of Standards

ISBN 0-626-07011-2

Gr6

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3

GF

SABS 1200 GF-19R4

Prestressed concrete

PRESTRESSED CONCRETE
CONTENTS
Page Number

Clause

1.
2.
2.1
2.2
2.3
2.4
2.4.1
3.
3.1
3.2
3.3

3.4
3.5
3.6
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5.
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.5
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
5.6
5.7
5.7.1
5.7.2

5.7.3
6.

6.1
6.2
7.
7.1

7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.4

7.4.1
7.4.2
8.

8.1
8.1.1
8.1.2
8.2
APPENDIX A.

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SCOPE
INTERPRETATIONS
Supporting Specifications
Application
Definitions
Explanation of Terms
Classes of structure
MATERIALS
General
Grouting Materials
Tendons
Anchorages and Couplers
Sheaths
Storage Capacity and Deteriorated Material
PLANT
Ceneral
Tensioning Apparatus
Attachment of Tendon to Tensioning Device
Mixing Equipment for Grout
Pumping Equipment
Mechanisms for Deflected Tendons
Casting Beds, Moulds, Formwork and Staging
Handling, Lifting and Stacking Equipment
CONSTRUCTION
General
Safety Precautions
Royalties
Tendons
Surface condition
Straightness
Cutting
Positioning of tendons and sheaths
Tensioning procedure
Grouting of Sheaths
General
Sheaths
Grout
Grout mix design
Mixing
Injection of grout
Grouting during cold weather
Compressive strength of grout
Permanent Protection and Bonding of External Tendons
Handling and Erection of Prestressed Units
Handling, transportation and storage
Assembly and erection
Forming structural connections
TOLERANCES
General
Prestressing
TESTING
General
Load Tests on Individual Prestressed Units
General
Non-destructive (service) test
Destructive (ultimate) test
Special test
Tests on Structures and Parts of Structures
Age at test
Test loads
Measurements during tests
Acceptance criteria
Tests on Grout
Bleeding
Compressive strength
MEASUREMENT AND PAYMENT
Measurement
General
Prestressing
Scheduled Items

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5
5
5
5
5
5
5
5
5
5
6

6
6
6

6
6
6
6
6

6
6

7
7
7

7
7
7

7
7
7
7
7
8
8
8
8
9

9
9
9
9

9
9
9
9
10
10
10
10
10
10
10
10
10
10
10
11
11
11
11
11
11
11
11
11
11
11
11
12

14

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5

SABS 1200 GF-1984

Prestressed concrete

SOUTH AFRICAN BUREAU OF STANDARDS

STANDARDIZED SPECIFICATION
for
CIVIL ENGINEERING CONSTRUCTION
GF : PRESTRESSED CONCRETE
1.

SCOPE

1.1

This specification covers requirements for prestressed concrete construction by means of pretensioning or
post-tensioning.
NOTE: The standards referred to in the specification are listed in Appendix A.

2.

INTERPRETATIONS

2.1

SUPPORTING SPECIFICATIONS. Where this specification is required for a project, the following
specifications shall, inter alia, form part of the contract document (NOTE: Items (b) and (c) below may
or may not be bound in the document):
a) Project specification;
b) SABS 1200 A or sABs 1200 W. or SABS 1200 AH, as applicable;
C) SABS 1200 G.

2.2

APPLICATION. This specification contains clauses that are generally applicable to prestressed concrete
construction. Interpretations and variations of the specification are set out in Portion 2 of the
project specification (see 2.1).

2.3

DEFINITIoPS. For the purposes of this specification the definitions and abbreviations given in the
applicable of the specifications listed in 2.1 and the following definitions shall apply:
Anchorage. A device comprising all the components and materials required to retain the force in a tendon
and to transfer this force to the concrete.
Characteristic strength. The manufacturer's guaranteed tensile strength of the prestressing steel below
which not more than 5X of test results in a statistical population are expected to fall.
Coil. One continuous length of finished strand or wire wound in closely packed concentric rings.
Coupler. A device that is located at the interface of two stages of prestressing and that couples the
tendons in the two stages.
Fixture. An item such as a bolt, anchorage, bearing or the like, cast or grouted into concrete.
Length of lay. The longitudinal distance, or pitch, of one complete turn of a helix.
Post-tensioning. A method of prestressing in which tendons are tensioned after the concrete has attained
its initial minimum specified strength.
Prestress. The stress induced in concrete by tendons.
Prestressed concrete. structural concrete in which effective internal stresses have been induced by
means of tendons.
Pretensioning. A method of prestressing in which tendons are tensioned before concrete is placed.
Pull-in. The elastic shortening of a tendon caused by movement of the tendon within the anchorage or
coupler components due to seating and gripping action during or immediately after transfer.
Sheath. A conduit that encloses a tendon and temporarily or permanently allows some movement between the
tendon and the surrounding concrete.
Strand. A number of wires of the same nominal diameter spun together in helical form round a core wire
of slightly larger diameter.
Tendon. A tensiooed element used in a concrete unit or structure to impart prestress to the concrete.
(A tendon may consist of one or more bars, wires or strands.)
Transfer. The action of transferring force from a tendon to the concrete. (It may cover work carried
out both on the Site and also during the manufacture of prestressed concrete units.)
Vent. An opening in a sheath that can be adjusted to control the release of air, the drainage of water
or the injection or release of grout.
Wire. R cold-drawn wire produced from a suitably treated hot-rolled rod. (The surface of a wire is
initially smooth but the wire may subsequently be indented or crimped by a mechanical process and given a
final stress-relieving treatment.)

2.4
2.4.1

EXPLANATION OF TERMS
Classes of Structure. A prestressed structure may, for the purpose of assessing its likely behaviour, be
classified as follows on the basis of the design limits placed on the flexural tensile stress:
Class 1 : No tensile stresses;
Class 2 : Tensile stresses, but no visible cracking;
Class 3 : Tensile stresses, but surface width of cracks do not exceed
a) 0,l mm for members exposed to a particularly aggressive environment such as the very severe conditions
defined in Subclause 2.4.1.4 of S M S 1200 G; and
I
b) 0,2 mm for all other members.

