Grouting post-tensioning ducts
Requirements for the grout—and
how to use it
U nbonded post-tensioning tendons are protected
against corrosion by coatings, wrappings, or
sheaths (see article on page 323). Bonded tendons are
installed in ducts or voids within the concrete and must
be grouted for protection after tensioning. The grouting
of tendons tensioned to 80,000 psi or more is a de-
manding job that requires special skills and materials.
Grout characteristics
Grouts to be pumped into tendon ducts must have
special characteristics to match the particular needs of
this application. Each of these characteristics is impor-
tant to the successful performance of the grout.
Fluidity: The grout should be capable of being mixed
to a highly fluid consistency so that it can be pumped as
much as several hundred feet, vertically or horizontally,
penetrating the cable strands and filling all voids as it
progressively moves through the duct. The ideal consis-
tency can be described as that of thin, hot tomato soup.
A more precise definition is that the grout passes
through a flow cone like that in Figure 1 in approximate-
ly 20 seconds (U.S. Army Corps of Engineers Specifica-
tion CRD-C 611).
Uniformity of manufactured product: Whether the
grout is prepackaged or job-mixed it must achieve the
20-second fluid flow with a minimum amount of water.
Also, after it has hardened it should assure the maximum
chemical and physical protection of the tendons. This
means that with either prepackaged or job-mixed mate-
rials stringent control should be exercised over the se-
lection of cements and chemical admixtures as well as
over the monitoring of proportioning and mixing.
Freedom from segregation or bleeding: When pumped
into the tendon ducts, the grout product must not segre-
gate or bleed at any point within the duct. Bleeding is to
be avoided because
• it results in loss of bond to tendon strands
• it causes voids, or bleeding lenses
• it results in inadequate protective coverage of the ten-
dons
• it offers a possible entry point for aggressive agents
later
Some grouts that may not bleed at atmospheric pressure
may well bleed when pumped under pressure. Under
these conditions the bleed water flows through the
HOW TO TEST THE GROUT
1. Moisten the inside surface of the cone with clean
water immediately before use.
2. Close discharge with finger and fill to top of coni-
cal section.
3. Remove finger from opening and simultaneously
start stop watch; count seconds to first break in out-
flowing stream of grout. This is the flow cone read-
ing for normal situations with readings of less than
30 seconds.
4. For thick grouts having readings over 30 seconds,
observe surface of grout in flow cone. Note time
when surface of grout disappears into discharge
opening. This time in seconds will be the approxi-
mate flow cone reading.
5. Wash flow cone thoroughly after each use.
strands of the tendons (a phenomenon sometimes
called filtering), particularly at lower temperatures.
Figure 2 shows a device developed to determine
whether bleed water was present, and if so how much, in
a vertical mock-up tendon duct 150 feet high at the Pont
Des Meules bridge in France. If bleed water collected in
the duct, it could be displaced by pumping in more grout
at the bottom, causing the bleed water to ove rf l ow the
top of the duct and be collected in the outer plastic cylin-
der.
When mixed to a 20-second flow, fluid grouts should
resist any tendency toward either segregation or bleed-
ing at in-place temperatures as low as 40 degrees F. This
temperature consideration is important because grouts
are retarded by low temperatures, giving more time for

Figure 2. To check the amount of bleeding
experienced by grouts for use on a bridge, some
vertical test ducts were surrounded with these
transparent plastic tubes.
bleeding to occur. When the temperature is lower, the
grout may be placed at a somewhat thicker consisten-
cy—for example, 30-second flow—and pumped at a
slower rate, not exceeding 2 feet per minute. The reduc-
tion in fluidity will compensate for the retarding effect
and lessen the likelihood of bleeding.
Bond and density: A necessary characteristic of the
grout, once in place, is that it expand. This expansive
action should begin while the grout is still plastic and
continue throughout the first 24 hours after the grout
has hardened, thereby putting the hardened grout in
compression. This affords good anchoring as well as
long-term protection of the structural system.
Essentials of grouting
Procedures and precautions for grouting post-ten-
sioning tendons were discussed in three articles pub-
lished in CONCRETE CONSTRUCTION in 1973 (References 1, 2
and 3). Anyone involved in the work of grouting tendons
should also be familiar with the recommended practice
(Reference 4) of the Post-Tensioning Institute.
Briefly, the necessary equipment and operations in-
clude the following:
• Inspecting ducts for flaws, misalignments, dents, sep-
arations or holes before concreting begins and making
any necessary corrections. Check with compressed air
Figure 3. End view of a grouted horizontal duct containing a
large void (left). This was formed by bleed water collecting
along what had been the top surface. On the right is a
cross section of another horizontal duct that has been
completely and properly filled. The grout set before bleed
water collected.
to be sure there is no leakage.
• Providing a high-speed mechanical grout mixer capa-
ble of producing a grout that is free of lumps or undis-
persed cement.
• Using control equipment capable of limiting the
pumping pressure to the desired value, not higher
than 300 psi gage, and also capable of allowing the
grout to be bypassed if necessary.
• Using a pump of a positive displacement type, capable
of grouting the largest tendon on the job in a continu-
ous operation of 20 minutes or less.
• Keeping the pump in operation as continuously as
possible because, if pumps are shut down for pro-
longed periods, grout will settle in both the pump and
the lines and create maintenance problems.
• Flushing the ducts, if they are cored concrete ducts,
with saturated limewater within 72 hours before
grouting. This is to remove debris. Flushing metal
ducts, howe ve r, is optional. Alternatively, ducts can be
checked with air pressure to see if there are any major
blockages or leaks. Leaks through which water can
pass should be repaired before grouting.
• Injecting grout at the proper rate, monitoring the in-
jection by watching gage pressure. At too low a pres-
Figure 4. A pump for grouting tendon ducts. A
pump of this size is said to deliver 2 to 4 gallons of
grout per minute at pressures up to 225 psi.
sure grout is not injected rapidly enough. At too high a
p re s s u re water may be caused to separate from the
grout. Gage pressures should usually be in the range of
 150 to 300 psi at the outlet from the pump, but never
more than 250 psi at the inlet to the duct.
• Keeping the grout hopper continuously full, while
pumping the grout through the duct and continually
wasting grout at the outlet end until there are no
longer any visible slugs of air or water being ejected.
• Holding the grout under pressure for at least 30 sec-
onds after the duct is filled before locking off.

References
1. “Post-Tensioning Tendons, Ducts and Grout Materials,”
CONCRETE CONSTRUCTION, 3 pages, May 1973, page 210.
2. “Post-Tensioning Grouts and Grouting Equipment,” CON-
CRETE CONSTRUCTION, 3 pages, June 1973, page 277.
3. Ensuring the Life of the Tendons, CONCRETE CONSTRUCTION,
3 pages, September 1973, page 421.
4. “Recommended Practice for Grouting of Post-Tensioned
Prestressed Concrete,” Post-Tensioning Manual, Third Edi-
tion, Post-Tensioning Institute, Phoenix, Arizona, pages 129-
135.

PUBLICATION #C830337
Copyright © 1983, The Aberdeen Group
All rights reserved