POST TENSIONING METHODOLOGY & OTHER DETAILS

Page 1 of 21

CONTENTS
Section

Description

Page No.

THE COMPANY

37

II

METHODOLOGY

8 16

III

QC, INSPECTION, MEASURING, TEST EQUIPMENT & SAFETY

PLAN

17

IV

STRESSING REPORT FORMAT

18

STRAND TRACEABILITY REPORT FORMAT

19

Page 2 of 21

ABOUT USHA MARTIN LIMITED

Usha Martin Limited, a multi unit, multi product organization, having its corporate office in
Calcutta, and a group turnover of over Rs.4000 Cores, was incorporated in the year 1960
as Usha Martin Black (Wire Ropes) Limited in technical Collaboration with Martin Black &
Co. Ltd., Scotland. The name was changed to Usha Martin Black Ltd. in 1979, then to
Usha Martin Industries Ltd. in 1983. Later it merged with Usha Belton Ltd., the jelly filled
telecom cable manufacturing unit of the group, in 1998 and has been re-named as Usha
Martin Limited from 1.5.2003. It is now the second largest wire rope manufacturing
company in the world.
Usha Martin Limited is one of the leading manufacturer of high tensile steel strands used in
the construction Industry. To keep pace with new concepts and constructional revolutions,
Usha Martin product basket encompasses a comprehensive range of LRPC strands.
During the year 1965, Usha Martin Black promoted another company named Indian
Splicing and Mechanical Accessories Ltd. in collaboration with C.C.L. Systems Ltd. of
U.K. , for manufacturing Hydraulic crimping tools, electrical fittings & accessories,
prestressing equipment & accessories, wire rope splicing equipment etc.. Subsequently, the
name of this company was changed to Usha Ismal Ltd., wherein ISMAL are the initials of
the previous name. During early nineties some of the group companies were merged under
the single name and thus Usha Ismal Ltd. became Usha Ismal Division of Usha Martin
Industries Ltd..
Since 1.4.2005, this division has been integrated with Wire Rope &
Speciality Products Division.
Usha Martin is also the leader in prestressing business in India since 1965. It started
manufacturing prestressing equipment & materials in collaboration with CCL Systems
Limited of Leeds, U.K., (presently known as CCL Stressing Systems Ltd.), which is known
worldwide for its prestressing expertise using Gifford Udall system.
Our products are also approved by Nuclear Power Corporation and exported to Middle East
countries, South East Asia, Australia etc.

Page 3 of 21

The major units of Usha Martin Limited are listed below:

Wire Rope & Speciality Products Division

Ranchi, India

North Division (Wire & Wire Rope)

Hoshiarpur, India

Steel Division (Integrated speciality steel unit) -

Jamshedpur, India

Machinery Division ( Wire Drawing Machinery) -

Ranchi, India

Rolling Mill Division ( Reinforcement Bars )

Agra, India

REGIONAL OFFICES OF USHA MARTIN LIMITED

East:

2A, Shakespeare Sarani, Mangal Kalash,

Kolkata 700 071.
Ph: 91 33 3980 0300
Fax: 91 33 2282 9029, 3980 0400

West:

168, C.S.T. Road, Agarwal Estate,

Near Metro Playing Cards, Kalina,
Santacruz (East), Mumbai 400 098.
Ph: 91 22 2652 6459, 2652 8597
Fax: 91 22 2652 6774

South:

Bangalore:

49 St. Marks Road, Jyothimahal 1 Floor,

Bangalore 560 001.
Ph: 91 80 2221 3076, 2221 1314
Fax: 91 80 2227 3552, 2221 7553

Chennai:

Plot No. L9/1, Phase II, Sipcot Industrial Park,

Sriperumbudur, Kancheepuram- 602105, Chennai.
Ph: 91 44 3717 5100
Fax: 91 44 3717 5200

Page 4 of 21

Hydrabad:

No. 11-6-27 Opposite to IDPL Factory, Balanagar,

Rangareddy, Hydrabad- 500037.
Ph: 91 93470 32765 (M)

North:

701, Suryakiran, 19, kasturba Gandhi Marg,

New Delhi 110 001.
Ph: 91 11 2331 5156, 2331 5157, 2331 5158
Fax: 91 011 2332 5586, 2332 0723

WEB:

http://www.ushamartin.com

THE ACTIVITIES OF ISMAL BUSINESS UNIT :