3.

MATERIALS

3.1

GENERAL. In addition to complying with the requirements of 3.2-3.6,

relevant requirements of Clause 3 of SABS 1200 G.

3.2

GROUTING MATERIALS. Materials used for grouting shall comply with the following requirements:
a) Cement shall be ordinary portland cement or rapid-hardening portland cement complying with the
relevant requirements of SABS 471;

materials shall comply with the

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S A W 1200 GF-1984
Prestressed concrete

b) Ssnd shall comply with the requirements of SABS 1083 for sand fur concrete except that the grading
shall be such that 100% passes through a 1,18 nun sieve;
c) Ldmixtures shall not contain chlorides, nitrates, sulphicles or sulphites. When aluminium powder is
used, the total expansion of the grout shall uot. exceed 10%.
3.3

TENDONS. Tendons shall consist of high tensile wire, strand or alloy steel bars. Wire and strand shall
comply with the applicable requirements of BS 5896. Bars shall be of cold-worked high tensile st.ee1and
shall comply with the requirements of BS 4406 for hot-rolled and processed bars.
The characteristic strength of the steel shall be as specified in the project specification or, in the
event of the Contractor electing to use, subject to approval, a steel with a different characteristic
strength, the strength of the steel shall be such that the structural components in which the steel is to
be employed perform in an approved manner the duty for which they were designed.
In addition, steel to be bonded to the concrete as pretensioning reinforcement shall not be galvanized
and shall be deformed either by indenting or crimping.
The Contractor shall obtain from the manufacturer in respect of each consignment of steel tor tendons, a
certificate stating the quality and the mechanical properties, and shall provide the Engineer with a
COPY

3.4

ANCHORAGES AND COUPLERS. hnchorages and couplers shall comply with the requirements of BS 4447, and the
Contractor shall provide the Engineer with the manufacturer's test certificate ( s ) as evidence that the
anchorages and couplers do so comply.

3.5

SHEATHS. Sheaths for tendons shall be of an approved type that takes into account the design friction
characteristics between sheath and tendon, and shall be of metal or of any other acceptable material.
Except for vents (see 2.3) each sheath shall be mortar-tight and shall be sufficiently strong to prevent
puncture, damage or excessive deformation during concreting operations. A sheath may be provided with a
threaded entry to permit the use of a screwed connector from the grout pump (see 4.5).
Where so directed, the Contractor shall submit samples of the sheaths that he proposes to USC.

3.6

STORAGE CAPACITY AND DETERIORATED MATERIAL. The storage capacity provided shall be adequate and shall
comply with the requirements of Subclause 3.7 of SARS 1200 G. Storage of all prestressiny steel shall be
above the ground and the steel shall be fully protected from the weather.
Material that has deteriorated, become contaminated or been damaged shall not be used in the Works and
shall be removed from the Site without delay.

4.

PLANT

4.1

GENERAL. In addition to complying with the requirements of 4.2-4.8, plant and equipment (including
formwork) shall comply with the relevant requirements of Clause 4 of SABS 1200 G.

4.2

TENSIONING APPARATUS. The tensioning apparatus shall be capable of applying to a tendon a controlled
force than can be increased gradually and in such a way that no significant secondary stresses are
induced in the teirdon, anchorage or concrete.
The Contractor shall supply suitable hydraulic tensioning jacks which may be manually, mechanical ly or
electrically operated. Each jack shall be so equipped that the force in the tendon during tensioiiing can
be measured by direct-reading load cells or be obtained directly from pressure gauges fitted in the
hydraulic system.
Such measuring devices shall have an accuracy of 29% or better.
A certified
calibration chart showing the relationship between the measuring device readings and the force on the ram
for both ascending and descending ram movements, shall be available on the Site. The Contractor shall
maintain all tensioning jacks in good working order, and he shall ensure true and accurate readings by
testing, calibrating and servicing the jacks before stressing each structure, or every 3 months during
stressing operations for a structure, whichever is the more frequent.
He shall provide the necessary facilities for measuring the elongation of each tendon to an accuracy of
within 2% or 2 nun, whichever is the smaller value.

4.3

ATTACHMENT OF TENDON TO TENSIONING DEVICE. The Contractor shall provide safe and secure means for the
attachment of each tendon to the jack or tensioning device.

4.4

MIXING EQUIPMENT FOR GROUT. The Contractor shall provide mixing equipment of a type that is capable of
producing grout of a uniform and smooth consistency. The equipment shall incorporate
a) sujtable screens for removing lumps and other foreign materials from the grout;
b) facilities to enable high speed mixing to be carried out continuously for between 2 and 4 min ; and
c) facilities for continuous agitation of the grout (by slow-speed mixing) while grouting is in progress.

4.5

PUMPING EQUIPMENT. The contractor shall provide grout pumping equipment that is capable of developing
and maintaining a pressure.of at least 0,7 MPa. Each pump shall be fitted with a pressure gauge and with
a controlling device that will effectively prevent the build-up of excessive pressure.

4.6

MECHANISMS FOR DEFLECTED TENDONS. The Contractor shall, where necessary, provide suitable mechanisms for
so holding down or holding up tendons that frictional losses are minimized. In addition the said
mechanism shall be such that
a) for a single tendon, the deflector in contact with the tendon will have a radius of at least 50 times
the tendon diameter in the case of a wire, or 10 times the tendon diameter in the case of a strand, and
that the total angle of deflection will not exceed 15O; and
b) it will so effect the transfer of prestressing forces to the concrete and at the same time release the
hold-down and hold-up forces, that any tensile stresses that develop in the concrete during the process
do not exceed the permissible tensile stress limits associated with and normally accepted for concrete of
the strength specified (see 5.4.5.1(k)).

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SiWS 1200 GF-1984

Prestressed concrete

4.7

CASTING BEDS, MOUI.I)S, FORMWOIK AND STAGING. Casting beds shall be properly aligned and levelled.
Moulds and formwork shall be such that the finished concrete surfaces are smooth and even and have true
clean axrises.
Formwork and staging shall be so designed that there will be no undue restraint on the elastic shortening
of the concrete at the time of transfer of prestress.

