BRIDGE OVER THE YAMUNA RIVER AT BARAPULLAH

PHASE III, NEW DELHI, INDIA

METHOD STATEMENT FOR

PRE-STRESSING WORKS
DSI - Project No.: L&T/BARA/PT/15 05 01-600

DSI - Document No.: L&T/BARA/PT/600-01

c 26.08.2017 Sergey R.K.G

b 21.06.2017 Sergey R.K.G

a 18.07.2017 Sergey R.K.G

Orig. 07.06.2017 Sergey R.K.G

Rev. Date Modification Designed Checked Approved

Copyright as per ISO 16016:

The copying, distribution and utilization of this document as well as the communication of its
contents to others without expressed authorisation by DSI is prohibited. Offenders will be held
liable for the payment of damages.
Table of Contents

1 GENERAL INFORMATION .................................................................. 2

2 POST TENSIONING MATERIALS & EQUIPMENT’S ........................ 3

3 PRE-INSTALLATION PROCEDURE .................................................. 4

4 PROFILING AND ASSEMBLY OF TENDONS ................................... 5

5 Stressing............................................................................................ 10

6 Grouting ............................................................................................. 11

7 Illustrative photos of used special equipment . Error! Bookmark not

defined.

8 Appendix............................................................................................ 17

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 INSTALLATION, STRESSING AND GROUTING OF THE
DYWIDAG BONDED PT-SYSTEM WITH STRANDS

1 GENERAL INFORMATION

This work instruction is prepared for the procedure of the PT works on Main Yamuna Bridge at Barapullah Phase
III, New Delhi. It describes step-by-step procedure of internal tendons, installation, stressing and grouting. The
Main Yamuna Bridge is an extra-dosed bridge. In this bridge, there are Internal bonded pre-stressing tendons
installed longitudinally in the box girder top and bottom slab and transversally deck slab of box girder. In addition
to this there are transverse tendons in outer webs terminating at deck level. Pre-stressing works are scheduled
to commence in July 2017 and will continue until June 2018.
This work procedure is generally based on the European Technical Approval ETA-13/0815 – “DYWIDAG Strand
- Bonded post-tensioning kit for pre-stressing of structures with 3 to 55 strands.” valid from 28.06.2013 to
27.06.2018. However, the other relevant codes are IS 14268 for Low Relaxation HT Strand of 15.2mm size and
other IRC provisions.
This document is related to the tendon sizes of type MA 6805, MA 6807, MA 6812, MA 6819 and MA 6827. The
tendons are assembled directly on site. All works concerning installation, stressing and grouting may only be
executed by personnel familiar with the DYWIDAG bonded PT-system with strands and who were instructed
and trained accordingly.
General rules for accident prevention must be observed as well as the special instructions given in the operation
manuals of the equipment.
The scope of work includes following activities:
 Supply of all Post Tensioning materials and equipment. However, the HT Strand shall be supplied by M/s
L&T from any of the reputed vendors in India duly tested and certified.
 Fixing of Anchorages in the formwork and connection with trumpets and ducts with leak proof jointing.
 Threading of the HT Strand in the ducts already installed in the structure.
 Stressing of the various tendons as per approved design and drawings.
 Grouting of the tendons.
This installation manual serves as a guideline throughout the complete installation process. Deviating
from this installation process may be possible and shall be discussed with DSI representatives in
advance.

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2 POST TENSIONING MATERIALS & EQUIPMENT’S

2.1. Post Tensioning Ducts: All ducts shall be Corrugated HDPE ducts in accordance with specification.

68 05 - Flat Duct with internal dimension of 25X95X2mm wall thickness & external dimension as 40X105
68 07 - Round Duct of ID 59mm and OD 74mm with 2.5mm wall thickness.
68 12 - Round Duct of ID 86mm and OD 101mm with 2.5mm wall thickness.
68 19 - Round Duct of ID 107mm and OD 123mm with 3mm wall thickness.
68 27 - Round Duct of ID 130mm and OD 146mm with 4mm wall thickness.

2.2. Post Tensioning Anchorages: All Anchorage shall be MA Anchorage unit as per European Technical
Approval ETA-13/0815 – “DYWIDAG Strand - Bonded post-tensioning. Each Anchorage unit shall consist
of following components:
- MA anchorage body
- Trumpet
- Wedge Plate
- Wedges
For details of anchorage system refer European Technical Approval ETA-13/0815 – “DYWIDAG Strand -
Bonded post-tensioning.
2.3. HT Strand: The HT Strands shall be 15.2 mm, LRPC conforming to IS: 14268 and supplied in form of coils
as per project specification.