During the initial period, this company under the name of Indian Splicing & Mechanical
Accessories Ltd. was engaged primarily in manufacturing of Hydraulic Crimping Tool for
crimping of electrical cables/conductors, Electrical Lugs & Fittings, Hydraulic Presses
and Accessories for wire rope splicing. Later, the company entered in the field of
Prestressing and started manufacturing Pre-tensioning and Post-tensioning Systems for
wires up to 8 mm diameter. During early 1980s, it also started manufacturing Prestressing
Systems for Strands.
Besides, Usha Ismal Division also introduced services to the construction industry for
jointing of reinforcement bars by Mechanical Splicing Method and industrial services for
On Line Leak Sealing and Metalocking.
The manufacturing unit of Usha Ismal Division is located at Ranchi in the newly formed
state of Jharkhand, and is about 415 km away from Calcutta. It has got regional offices in
Calcutta, Bangalore, Bombay and Delhi.
Ismal anchorages/sheathing have been tested to meet the requirements of various codes ,
e.g., BS 4447, FIP recommendations, BIS 1343, IRC 18 etc. and have also been approved
by Nuclear Power Corporation of India. The current manufacturing capacity of Ismal for
anchorages is up to 31T13 and for sheathing up to 110 mm diameter. Besides the
anchorages and sheathing, the hydraulic jacks & pumps ( both multipull and single pull starting from 6 Ton to 500 Ton capacity to suit the present requirement of Indian customers)
and grouting machines are also manufactured in-house. Ismal post tensioning system has
been used extensively by all the major civil construction companies in many major projects.

Page 5 of 21

Page 6 of 21

Page 7 of 21

Post tensioned Buildings

Techno Park,Vadodara
Business Park, Kolkata

Synthesis

Techno Park,Vadodara

Sl.

Project

Cognizant Building, Kolkata

Location

Description

Owner/Client

Consultant

Contractor

Status

No.
1

Techno Park

Boroda,
Gujrat

30,500 m2 of
PT Slab

Larsen &
Toubro Ltd.

Larsen &
Toubro Ltd.

Larsen &
Toubro Ltd.

Completed

CTS

35,000 m2 of
PT Slab

Larsen &
Toubro Ltd.

Completed

Synthesis
Business Park

C. P. Khanra

SMS

Completed

Shopping Mall
Cum
Multiplex
Vatika City
Centre

Ranchi,
Jharkhan
d
Jaipur,
Rajastha
n
Chennai,

5,800 m2 of
PT Slab

Cognizant
Technical
Services
Bengal Shrachi
Housing
Development
Ltd.
Mathur & Kapre
Associates Pvt.
Ltd.
Vatika
Landbase
Private Limited
Arun Excello

Larsen &
Toubro Ltd.

Bantala,
West
Bengal
Rajarhat,
West
Bengal

J. S.
Sabharwal

M/s Gupta
Enterprise

Completed

M. N.
Consultants
Pvt. Ltd.
Larsen &

Wig Brothers
Construction
Pvt. Ltd.
Larsen &

Completed

5
6

Estancia IT

PT beams,
92 MT
Approx.

63,000 m2 of
PT Slab
PT beams,

Page 8 of 21

Completed

SEZ
7

Barnoporicho
y Book Mall

Tamil
Nadu
Kolkata,
West
Bengal

140 MT
Approx.
80,000 m2 of
PT Slab &
Beam

Ltd.

Toubro Ltd.

Toubro Ltd.

Bengal Shelter
Housing
Development
Ltd.

SPA
Consultants

Bridge &
Roof Co.
India Ltd.

On-going

METHOD STATEMENT FOR EXECUTION OF POST TENSIONING WORK ADOPTED

BY USHA MARTIN LIMITED.
SL. No.
1.0
1.1

DESCRIPTION
STORAGE:
LRPC Strands, anchorages, sheathing etc. to be covered for
protection from dust/rain water etc.

1.2

Sheathing to be protected from any possible damages caused

by other heavy materials.

CL / MC

1.3

Wedges to be protected from corrosion.

UML

1.4

Manufacturers test/inspection certificates for

sheathing & anchorages to be verified prior to use.

Page 9 of 21

strands,

RESPONSIBILITY
CL / MC

SC / CL

* CL Client, MC Main Contractor, SC Structural Consultant, UML Usha Martin Ltd.

SL. No.

DESCRIPTION

RESPONSIBILITY

2.0
2.1

METHOD OF TENDON PREPARATION:

Set up tendon fabrication bay in clean area of site preferably
in a lean concrete base. The bay expected to be long enough
to accommodate the largest tendon.

2.2

Computation of requisite length of the cable as stated in the

drawing, adding due allowances for profiling and gripping
length of jacks.

UML

2.3

Uncoil the strand manually without any twist/tweak.