4.8

HANDLING, LIFTING AND STACKING EQUIPMENT. The Contractor shall provide adequate equipment for so
handling, lifting and stacking precast units that they are protected from permanent damage caused by
stresses induced during handling or stacking, or by the use of slings, chains or hooks.

5.

CONSTRUCTION

5.1

GENERAL. In addition to complying with the requirements of 5.2-5.7 the Contractor shall comply with the
relevant requirements of Clause 5 of SABS 1200 G.

5.2

SAFETY PRECAUTIONS. The Contractor shall take particular precaution during and after tensioning to
protect persons from injury and equipment from damaqe that may be caused by a sudden release of stored
energy in the event of failure of any tendon or equipment.

5.3

ROYALTIES. Where applicable, the Contractor shall pay any royalties that may be due on whatever
prestressing system is adopted and he shall indemnify the Employer against any claims that may arise from
any infringement or alleged infringement of patents.

5..4
5.4.1

TENDONS
Surface Condition. The Contractor shall ensure that all prestressing tendons and internal and external
surfaces of sheaths are, at the time of incorporation of the tendons and sheaths in the structural unit,
free from pitting, loose millscale, loose rust, paint and oil, grease, soap and other lubricants, and any
other harmful matter. A tendon may be cleaned by wire brushing or by passing the tendon through a
pressure box containing carborundum powder. Solvent solutions for cleaning shall not be used without the
approval of the Engineer.
Any prestressing steel or sheath which, in the opinion of the Engineer, is excessively rusty or otherwise
unsuitable, shall be removed from the Site.
Straightness
a) Wire and strand. Wire and strand shall be in coils of diameter such that the curvature of the
uricoiled wire or strand complies with the applicable requirements for curvature given in BS 5896.
b) Bars. Prestressing bars, as delivered, shall be straight, except that where small adjustments will
achieve straightness, such adjustments may be made by hand on Site under the supervision of the Engineer.
Straightening of bars shall be carried out at ambient temperature. If the ambient temperature is less
than 5OC, any heating required to raise the temperature of the bars above 5OC shall be done by means of
steam or hot water.
Bars that are bent in the threaded part shall be rejected.
Cuttinq
All cutting to length and trimming of ends shall be done by means of
a) a high-speed abrasive cutting wheel, friction saw or any other mechanical method approved by the
Engineer; or
b) an oxy-acetylene cutting flame, excess oxygen being used to ensure a cutting rather than a melting
action and the cutting being so done that neither the flame nor splashes come into contact with the
anchorage or with other tendons.
In the case of post-tensioning systems, cutting shall be done as specified in 5.4.3.1(a),
the heating
effect on the tendon being kept to a minimum and being such that the temperature of the tendon adjacent
to the anchorage does not exceed 20OoC.
The tendons or the elements of the tendons, as relevant, shall be cut or released in the order that will
produce the least lateral eccentricity of prestress at any stage.
Positioning of Tendons and Sheaths
Subject to the tolerances permitted in terms of Clause 6 , tendons and sheaths shall be accurately located
and their vertical and horizontal position maintained accurately as shown on the drawings.
The assembly of post-tensioning tendons shall be done on raised platforms or tables that are fully
protected from the weather.
The Contractor shall use separate carriers for so supporting and fixing in position the tendons or the
sheaths, as applicable, that they will not be displaced by heavy or prolonged vibration, pressure of the
wet concrete, workmen or construction traffic. Tendons and sheaths shall not be supported or fixed by
being welded to reinforcing steel. Carriers shall be so fabricated (by means of welding) and so located
that they will not unnecessarily increase friction in tendons when the tendons are being tensioned.
Sheaths shall be handled carefully to avoid their being damaged and in order to ensure that they retain
their cross-section and profile.
Joints in sheaths shall be securely taped to prevent penetration of the sheaths by concrete or laitance.
Ends of sheaths shall be sealed and protected after the stressing and grouting operation.
Tendons shall be clearly marked at each end so that extensions, slips or other movements that occur can
be accurately measured.
Tensioning Procedure
General.
The sequence of prestressing shall be such that the permissible stresses in the unit or
structure, as specified in the prestressing force diagram given in the project specification or shown on
the drawings, are not exceeded. The Contractor shall submit for approval a program indicating the
sequence in which prestressing will be carried out, and shall obtain approval before commencing each
tensioning operation.
The Contractor shall, in respect of each tensioning operation, comply with the following requirements:
a) Tensioning shall be carried out by personnel who are suitably qualified and under constant comwtent
supervision.
b) Immediately after concreting has been completed, the sheaths shall be flushed with water and the water
expelled by compressed air.

5.4.2

5.4.3
5.4.3.1

5.4.3.2
5.4.3.3
5.4.4
5.4.4.1
5.4.4.2
5.4.4.3

5.4.4.4
5.4.4.5

5.4.4.6
5.4.5
5.4.5.1

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1200 GF-1984
Prestressed concrete

SN)S

5.4.5.2

c) llnless t h e s i d e s of a i i n i t are outward s l o p i n g i n a d i r e c t i o n such t h a t u p l i f t w i l l n o t b e impeded,