2.4. PT Equipment: Post tensioning equipment for various anchorage systems shall be used as per following
details for this project.

PT Stressing Jacks:
- 68 05, Multi Strand Jack type HOZ 1700/ 150 or equivalent
- 68 07, Multi Strand Jack type HOZ 1700/ 150 or equivalent
- 68 12, Multi Strand Jack type HOZ 5400/ 250 or equivalent
- 68 19, Multi Strand Jack type HOZ 5400/ 250 or equivalent
- 68 27, Multi Strand Jack type HOZ 6800/ 250 or equivalent

PT Strand Pusher
PT Hydraulic Pumps
PT Grouting Pump
PT Grout Agitator

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3 PRE-INSTALLATION PROCEDURE

Before commencement of actual installation work following steps must be strictly performed:

 Check as per design and drawings that all material required for installation, such as ducts, anchorage
components and all other accessories are available in required quantity and if all these materials conform
to requirements.
 Check if working platforms and scaffolding etc. are according to H&S regulations,
 Check the provided power supply,
 Check reinforcement i.e. supports for tendons are stiff enough to bear the weight of pre-stressing Tendon.

If any nonconformity will be observed than the responsible people of L&T shall be informed immediately.

During installation of tendons the following points need to be considered:

 PE round ducts will be used for longitudinal PT in box girder top & bottom slab
 PE flat ducts will be used for transversal PT in the deck slab,
 Ducts shall be fixed to supports (rebar stools) by means of GI wire,
 Vents shall be installed at pre-decided suitable points and spacing as required by profile and specification,
 Positioning of the tendons as per Specification,
 Fixing of ducts need to be tight, so that the tendon does not move during concrete pour,
 Maximum spacing between duct supports shall be lower than 1.0m. In section with maximum tendon
curvature the spacing shall be reduced to 0.6m to 1.0m,
 Joints between anchorage body, trumpet and duct need to be tight, so that the tendon is not blocked by
Leakage of grout during concrete pour. These joints must be sealed properly either by Heat Shrink Tubes
or Masking Tapes. Please also refer to assembly drawings for more details;
 Venting ducts need to be installed at all grouting and venting points, vent tubes need to be led above the
concrete level and need to be secured against bending into concrete. Vents should be led at least 500mm
above the surface of the concrete. Vents shall be labelled to allow for easy identification,
 The vents MUST be installed on the upper surface of duct, anchorage body etc. so that the empty void in
the tendon is completely filled during grouting. Cap is vented through a vent tube which must be connected
to cap in top possible position,
 Vent tubes need to be closed by means of temporary plugs during concrete pour,
 Each tendon shall have the minimum straight section of duct as specified in ETA-13/0815;
 Additional reinforcement (e.g. helix) in anchorage zone shall be fixed by means of tie wire. The helix needs
to be positioned centrically to the tendon’s axis. Welding is strictly forbidden when strands are already
installed in ducts.

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4 PROFILING AND ASSEMBLY OF TENDONS
Installation of ducts and anchorages
This project involves three different type of constructions as under:

- Cast in-situ construction of Pier Table with Diaphragm involving longitudinal tendons of 68 12 & 68 19
and transverse tendons of 68 27 size
- Pre-Cast Segmental construction for subsequent segments S1 to S16 involving longitudinal tendons of
68 12 & 68 19 and transverse tendons of 68 05 and 68 07 size
- End span construction as cast in-situ involving longitudinal tendons and transverse tendons

Profiling of Duct
- Profiling of duct shall be always carried out as per approved drawings (good for construction).
- Ducts of correct size and dimensions shall be provided for various cast in-situ and pre-cast locations
as per drawings and coupled to required length. All duct joints must be grout tight by use of Heat
Shrink Tube or Masking Tape.
- Allowable tolerance for profile in both vertical & transverse direction shall be with in ± 5 mm for
Longitudinal tendon & ± 1mm for Transverse tendon of dimension value mentioned in drawing.
- Profile should be free from kinks and smooth.
- Bursting reinforcement of required diameter as per anchorage system should be prepared well in
advance and same should be fixed in proper position along fixing of ducts with guide.
- The basic requirement of profiling is to keep the tendon in position as per design co-ordinates till the
ducts are completely embedded in concrete. The method proposed is assumed good to
achieve above requirement, however any other better alternative can be adopted as per
site/structure suitability to achieve design profile towards maximum accuracy.

Fixing of Anchorages
Installation of MA anchorages will be performed according to the following steps:
- Anchorage Recess box shall be prepared as per angle of emergence and dimensions required as per
proposed stressing jack to be used as mentioned in drawing. A typical Cone box shall be as shown in
the sketch below:

- Threaded bolts shall be screwed in the threaded holes of the MA anchor body and PE trumpet shall be
screwed in the anchor body.
- Holes shall be drilled in formwork where the anchor bodies need to be installed (formwork forming the
recess for pre-stressing). Arrangement of holes needs to fit arrangement of threaded holes in
anchorages so that the venting connector in the anchor body is situated on top of it. Please refer to
assembly drawings for more details.
- Though pre-stressing steel will be installed after pouring of concrete but in order to ensure the clear
duct the central hole in the recess formwork has to be cut and it should be at least as big as the center
hole of the anchor body so that either a dummy PVC pipe can be inserted or strands can be installed
as the case may be.

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 - Plug the threaded rods through the drilled holes and tighten to formwork by means of washers and
nuts. Connection between formwork and installed anchorage need to be tight. Any possible visible
leaks need to be sealed (e.g. by means of silicone sealant or similar);
- Any additional reinforcement of the anchorage (e.g. helix) has to be fixed properly. Any welding
operations within the anchorage zone are allowed as long as no pre-stressing steel is installed in the
duct yet. Helix needs to be positioned centrically to tendon’s axis,
- The relevant ETA-13/0815 shall be followed for the edge and axis distances.

Prefabrication and installation of tendon sheathing shall be executed according to following steps:
- Empty ducts will be cut to the required lengths as shown on assembly drawings, vents and all other
required accessories as shown on the assembly drawings will be installed.
- Undertake full inspection of duct and mark up any areas of damage (crushing/ pinholes or tearing).
- Inspect proposed repair area and if damage results in a reduction of cross section or is deemed to
weaken the duct, discard duct.
- If damage area is deemed repairable, apply sufficient heat shrink sleeve, approx. 150mm either side
of damaged area and record repair on air test sheet.
- Before placing the pre-assembled sheathing onto reinforcement (rebar stools) it has to be made sure
that the transversal supports are installed on the correct heights according to tendon layout drawings.
Maximum spacing between duct supports shall be lower than 1.0m. In section with maximum tendon
curvature the spacing shall be reduced to 0.6m to 1.0m. Additional supports may be required in order
to assure proper positioning,
- All intermediate connections between the vent, duct, and trumpet will be sealed properly.
- Strand protrusion for the stressing anchorage side shall be led through the installed anchorage head,
- All joints between anchorage and trumpet need to be sealed,
- Tendon needs to be fixed to transversal supports by means of tie wire or similar,
- Intermediate grout port will be installed. One must be sure, that the venting duct is unobstructed i.e.
whether the connection between duct and vent is clear.
- Adequate supervision during concreting must be available to prevent any damage to the installed
ducts.

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Installation of strands

Pre-stressing HT strand shall be delivered to the site in coils. Strands with a diameter of 15.2 mm as per contract
specifications will be supplied. All HT strand Mill Test Certificates shall be provided to Site Engineer before taking
up any installation of Strand. Strands must be free from dirt and rust.