s i d e forms s h a l l be removcd b e f o r e t h e u n i t is s t r e s s e d .
d ) Tensioning s h a l l be so c a r r i e d o u t t h a t t h e stress i n t h e tendons i n c r e a s e s g r a d u a l l y and a t a steady
rate.
e) While t h e ambient temperature is below OC, t e n s i o n i n g s h a l l n o t be c a r r i e d o u t w i t h o u t t h e apixoval
of t h e Engineer.
f ) Except where load c e l l s a r e used, t h e C o n t r a c t o r s h a l l make allowance d u r i n g s t r e s s i n g for f r i c t i m
l o s s e s i n t h e j a c k and i n t h e anchorage.
g ) Tendons s h a l l be s t r e s s e d t o t h e s p e c i f i e d f o r c e , and t h e C o n t r a c t o r s h a l l t a k e s u f f i c i e n t
The C o n t r a c t o r s h a l l e n s u r e t h a t t h e
measurements t o enable him t o complete a force-extension diayram.
measurement of e x t e n s i o n is c o r r e c t e d f o r any p u l l - i n of t h e tendon o c c u r r i n g a t t h e non-jacking end, and
f o r any s l a c k i n t h e tendon.
h ) Where t h e f u l l stress cannot b e a t t a i n e d i n a u n i t because of breakaqe, s l i p p a g e or blockage of a
s h e a t h , and replacement o t h a t u n i t i s n o t p r a c t i c a b l e , t h e C o n t r a c t o r s h a l l inform t h e Engineer a s t o
how he i n t e n d s to r e c t i f y t h e f a u l t .
The C o n t r a c t o r s h a l l not proceed with such r e c t i f i c a t i o n w i t h o u t
t h e approval of t h e Engineer, and such approval s h a l l n o t r e l i e v e t h e C o n t r a c t o r of r e s p o n s i b i l i t y f o r
rectification of the fau l t.
i) In t h e case o f curved tendons, or tendons made up of a number of components, or tendons loaded i n
s t a g e s , t h e Enqineer w i l l s p e c i f y t h e o r d e r of l o a d i n g and t h e magnitude of t h e l o a d f o r each component
of t h e tendon.
j) During t h e p e r i o d between s t r e s s i n g t h e tendons and covering them w i t h g r o u t , c o n c r e t e or o t h e r
permanent p r o t e c t i o n , t h e C o n t r a c t o r s h a l l e f f e c t i v e l y p r o t e c t t h e t e n s i o n e d tendons and t h e i r anchorages
and s h e a t h s from c o r r o s i o n , and s h a l l p l u g t h e ends and v e n t s of a l l such s h e a t h s .
k) I n t h e case o f p o s t - t e n s i o n i n g , t h e tendons s h a l l not be s t r e s s e d u n t i l t h e c o n c r e t e s t r e n g t h h a s been
found by v a l i d test r e s u l t s t o b e a t l e a s t e q u a l t o t h e s p e c i f i e d s t r e n g t h , when r e l e v a n t f o r t h e s t a g e
concerned.
1) I n t h e c a s e of p r e t e n s i o n i n g , t r a n s f e r s h a l l n o t t a k e p l a c e u n t i l t h e c o n c r e t e s t r e n g t h h a s been
found by v a l i d test r e s u l t s t o be a t l e a s t e q u a l t o t h e s p e c i f i e d s t r e n g t h , when r e l e v a n t f o r t h e s t a g e
concerned.
m) The C o n t r a c t o r s h a l l keep r e c o r d s of every s t r e s s i n g o p e r a t i o n and s h a l l d e l i v e r a copy of t h e s e
r e c o r d s t o t h e Engineer w i t h i n 24 h of t h e completion of s t r e s s i n g . Such r e c o r d s s h a l l i n c l u d e t h e d a t e ,
t h e c o i l number, t h e s t r e s s i n g f o r c e , t h e e x t e n s i o n , t h e u n i t number or p o s i t i o n , t h e c o n c r e t e cube
s t r e n g t h a t t h e time of s t r e s s i n g , and any o t h e r r e l e v a n t information.
F i n a l s t a g e . The f i n a l s t a g e of t e n s i o n i n g w i l l b e deemed t o have been s a t i s f a c t o r i l y accomplished when
t h e tendons comply with a l l of t h e f o l l o w i n g requirements:
a ) Each tendon s h a l l have been t e n s i o n e d t o t h e r e q u i r e d f o r c e ;
b ) The measured e x t e n s i o n on i n d i v i d u a l tendons s h a l l be w i t h i n 6% o f t h e t h e o r e t i c a l e x t e n s i o n ;
c) The average of t h e measured e x t e n s i o n s of a l l t h e tendons i n a u n i t s h a l l n o t d e v i a t e from t h e
t h e o r e t i c a l e x t e n s i o n by more t h a n 3%;
d ) The release or p u l l - i n , or b o t h , as r e l e v a n t , s h a l l , i n t h e c a s e o f each tendon, b e w i t h i n 2 mm o f t h e
designated value.
Should any i n d i v i d u a l tendon o r group of tendons f a i l t o comply with any of t h e a p p l i c a b l e requirements
of ( a ) - ( d ) above, t h e C o n t r a c t o r s h a l l i m e d i a t e l y a d v i s e t h e Engineer and o b t a i n a r u l i n g a s t o t h e
procedure to b e followed.
I n t h e e v e n t of t h e f r i c t i o n of any tendon being too high, t h e C o n t r a c t o r may, s u b j e c t t o t h e approval of
t h e Engineer and a f t e r having f i r s t r e l e a s e d t h e t e n s i o n i n t h e tendon, i n j e c t an approved water-soluble
l u b r i c a n t i n t o t h e sheath.
The c o s t of any remedial and c o r r e c t i v e measures ( i n c l u d i n g t h e r e l a x i n g and t h e r e t e n s i o n i n g of
tendons) t h a t have been n e c e s s i t a t e d by f a i l u r e o f one or m o r e tendons t o comply w i t h t h e requirements
given above s h a l l be f o r t h e C o n t r a c t o r ' s account.
A f t e r t h e t e n s i o n i n g has been approved by t h e Engineer, t h e C o n t r a c t o r may c u t o f f t h e p a r t of t h e
tendons p r o j e c t i n g beyond t h e anchorages. He may c u t t h e p r o j e c t i n g p a r t of tendons b e f o r e g r o u t i n g i s
carried out.
,