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Following steps must be strictly followed while handling the pre-stressing steel:
 Coiled strands shall be stored within the production shed at any time, so that they are protected from rain
and other weather conditions. If covered warehouse is not available it shall be protected from humidity and
its’ cover must allow air circulation.
 Strand Coils need to be stored on a horizontal and flat surface horizontally;
 Strand Coils need to be stored on timber. Wooden spacer shall be used if coils need to be stored on each
other. If coils are meant to be stacked in more than one tier, it has to be made sure, that centers of gravity of
each coil in the stack are aligned to a vertical line. Height of such stack should not be exceeded 3 coils;
 Strand Coils need to be unloaded with care and with suitable lifting devices (e.g. telehandler or similar).
Coiled strands need to be unloaded in the way that its surface is not spoiled by lifting method (e.g. lifting
slings rather than steel chains shall be used), Strand Coils shall be shifted to required installation locations
and loaded in un-coiler / Strand dispenser. It is strictly forbidden to cut any strand from coil if the coil is outside
of secured strand dispenser,
 Cutting of strand shall only be done with a cutting wheel attached to the electric grinder or table mounted
chop saw. No Strand cutting shall be permitted with cutting torch,
 It is recommended to clean the ducts by compressed air to make ducts free from dust/water or moisture if
exists prior to strand installation (threading).
 Strand are to be cut to required length as per the cutting schedule prepared in advance. Strand should be
cut to a correct length considering one side or both side stressing and type of jack used. Strands should be
cut on elevated platform with supports at regular intervals to avoid bends & sagging of strands in order to
ensure proper cutting length, as well as to keep strands clean from dirt and moisture. Strands can also be
pushed directly in the ducts from un-coiler for longer tendon lengths which manually cannot be pushed.
 Tendon/strand record sheet should be maintained for all structure in order to prepare elongation calculation
for tendons.
 Strand length protruding outside the concrete surface should be protected (covered) against dust & moisture
on both sides until stressing operation starts.

For strands installation following equipment will be use:

 strand dispenser;
 pushing machine (roll or chain);
 high pressure oil pump;
 strand guiding pipe;
 Pushing hose;
 Pushing cones;
 Lifting equipment for feeding of dispenser. The size and capacity of both dispenser and lifting device need to
be adjusted to on-site conditions and pre-stressing steel coil size.
Configuration of equipment for strand pushing will be as follows:
Strand dispenser  Pushing machine  Strand guiding pipe ( into duct)
Arrangement for simultaneous stressing of two Tendons symmetrical about centerline shall be made wherever
it is required as per design and drawing. However, the strands should be precut so that the actual pushing time
will be minimized.

Before proceeding with installation several points need to be controlled:

 Check the equipment e. g. grinder and the pushing device.
 Check working platform in respect to size and loading capacity (if scaffolding is required);

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 Is the breadth of the working area sufficient, to assemble the pushing devices (breadth scaffold > 4.00 m)?
 Is the scaffolding stable?
 Does the working platform / area meet the H & S regulations?
 Check the on-site power supply:
 Power supply needs to be stable without voltage and current spikes and fluctuations;
 Power supply needs to be secured according to H&S regulations;
 Check the operation of pushing machine. Connect the machine to power supply and carry out a test run to
check whether electric current is sufficient and if equipment is working properly.
Three major parts of equipment i.e. dispenser, pushing machine and guiding pipe are connected with a pushing
hose, through which strand will be uncoiled (pulled) by a pusher and pushed into a duct through a strand guiding
pipe. To assemble pushing devices and to proceed with strand installation the following steps need to be taken:
 Place the pushing machine in position and install the hydraulic pump. The pushing machine needs to stand
stable,
 Fix the guiding pipe at the anchorage or at the end of a duct,
 Place the dispenser in position. The dispenser needs to be positioned on stable surface,
 A coil of strands shall be lifted into the dispenser by means of a sufficient lifting device and secured inside.

NOTE: Before cutting steel bands which secure strands from uncoiling, it has to be made sure, that
arrow showing uncoiling direction is pointing in a correct direction. Arrowhead marked on a coil shall
be pointing in the direction of a pusher.

 After the coil inside the dispenser is secure the securing bands may be cut and removed,
 The dispenser output shall be connected with the pushing machine by the pushing hose, the hose from the
pushing machine shall be exceeded to the strand guiding pipe,
 The strand guiding pipe needs to be fixed by means of e.g. screws or chain to the fed tendon,
 Strand starting in the dispenser needs to be pushed manually (by hand) through the connection hose into
the mechanism of the pushing machine,

NOTE: It has to be made sure, that nobody stands directly behind the anchorage on the other end of
the tendon,
 The first strand shall be pushed gently till it appears at guiding pipe,
 A pushing cone needs to be installed on the strand,
 The strand shall be pushed inside the duct until it has required protrusion on the other end,
 The strand needs to be cut with required protrusion from pushing side. Cutting will be done using angle
grinders. Usage of flame cutters is forbidden,
 When the tendon is completed guiding pipe shall be move to next a one,
 This pushing procedure as described above will be repeated until the required number of tendons is
prefabricated.
 After the pushing process is finished a report (strand installation protocol) will be prepared. It will allow a clear
traceability of built-in material. The report will at contain at least:
 Date of works;
 Basic information about strand i.e. manufacturer, date of manufacturing;
 Information about strands i.e. charge number.

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5 Stressing
Stressing of installed tendons may be taken up as soon as design requirements are fulfilled. Please follow the
designer’s stipulation on execution drawings as well as ETA-13/0815 requirements. As stipulated on the
drawings the mean cube concrete strength shall be at least 45N/mm2 at the time of stressing:

 Stressing up to 100% of the given force – 45N/mm2

If any information is missing or is not specified DSI responsible supervisor shall discuss with L&T design
coordinator/ Clients representative for clarifications.
For stressing the following special equipment will be used:
 Stressing jack;
 Hydraulic pump;
 High pressure hoses;
 Pressure Gauges
Pressure Gauges are to be calibrated after every 6 months.
The actual Stressing operation on construction site will be done in following steps.

 All Anchorage zones shall be checked for possible cracks and honeycombs etc. well in advance at cast-in-
situ locations or in pre-casting yard for pre-cast segments having anchorages jointly with L&T site
engineer/Engineer’s representative. Any suspicions need to be reported by DSI to L&T/Engineer’s
representative and remedial measures to be decided by L&T. All anchorages beyond suspicion needs to be
cleaned from residual concrete. Especially contact surface of MA Anchor body and Jack and threads need to be
clear of dirt e.g. concrete.

 Wedge plates with wedges will be installed. Wedges suitable for actual strand diameter shall be used. Refer
to ETA-13/0815 for more details,
 Power Pack (Hydraulic Pump) shall be connected to stable Power supply without voltage and current spikes
and fluctuations,
 Pre-approved Stressing records and corrected elongation values based on theoretical E and A value
against actual value needs to be checked and made available without any nonconformities,
 Minimum actual concrete strength required to proceed with stressing operations needs to be confirmed by
L&T responsible staff/Engineer’s representative and Stressing record signed.

 All Hydraulic equipment such as Jacks, Power packs etc. must be test run before starting the actual work.
 The equipment (jack, gauge – manometer) must possess necessary calibration certificates;
 The stressing sequence of various Tendons according to the design drawing must be followed strictly. No
deviation shall be permitted without written permission of L&T/Engineer’s representative. Stressing of a tendon
may be in single step or in two steps which need to be checked against the maximum stroke of the jack and
minimum elongations values as per drawing. The corrected elongations against theoretical elongation as per
drawing are included on the stressing record for each Tendon and accordingly number of steps shall be pre-
decided.

 Step by step pressure, load and elongation shall be recorded for various stages of stressing.
 The correction factor for initial pre-decided pressure shall be calculated so that the corrected actual
elongation is calculated.
 If the calculated elongation is reached before the specified gauge pressure, continue tensioning till the
specified gauge pressure is attained, provided the elongation does not exceed 1.05 times the calculated

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elongation. If 1.05 times the calculated elongation is reached before the specified gauge pressure is attained,
stop stressing and inform the engineer.
 If the calculated elongation has not been reached at the specified gauge pressure, continue tensioning by
intervals of 5Kg/sq. cm. until the calculated elongation is reached, provided the gauge pressure does not exceed
1.05 times the specified gauge pressure.
 If the elongation at 1.05 times the specified gauge pressure is still less than 0.95 times the calculated
elongation, DSI technical department should be informed and further Stressing process for the Tendon in
question shall be put on hold until the cause is investigated in following steps:

o Check the correct functioning of the jack, pump and leads

o Check the correctness of modulus of elasticity for the lot of strand used in the tendon.
o Check the correctness of cross sectional area for the lot of strand used in the tendon.
o In case all above is found correct and there is marginal difference in the elongation the matter should
be reported to the designer for his review and decision.

 After entire stressing operation is finished the relevant stressing record shall be provided to DSI technical
team. Pre-stressing record shall at consist of following:

o Date of stressing;
o Locations of tendons e.g. section number;
o Weather conditions;
o Equipment (jack and manometer) numbers;
o Stressing records with tendons numbering and theoretical and actual values of pressure and
elongations as well as deviation value in %;

 As soon as the stressing record is approved by L&T technical team/Engineer’s representative and no
slippage is observed at the stressing end as well as dead end the strand shall be cut leaving a protrusion of
~15mm minimum beyond wedges.