5.5
5.5.1
5.5.1.1

5.5.1.2

5.5.1.3
5.5.2
5.5.2.1
5.5.2.2
5.5.3

GROUTING OF SHEATIIS
General
When t h e s h e a t h s of p r e s t r e s s e d c o n c r e t e u n i t s are being g r o u t e d , t h e C o n t r a c t o r s h a l l e n s u r e t h a t
a) t h e s t r e s s e d tendons are p r o t e c t e d , and
b) a n e f f i c i e n t bond is achieved between t h e s t r e s s e d tendons and t h e c o n c r e t e o f t h e u n i t .
When s h e a t h s a r e being g r o u t e d t h e C o n t r a c t o r s h a l l , i n o r d e r t o comply with t h e requirements g i v e n i n
5.5.1.1 above, e n s u r e t h a t
a) e f f i c i e n t equipment is used;
b ) workmanship i s c a r e f u l and s u p e r v i s i o n competent;
c) t h e g r o u t i s mixed with a water/cement (w/c) r a t i o o f between 0,38 and 0,43;
d ) t h e g r o u t t o b e i n j e c t e d h a s good f l u i d i t y and low s e d i m e n t a t i o n (i.e. a l o w tendency t o b l e e d ) i n t h e
plastic state;
e) t h e g r o u t develops a c c e p t a b l e d u r a b i l i t y and d e i i s i t y w i t h l o w s h r i n k a g e i n t h e hardened state;
f ) t h e g r o u t forms an adequate bond w i t h t h e tendons and t h e s i d e s of t h e s h e a t h s ; and
9 ) t h e methods adopted s h a l l be such t h a t they can be c a r r i e d o u t on t h e S i t e e f f e c t i v e l y and r e a s o n a b l y
easily.
When so r e q u i r e d by t h e Engineer, t h e C o n t r a c t o r s h a l l undertake b l e e d i n g tests (see 7.4.1) or g r o u t i n g
t r i a l s , o r both.
Sheaths
The C o n t r a c t o r s h a l l p r o v i d e and use a v e n t a t each crest i n t h e case of a p r o f i l e d s h e a t h , and a t
i n t e r v a l s of not more t h a n 1 5 m, i n t h e case of a s t r a i g h t sheath.
A l l s h e a t h s s h a l l be thoroughly c l e a n e d b e f o r e g r o u t i n g i s c a r r i e d out.
Grout.
An approved p l a s t i c i z e r s h a l l be used i n t h e g r o u t .
The g r o u t s h a l l be such t h a t , when it i s
t e s t e d i n accordance with 7.4.1,
b l e e d i n g does not exceed 2% a f t e r 3 h or 4% max. when b l e e d i n g i s
complete, and t h e b l e e d water s h a l l be re-absorbed f u l l y a f t e r 24 h.
I
-

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SABS 1200 GF-1984
Prestressed concrete

5.5.4

5.5.5

5.5.6

5.5.7

Grout Mix Design. At least one m n t h before the commencement of grouting on the Site, tests shall be
carried out to determine whether the grout complies with the requirements of this specification for
fluidity, bleeding and strength. After a grout mix design that yields a grout complying with the said
requirements has been agreed upon between the Contractor and the Engineer, the mix design shall not be
altered unless trial mixes of any altered mix are made and tested and the written permission of the
Engineer for use of the altered mix has been obtained.
Mixing. When grout is mixed, water shall be added to the mixer first and then the cement. Only after
the water and cement have been thoroughly mixed shall any admixture or sand be added. Mixing shall then
he continued until a uniform consistency is obtained but, in any event, for at least 2 min. The w/c
ratio of the mix shall be as low as possible within the range 0,35-0,s by mass, and the mix shall have
the required fluidity. Mixing shall not be done by hand.
Injection of Grout. The Contractor shall carry out grouting as soon as practicable after the tendons
have been stressed, but not before the stressing records have been approved.
Grouting operations shall comply with the following requirements:
a) The method of injectinq grout shall be continuous and slow enough to avoid segregation of the
components of the grout and to ensure complete filling of the sheaths and complete encasement of the
tendons. The pump suction intake shall at all times during the grouting operation be kept below the
surface of the grout.
b) The Contractor shall allow grout to flow successively from each intermediate vent and from the free
end of a sheath until the consistency of the effluent grout is equivalent to that of the grout injected.
He shall then close off the inlet opening firmly and close off intermediate vents, one after the other,
following the direction of the flow. IIe shall carry out further injections as necessary to fill any
cavities that are found.
c) When injection of grout has been completed, the injection tube shall be sealed off under pressure
which shall be maintained until the grout has set.
d) Twenty-four hours after the injection of grout, the vents (if any) shall be opened, and any voids that
may be present shall be filled with grout poured in under gravity.
Grouting during Cold Weather
a) When the weather at the Site is cold, the Contractor shall keep accurate temperature records statina
maximum and minimum air temperatures and the temperatures (at the time of grouting) of the units to be
grouted.
b) The Contractor shall not use any materials in which snow, frost or ice is present and he shall ensure
that the sheaths and equipment are completely free of snow, frost and ice.
c) Except where the unit is so heated as to maintain the temperature of the grout above 5OC for at least
4 8 h after the grout has been placed, the Contractor shall not place any grout when the temperature of
the unit is below 5OC or is likely to fall below 5OC during the next 48 h
d) Except when the heating of sheaths is accompanied by a general external heating of the unit or
structure, sheaths shall not be heated in any way.
e) Grout materials shall be maintained at a temperature of at least 5OC.
Compressive Strength of Grout. Cubes (of sides 100 mm) made of the grout used, and cured at a temperature of 22-25OC and a relative humidity of at least 90% for the first 24 h, and then kept in water at
22-25OC. shall have a compressive strength exceeding 20 MPa at 7 d

5.5.8

5.6

PERMANENT PROTECTION AND BONDING OF EXTERNAL TENDONS. After having been tensioned, external tendons in
structures such as circular structures for water storage, shall receive permanent protection against
mechanical damage and corrosion.
Such tendons shall be so encased in a dense concrete, mortar or grout that acceptable durability and
density with low shrinkage is developed in the hardened state and an adequate bond is formed with the
tendons and with the parent concrete. The encasement material may be applied by means of compressed air
or by any other means that can effectively and reasonably easily be used on Site. An approved
plasticizer may be incorporated in the grout mix.
When so required by the Engineer, the Contractor shall undertake preliminary tests on the encasement
materials he proposes to use, to obtain a mix design that will yield a concrete, mortar or grout
complying with the requirements for durability, density, shrinkage and bonding given above. After a mix
design has been agreed upon by the Contractor and the Engineer, the design shall not be altered unless
trial mixes have been made and tested, and the written permission of the Engineer for the use of the
altered mix has been obtained.
Protection and bonding of the tendons shall be effected within 7 d after final tensioninq of the
tendon(s1, or as specified on the drawings, but shall not be undertaken without the prior approval of the
Engineer.
After the encasement or bonding has been completed the anchorages shall be encased in concrete or qrout,
or completely coated with a corrosion-resistant material. The protection provided shall be such that it
prevents the ingress of water and aggressive agents.