As mentioned above stressing will be done with multi strand jacks. Elongation will be measured on strand
protrusion behind the jack. It will be adjusted by wedge draw in on stressing anchorage and strand elongation
between wedge plate and wedges of the jack. All values will be put into the stressing record.

A detailed step by step stressing procedure can be found in Appendix 1 of this document.
Measurement will start after Tendon is stressed up to 80Kg/Cm2 amounting to approximately 20% of the final
force. This first step which is approximately 20% of force is done in order to eliminate the wedge slip on fixed
end anchorage and to remove the slack in the strand within the duct. This reading at approximately 20% of the
force is considered as initial reading as “0” measurement and from this point actual elongation of strands will be
measured and recorded. However, the various reading shall be reasonably in a linear manner.

6 Grouting
General
Grouting of tendons shall be carried out according to Appendix -1800/III of Specification for Roads and Bridges.
The purpose of grouting of the Tendon is to provide permanent protection to the PT- Strand against corrosion
and to develop bond between pre-stressing steel and surrounding concrete. The grout ensures encasement of
steel for corrosion protection and fills the duct space which prevents water / air passage.
Grouting of stressed tendons shall be done as soon as possible after stressing operations are completed.
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General requirements for the stressed Tendons allows 2 weeks period between stressing and grouting process
without taking any additional actions. If this period is longer the ducts shall be properly cleaned with dry
compressed air in order to remove any possible moisture from the inside and the vents need to be properly
sealed. Grout shall consist of following materials:
o Water: Water used for mixing cement & admixture (if any) shall be potable water free from impurities.
Contaminated water from Sea or creek should not be used at all.
o Cement: Ordinary Portland cement should be used for preparation of grout. It should be fresh as
possible & free from any lumps.
o Admixture: It is recommended to use admixture if it improves quality of grout, i.e. increasing fluidity,
reducing bleeding & expanding grout to reduce shrinkage. Admixture should not contain chlorides,
nitrates, sulphides or any other materials which can damage steel or grout.
Testing of Grout properties:

Grout tests must be performed well in advance to ascertain the quality & properties of grout mix and recorded
for further reference. Water cement ratio must be kept as low as possible to achieve consistent & workable grout;
maximum w/c ratio should not exceed 0.45. Properties can be checked during grout trial mix and then grout mix
design with specified w/c ratio and additive (if required) is confirmed for grouting of tendons of various structures.
Recommended tests for Grout to be used are as under:
Grout Temperature: The temperature of the grout after accounting for the ambient temperature of the structure
shall not exceed 25°C. Hence, grout may have to be made with chilled water if required, and other necessary
precautions to obtain above specified grout temperature.

Fluidity (viscosity): The fluidity of the grout expressed in seconds is a measure of time necessary for a stated
quantity of grout to pass through the orifice of the cone under stated conditions.

The test shall be performed by Cone Method as per ASTM C939. The test apparatus for the test is a cone of
dimensions given in the figure below. The removable Sieve fitted on the top of cone is of 1.5mm aperture size
and it is removable type. A stop watch and a graduated cylinder of minimum 1 lt. Capacity shall be required.
The time taken to fill a liter of grout in measuring cylinder passed through the cone is recorded and the limits are
as under:
Fluidity T0 ≤ 25 sec.
T30 ≥ 10 sec.
T0 – Initial Fluidity
T30 – Fluidity at 30 minutes after mixing.

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Sieve test: The tests will be conducted with 150mm diameter sieve with aperture ≤ 2mm. After pouring at least 1l of
freshly mixed grout sieve will be checked against absence of lumps.

Bleed test: Bleeding of Grout is the phenomenon of separation of water from grout Mix. The Bleeding shall be sufficiently
Low to pevent excessive segregation and sedimentation of the grout material. The bleeding shall not exceed 0.3 % of the
volume of the Initial Volume of the Grout after 3 Hrs of rest. This test is called Wick-induced test.

Compressive Strength: The Compressive strength of 100x100x100mm cubes made out of proposed grout at 7 days
should be 27 N/mm2 and 30 N/mm2 at 28 days as per appendix 1800/III of MORTH specifications for Road & Bridge
works. Cubes shall be cured in moist atmosphere for first 24 hours and subsequently in water. These tests shall be
conducted in advance. The 7 day strength is not mandatory if 28 day strength requirement is fulfilled.

Grout trial test: This test is required to ensure that all ingredients used in the grout (water, cement & additives if
any to be used.) are good and meet the desired quality and other grout properties as per specification/standard.
With past experience and proposal of any new cement, additives; grout tests are carried out with assuming a
water cement ratio and quantity of additives to be added as per additive specification. Different W/C ratio can also
be used; until the grout meet the required criteria and the same should be fixed for grouting operation for various
structures. In any case W/C ratio (e.g. For W/C ratio 0.4 i.e. 20 letters. of water for 50 kg of cement) should not be
more than 0.45. Grout trial test should be recorded for further reference.

Frequency of testing shall be as follows:

 Fluidity test (min. three Initial tests and every time Cement or admixture is changed)
 Bleed Test (Wick-induced test) (min. one Initial tests and every time Cement or admixture is changed)
 Compressive strength test (min. three Initial tests and three cubes per grouting operation)

The entire testing procedure and frequency during the grouting operations shall be conducted in accordance to
the latest revision of method statement. However, once the continued testing compliance is proved the testing
frequency can be reviewed and reduced to a minimum with the approval.

Grouting procedure:

Cement for Grout shall be stored in closed areas away from harmful weather conditions. Cement shall be free
of cakes and lumps and shall have uniform color and texture. For grouting the following minimum conditions are
required:
Grout shall be prepared and pumped into ducts using following Grouting Equipment for mixing and injecting:

 Mixing container with mixing device (turbo mixer) for preparation of optimal colloidal grout,
 Supply container with low speed agitator to prevent grout from sedimentation,
 Grout pump.

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Grouting shall be executed according to following steps:
 Ducts shall be cleaned with clean water same as used for grouting followed by compressed air to confirm
that ducts are free and to get out possible remains of water and dirt,
 Before the commencement of grouting works sufficient volume of water needs to be supplied or an unlimited
access to water pipe providing water which provides water of sufficient pressure and quality. Water will be used
for grouting and cleaning works as well,
 It has to be made sure, that power supply is reliable and assures uninterrupted power supply during grouting
operations. An emergency generator needs to be supplied if this cannot be guaranteed.
 After first batch of grout has been mixed testing procedures described above shall be carried out.
 If fluidity and sieve test meets the requirements one shall start pumping grout into ducts,
 Pumping will start from stressing anchorage. Grouting hose will be connected to first vent. During the entire
grouting operations quantity of grout in agitator and grouting pressure on the pressure gauge need to be
observed. The maximum pressure at any time should not exceed 1 Mpa,
 As grout reaches the venting point it should be allowed to flow as long as its consistency is the same as
consistency of grout in agitator judged visually the vent shall be closed with grouting valve,
 This procedure will continue with all subsequent vents until the last vent is reached,
 After closing all valves apart from the one on the inlet vent the pump shall be turned on for a short period
of time to increase grout pressure in the tendon upto 0.5 Mpa (5 kg/cm2) for 1 minute and close the valve at inlet;
 Above stated procedure shall be carried out on each tendon,

After grouting is completed the equipment will be cleaned and all dirt and grout remains will be disposed properly.
Grouting process shall be documented with grouting record which shall include at least:
 Designation of element/section that has been grouted;
 Date of grouting;
 Grout compositions;
 Information about weather conditions;
 Material description i.e. cement type and producer, admixture type and producer
 Temperature of each grout element: water, cement, admixture (if used);
 Fluidity test results;
 Theoretical and actual volume of grout used. Because of characteristics of grouting works this will be
calculated with accuracy of about 1 mixture. Theoretical consumption of cement (consumption per meter of
tendon multiplied by total tendons length) will be compared with number of mixtures done during grouting
operations to be sure that ducts have been completely filled.
The report shall be signed by the pre-stressing works supervisor.

7 Protection of Ends
The exposed ends of the Strands and the Concrete surfaces of the ends of the units shall be wire brushed
clean of all rust, loose mortar, grease and dirt.

The exposed end of the strands and concrete surface within 50mm of tendons shall be then abraded to
provide a clean sound surface. An epoxy tar paint suitably formulated to give a dry film thickness of 80 micron
per coat, shall then be immediately applied over the ends of the tendons unless otherwise directed.