5.7
5.7.1
5.7.1.1

HANDLING AND ERECTION OF PRESTRESSED UNITS

Elandling, Transportation and Storage
Prestressed units shall not be removed from castinq beds until the units have been sufficientlv stressed
to ensure that they resist, without permanent damage, all stresses induced during such movement.
The position of lifting and supporting points, the method of lifting and the type of equipment and
transport shall be subject to approval by the Engineer.
The Contractor shall place legible and indelible identification, date, location and orientation marks on
each unit, as and where necessary.
Packing pieces shall be such that they do riot discolour or otherwise permanently damage the units.
Units shall be so stacked that the accumulation of trapped water and dirt is prevented.
Assembly and Erection
General. The method of assemblv and erection agreed to with the Ensineer shall be strictly adhered to on
Site. Immediately after a unit has been placed in position and before the lifting equipment is removed,
temporary supports or temporary connections between units shall be provided as necessary. The final
structural connections shall be completed as soon as is practicable.
Temporary supports during construction. Temporary supports shall be so arranged and designed by the
Contractor that account is taken of
a) all construction loads (including wind loads) likely to be encountered during the completion of
connections between any combination of precast and in-situ concrete structural units;

5.7.1.2
5.7.1.3
5.7.1.4
5.7.1.5
5.7.2
5.7.2.1

5.7.2.2

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1200 GF-1984
Prestressed concrete

SABS

5.7.3

10

b) when appropriate, movements, includiug those due to shrinkage of concrete and to any tensioning;
c) the need to prevent any local collapse from becoming progressive should a unit break accidentally and
strike against another during erection; and
d) proper finishing and curing of any in-situ concrete, mortar or grout.
Temporary supports shall not be removed or released until adequate strength has been attained in the
in-situ portion of the structural connections.
Forming Structural Connections. The Contractor shall
a) ensure that he has obtained the Engineer's approval of a unit before commencing the structural
connection;
b) inspect each structural connection to ensure that it complies with the design requirements set out in
the project specification;
c) ensure that each precast unit is free from irregularities of such size and shape as may lead to damage
caused by stress concentrations;
d) ensure that the contact surfaces of each precast unit have been suitably prepared to achieve the
specified bond between the precast and in-situ concrete, or to enable the specified frictional resistance
to be developed at a bearing;
e) pay particular attention to
1) checking that the location of reinforcement and structural steel sections in the ends of precast units
are within the specified tolerances, and
2 ) the introduction of any additional reinforcement needed to complete a connection;
f) carry out the packing of connections in accordance with the assembly instructions;
9) when connections between units, particularly the horizontal joints between successive vertical lifts,
are load-bearing and are to be packed with mortar or concrete, carry out tests to ensure that the
material for the connections is suitable for the purpose and that the proposed method of filling will
result in solid joints; and
h) ensure that the composition and w/c ratio of in-situ concrete or mortar used in any connection is as
specified, and that in-situ material is thoroughly compacted.
No expanding agent shall be used without the prior approval of the Engineer.

6.

TOLERANCES

6.1

GENERAL. The relevant tolerances specified in Clause 6 of SABS 1200 G shall apply, in addition to those
specified in 6.2.

6.2

PRESTRESSING. Prestressing tendons shall be placed and maintained in position within the limits of the
following permissible deviations:
Permissible deviation, mm
Degree of accuracy
..-111
11
I
a) In the direction of the width of the unit
*
*
Units of width up to 200 mm
10
-++ 20
*
Units of width over 200 mm
*
b) In the direction of the depth of the unit
*
Units of depth up to 500 nun
+ 5
*
*
Units of depth over 500 mm
-+ D/ioo but not
more than 25
* As stated in the project specification, if required.

_ I

.
I

..................................
...................................
..................................
...................................

7.

TESTING

7.1

GENERAL
In addition to the relevant tests for concrete given in Clause 7 of SABS 1200 G, units, structures and
grout s h a l l , when so required (see 7.2.1). be subjected to the appropriate of the tests given in 7.2-7.4.
The relevant test methods given in BS 5896 and BS 4486 shall apply to steel wire, strand and bars used
for stressing.

7.2
7.2.1

LOAD TESTS ON INDIVIDUAL PRESTRESSED UNITS

General. hhere so required in terms of the project specification and scheduled, the Contractor shall
carry out the applicable of the tests given in 7.2.2-7.2.4.
In every case the test loads shall be
applied and removed incrementally.
Non-destructive (Service) Test. The unit shall be supported at its designed points of support and loaded
for 5 min with a load equal to the sum of the characteristic dead load plus 1.25 times the characteristic
imposed load. The deflection shall then be recorded. The maximum deflection measured after application
of the load shall conform to the applicable requirements of the project specification.
The recovery shall be measured 5 min after the removal of the applied load and, thereafter, the load
shall be re-imposed. The percentage recovery after the second loading shall be not less than that after
the first loading and not less than 90% of the deflection recorded during the second loading. A t no time
during the test shall there be, in the opinion of the Engineer and in the light of a reasonable
interpretation of relevant data, any sign of weakness or faulty construction in the unit(s) under test.
Destructive (Ultimate) Test.
The unit shall be supported at its design points of support and loaded to
its ultimate design load. The unit shall not fail within 15 min after the application of the test load.
A deflection exceeding 1/40 of the span will be regarded as failure of the unit.
Special Test. F o r very large units or units not readily amenable to the tests specified in 7.2.2 and
7.2.3
(such as columns, the precast parts of composite beams, and units designed for continuity or
fixity), the testing arrangements shall be agreed upon between the Contractor and the Engineer before
such units are cast.