A second coat of paint shall be applied prior to drying out of the first coat.

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8 Illustrative photos of used special equipment

Attachment 1 – Dispenser and pushing machine

Photo 1 – Configuration of dispenser and pushing machine

Photo 2 – Different types of dispensers

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 Photo 3 – Pushing machine with uncovered pushing mechanism

Photo 6 – Oil pump

Attachment 3 – grouting machine and grouting equipment

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9 Appendix
This Appendix 1 describes a step by step procedure of the tensioning of pre-stressing tendons.
1. General information
Tensioning of the tendons will be performed according to:
 Designer’s guidelines such as but not limited to stressing forces, stressing sequence etc.
 Stressing records prepared by DSI
 ETA-13/0815 – “DYWIDAG Strand - Bonded post-tensioning kit for pre-stressing of structures with 3 to 55
strands.” valid from 28.06.2013 to 27.06.2018
Each stressing process will be documented with a stressing record showing theoretical and actual values of
tendon elongations and the achieved stress level (force, oil pressure in the jack).
Stressing of strands is performed within elastic range of strain-stress curve of the strands. Hence all the
intermediate values can be calculated proportionally. Designer calculates the theoretical tendon elongation
based on:
 Sheathing type (HDPE)
 Tendon layout
 Free tendon length
The elongations given by the designer already include the concrete shortening due to compression.
Designer results do not include:
 Wedge slip on stressing and fixed end anchorage. For a stressing anchorage equals 6mm. All values of
wedge slip are given in the ETA13/0815.
 Tendon elongation of the free length between wedge plate and wedges inside the jack

Project specific information will be added to stressing records by DSI. It is not allowed in any of the stressing
steps to stress the tendon with/to a force exceeding the overstressing forces from Annex 6 of the ETA.

Stressing procedure
Stressing will be performed in the following steps (after it is confirmed that all requirements from method
statement for pre-stressing works have been fulfilled):
 The stressing record sequence needs to be followed. This sequence is given by the designer.
 At first the tendon needs to be tensioned up to approximately 20% of the pre-stressing force. This is done
in order to:
o Seat the wedges of the fixed end anchorage equally with the same force,
o Remove the slack of strands alignment in the duct.

At this stage, the marking of the strands shall be done behind the jack to take as Initial point and from this point
the tendon elongation shall be measured. Marking can be done on a single strand only.
As stressing of Tendons is within elastic range of strain-stress curve of the strands the tendon elongation
between approximately 20 % to 100% of the force can be easily calculated. As soon as the required force of the
first step (50%) is achieved and the elongation is measured, if the calculated elongation is in line (±5% difference
is allowed) with the actual measured elongation, wedge shall be locked, the jack shall be released and retracted
on the tendon and second step of stressing is commenced. The jack pressure shall be again brought to 50%
and initial reading shall be recorded once again. After recording the second stage initial reading the stressing
from 50% to 100% shall be completed. Elongation shall be measured in the same manner as first step. Allowed
differences between actual and calculated tendon elongation are ±5% (same as above).

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Table below shows a blank table used to prepare a stressing record.

Clarification of values in the columns:

 Column 1 – Stressing order

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 Column 2 – Tendon designation according to designer’s drawings
 Column 3 – Designation of the stressing end (if required)
 Column 4 – Tendon length between anchor plates and/ or H-anchor (end of plastic duct)
 Column 5 – Theoretical tendon elongation
 Column 6 – Shortening of the concrete due to stressing of the Tendon
 Column 7 – Wedge slip
 Column 8 – Steel elongation on the free length between anchor plate and wedges inside the stressing
jack
 Column 9 – Sum of values from columns 5 – 8 which the total tendon elongation
 Column 10 – Concrete shortening resulting from stressing of the Tendon from this step
 Column 11 – Elongation required in order to achieve the designed force after taking into consideration
stressing of Tendons following Tendon stressed in this step
 Column 12 – Stressing force specified by the designer before seating of the wedges in the anchor plate
 Column 13 – Stressing force required to achieve stressing force from column 12 with consideration of
concrete shortening

Note: Usage of elongation measuring clamp is optional and is only one option to measure the
elongation. The decision to use it needs to be made on site by the post-tension supervisor depending on the
access to the stressing area.

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