1.2.2

7.2.3
7.2.4

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11

7.3
7.3.1

7.3.2

7.3.3

1.3.4

7.4
7.4.1

7.4.2

SABS 1200 GF-1984

Frestressed concrete

TESTS O N STRUCTURES AND PARTS OF STRIJCTURES

3 e at Test. Where particular tests on structures or on parts of structures are required in terms of the
project specification and are scheduled, the Contractor shall carry out the tests as soon as possible
after the expiry of a period of 28 d that commences at the time of the placing of the concrete. When a
test is required for a reason other than that the quality of the concrete in the structure has to be
assessed, the test may be carried out earlier than the end of the said 28 d period, provided that the
concrete has already reached its specified strength.
When prestressed concrete is tested, allowance shall be made for the fact that the effective prestress at
the time of testing will be greater than the value that will prevail during the working life of the
structure.
Test Loads. Test loads shall be applied incrementally and as follows:
~a) The test loads to be applied for the determination of the limit states of deflection and local damage
shall be the characteristic dead and imposed loads. When the ultimate limit state is being considered,
the test load maintained for a period of 24 h shall be the greater of
1) the sum of the characteristic dead load and 1,25 times the characteristic imposed load, and
2) 1,125 times the sum of the characteristic dead and imposed loads.
Should any part of the characteristic dead load not be in position on the structure, compensating loads
shall be added as necessary.
b) Where only part of a structure is to be tested, special precautions shall be taken to ensure that all
the units actually under test are subjected to the full test load, proper allowance being made for load
sharing between units.
Measurements during Tests. Measurements of deflection and crack width shall be taken immediately aftrr
the application of each incremental load. In the case of the 24 h sustained load test, measurement of
deflection and crack width shall be taken at the end of the 24 h period of loading, after removal of the
load and after the 24 h recovery period. Sufficient measurements shall be taken to enable side effects
to be taken into account. Temperature and weather conditions shall be recorded during the test.
Acceptance Criteria. Subject to due allowance being made for the possible effects on a structure or part
of a structure of variations in temperature and humidity during the period of the test, the following
acceptance criteria shall apply:
a) For Class 3 prestressed concrete structures, units that are intended to be exposed to very severe
conditions, as defined in Subclause 2.4.1.4 of SABS 1200 G, the maximum width of any crack measured
immediately on application of the test load for local damage shall not exceed 0,07 mm and, for all ot.her
units, the width of any such crack shall not exceed 0,13 nun.
For Class 1 and Class 2 prestressed
concrete structures, no visible cracks shall occur on application of the test load for local damage.
b) For units that are spanned between two supports, the deflection measured immediately after application
of the test load for deflection shall not exceed 1/500 of the effective span.
NOTE: Before cantilevered parts of structul-es are tested, the criteria for acceptance shall be agreed
upon between the Contractor and the Engineer.
c) If the maximum deflection in millimetres, occurring during a period of 24 h under the test load, is
less than 4 0 L2/d, where L is the effective span in metres and d the overall depth of construction in
millimetres, it is not necessary for the recovery to be measured and the criteria of (d) and (e) do not
apply.
2
d) If the maximum deflection is equal to or more than 4 0 L / d as given above and if, within 24 h of the
removal of the test load for the ultimate limit state calculated in accordance with 7.3.2, a Class 3
prestressed concrete structure does not show a recovery of at least 75% of the maximum deflection that
occurred during the 24 h under load, the loading shall be repeated.
The structure will be regarded as having failed to pass the test if there is not a recovery of at least
75% of the maximum deflection that occurred during the second loading.
e) If, within 24 h of the removal of the test load for the ultimate limit state calculated in accordance
with 7.3.2, a Class 1 or Class 2 prestressed concrete structure does not show a recovery of at least R 5 %
of the maximum deflection that occurred during the 24 h under load, the loading shall be repeated.
The structure will be reyarded as having failed to pass the test if the recovery after the second loading
is not at least 85% of the maximum deflection that occurred during the second loading.
TESTS ON GROUT
Bleeding. A sample of the grout shall be placed in a covered graduated cylinder of diameter
approximately 100 mm and fitted with a thermometer. The height of the grout in the cylinder shall be
100 nun.
The temperature of the grout shall be kept at 20 2 2O C and bleeding shall be checked for
compliance with 5.5.3.
Compressive Strength. Grout shall be sampled in accordance with SABS Method 861 and tested in accordance
with SABS Method 863 for compliance with 5.5.8.

8.

MEASUREMENT AND PAYMENT

8.1

MEASUREMENT
General. Except as otherwise required in terms of 8.1.2 and 8.2, the terms of Clause 8 of SABS 120b G
shall be applicable to prestressed concrete.
Prestressing. Where prestressing is sufficiently detailed on the drawing or in the schedule, measurement
Where different systems compete with one another at the tender stage,
will generally be by mass.
measurement may be made in terms of units that are the product of force and length or in terms of force
units as specified in 8.2.7.1 and 8.2.7.2, respectively.

8.1.1

8.1.2

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SABS 1200 GF-1984
Prestressed concrete
8.2
8.2.1

8.2.2

8.2.3
8.2.3.1
8.2.3.2

8.2.3.3

8.2.3.4

8.2.4

8.2.5

8.2.6
8.2.7
8.2.7.1

12

SCHEDULEI) ITEMS
Establishing on Site, Maintenance and Dismantling of Pensioning Beds and Equipment
This item will he scheduled only where the Contractor is required to establish facilities on
the Site as part of his temporary works for tensioning in-situ concrete.
The rate shall cover the cost of setting up, operating, maintaining and, on completion of
the work, dismantling the brds and equipment.
Manufacture of Precast Prestressed Units
The dimensions or the drawing number of individual units will be stated.
Separate items will be scheduled for different qualities of concrete and different types and
sizes of units (small units of volume not exceeding 0.5 m3 of formed concrete will be
grouped).
The rate shall cover the cost of royalties, if any, of all material including concrete and
reinforcinq and prestressing steel, of formwork and moulds, and of all labour and equipment
required for mixing, placing, compacting, floating off, stressing, tenlporary stacking and
curing.
Casting of Prestresspd Units on Site (i.e. casting and tensioning of units in place in the
structure or alongside the structure or on a casting bed on Site).
Formwork, concrete and reinforcing steel. The provisions of SABS 1200 G shall apply to
formwork, to concrete and, except as provided for in 8.2.3.3, to reinforcement.
Supply and install sheathing and tendons (characteristic strength stated)
Separate items will be scheduled for tendons of different materials, cross-sections, types
of construction, etc.
The mass of tendons measured will include the mass of any loop or fan.
The rate shall cover the cost of supplying sheathing complete with threaded inlets and with
vents, of fixing the complete sheathinq to formwork, of supplying and making up tendons
(including the cost of spacers and waste) and of threading the tendons through the sheaths.
supply and install anchorages and couplers to suit tendons
a) Anchorage at jacking end
b) Anchorage at dead end
c) Coupler at jacking end
d) Coupler at dead end
The rate shall cover the cost of supplying, fabricating, storing, handling, protectinq,
forming a recess for the anchorage and, when relevant, for the coupler, installing and
fixing the complete anchorage assembly (including, when relevant, the coupler) to formwork,
together with the cost of the reinforcement design for the whole anchorage zone and the cost
of the helical reinforcement supplied a& part of the anchorage assembly.
The rate for loop or fan anchorages shall exclude the cost of the length of tendon forming
the loop or fan, which will be measured under 8.2.3.2.
Post-tensioning and grouting of items supplied under 8.2.3.2 and 8.2.3.3
Separate items will be scheduled for longitudinal, transverse and vertical tensioning.
The rate shall cover the cost of
a) royalties (if any, and if not already covered);
b) site supervision and labour;
c) plant and materials;
d) prestressing of the unit by tensioning all or a few tendons at a time;
e) anchoring off or coupling, or both;
f) trimming of tendon ends; and
9) flushing out, grouting and making good the anchorage recesses.
Erection and Building-in of Units
The mass of each unit and details of connectioiis will be stated.
Separate items will he scheduled for different sizes and different positions of units to be
erected.
The rate shall cover the cost of removal from temporary stacking, erection (including the
cost of hoisting, scaffolding and temporary supports), building-in or fixing into position
and construction of all structural connections.
Miscellaneous Built-in Steelwork
Separate items will be scheduled for different masses and sizes of miscellaneous built-in
steelwork.
The rate shall cover the cost of supplying and delivering (or taking delivery, as
applicable), fixing into position and building into concrete the various items of steelwork.
Special Tests
The sum shall cover the cost of complying with the requirements for tests stated in the
project specification and in 7.2 or 7.3, as applicable.
Alternatives to Suhclauses 8.2.3.2 and 8.2.3.3
supply and install sheathing and tendons
The unit, meganewton metre, will be calculated as the product of the characteristic strength
in megapascals of the prestressing steel, the cross-sectional area of the tendon in square
metres and the length of the tendon in metres between the faces of the anchorages. In the
case of fan and loop anchorages the length of the tendon will include the length of tendon
forming the loop or fan.

.......... Unit:

....................................................

Unit:

.................. Unit:

.................................................................
....................................................................
...................................................................
......................................................................

Sum

NO.

OK

Unit:
Unit:
Unit:
Unit:

NO.

Unit:

No.

Unit:

No.

Unit:

ky or t

...............................................................................

Unit:

Sum

....................................................

Unit:

MN.m

....................

...........................................................

............................................................

NO.

NO.
No.

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13

8.2.7.2

SABS 1200 GF-1984

prestressed concrete

Separate items will be scheduled for tendons of different materials, cross-sections,

characteristic strengths, types of construction, etc.
The rate shall cover the cost of supplying sheathing complete with threaded inlets and with
vents, fixing the complete sheathing to formwork, supplying and making up tendons (including
the cost of spacers and waste) and threading the tendons through the sheaths.
Supply and install anchorages and couplers to suit tendons
a) Anchorage at jacking end
b) Anchorage at dead end
c) Coupler at jacking end
d) Coupler at dead end
The unit, meganewton, will be calculated as the product of the characteristic strength in
megapascals of the prestressing steel and the cross-sectional area of the effectively
anchored or coupled tendon in square metres.
The rate shall cover the cost of fabricating, supplying, storing, handling, protecting,
forming a recess for the anchorage and, when relevant, for the coupler, installing and
fixing the complete anchorage assembly (including, when relevant the coupler) to formwork,
together with the cost of the reinforcement design for the whole anchorage zone and the cost
of helical reinforcement supplied as part of the anchorage assembly.
The rate for loop or fan anchorages shall exclude the cost of the length of tendon forming
the loop or fan.

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Unit:
IJnit:
Unit:
Unit:

MN
MN

MN
MN

This eStandard is exclusively for use on one standalone PC. To access it from a file server or intranet constitutes a
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SABS 1200 GF-1984
Prestressed concrete

14
APPENDIX A.

APPLICABLE STANDARDS

Reference is made to the applicable issues (see Subclause 2.2 of SABS 1200 A , SABS 1200 AA or SABS 1200 AH,
applicable) of the following standards:
BS 4447
BS 4486
BS 5896
SABS 471
SARS 1083
SABS 1200 A
SAAS 1200 AA
SABS 1200 AH
SABS 1200 G

SABS Methods

as

The performance of prestressing anchorages for post-tensioned construction

Hot rolled and hot rolled and processed high tensile alloy steel bars for the prestressing of
concrete
High tensile steel wire and strand for the prestressing of concrete
Portland cement (ordinary, rapid-hardening, and sulphate-resisting)
Aggregates from natural sources
Civil engineering construction: General
Civil engineering construction: General (small works)
Civil engineering construction: General (structural)
Civil engineering construction: Concrete (structural)
861 Sampling of freshly mixed concrete
863 Compressive strength of concrete (including making and curing of the test cubes)

ISBN 0-626-07011-2

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