UML

2.4

Cutting of requisite length of strands evenly by abrasive

cutter.

UML

2.5

Cleaning of strands with cotton/cloth using kerosene/petrol in

order to remove grease/oil/rust/dust etc., if required.

UML

2.6

For single end stressing, placement of dead end of strand in

basket rig, locating recess & place wedges in barrel.

UML

2.7

Extend ram of the strand in basket rig to produce the basket.

UML

2.8

Release ram, remove wedges & remove strand from rig.

Check formation of the basket.

UML

2.9

Bundle strands in tendon groups by binding wire with

identification tag for ease of installation.

UML

Page 10 of 21

MC / CL

* CL Client, MC Main Contractor, SC Structural Consultant, UML Usha Martin Ltd.

SL. No.

DESCRIPTION

RESPONSIBILITY

3.0
3.1

METHOD OF INSTALLATION:
Mark out anchorage position on slab side shutters from
drawings.

UML / MC

3.2

Mark tendon line and chair positions as per drawing on slab

UML

soffit.
3.3

Drill & cut side shutters to accept anchorage & strand

protrusions.

MC

3.4

Install manufacturers special box where necessary & chairs

for leveling the cables according to the drawing.

UML

3.5

Fix tube unit of anchorages & pocket formers to side shutters

using binding wire or fasteners.

UML

3.6

Lay sheathing/duct in line in appropriate/required length for

each tendon and couple individual lengths.

UML

3.7

Seal sheathing/duct joints by masking tape.

UML

3.8

Push the appropriate bunch of strands into the duct manually

for every tendon. For ease of threading ( strand insertion ) ,
each individual strand may also be pushed in.

UML

3.9

Fix chairs using binding wire with bottom reinforcement and

place the tendons on the supports.

UML

3.10

In case of a dead end, adequate length of strand as specified

in the drawing should remain uncovered by sheathing for
direct bonding with concrete. The end of the sheathing should
be sealed with cotton waste/masking tape to ensure that
concrete does not enter the duct.

UML

Page 11 of 21

3.11

Tie dead end basket anchorages to reinforcement ensuring

appropriate cover & the correct height above the soffit as
shown in the drawings.

UML

3.12

Fix bursting reinforcement as specified in drawing.

MC

3.13

Check installation of all ducts for line & level.

UML / CL / SC

* CL Client, MC Main Contractor, SC Structural Consultant, UML Usha Martin Ltd.

SL. No.

DESCRIPTION

3.14

Install grout vents at the end of the ducts near the dead end
using vent pipe fittings and HDPE pipes. Ensure that the grout
vent tubes protrude around 300 mm above the concrete
surface & seal the end of the vent tube by tape to prevent
damage during concreting. Restrict spacing of grout vents
within 20 m.

UML

3.15

Make
final
check
of
installation
as
per
drawings/specifications & carry out any snagging works.

the

UML / CL / SC

3.16

Inform main
concreting.

for

UML

4.0
4.1

METHOD OF CONCRETING:
During the time of concreting (by some other agency),
pertinent precautions are to be taken to ensure that the ducts
doesnt get punctured by the needle vibrator.

4.2

Necessary precaution should be taken to ensure that the

ducts, the recess formers, dead end etc. do not move away
from their respective locations at the time of concreting.

contractor

that

slab/beam

Page 12 of 21

RESPONSIBILITY

is

ready

MC

MC

* CL Client, MC Main Contractor, SC Structural Consultant, UML Usha Martin Ltd.

SL. No.

DESCRIPTION

RESPONSIBILITY

5.0
5.1

METHOD OF STRESSING:
Prior to the stressing, side shutters and recess formers must
be removed to allow installation of bearing plate & wedges.

5.2

If the pocket needs minor chipping , the same has to be

arranged to ensure adequate space for placing bearing plate
and jack.

MC

5.3

Before fixing the bearing plate, strand shall be cleaned by

petrol/kerosene at the gripping point to ensure that no
dirt/dust/rust is there.

UML

5.4
5.5

Fix bearing plate and install wedges at the live end/s.

Tighten the wedges in the bearing plate by using a
appropriate pipe and hammer to ensure that the bearing plate
seats properly on the face of the tube unit casting.

UML
UML

5.6

Modify the specific elongation upon the actual modulus of

elasticity & cross sectional area of strands, actual jack
efficiency as specified in the manufacturers test certificate.

UML

5.6

Apply 25% of initial stressing load on each strand of the

tendon, lock off the wedges and take out the jack.

UML / CL / SC

5.7

Mark the strands just at the face of the wedge with marker
pen. Apply the jack to each strand in turn & extend to
stressing load in one smooth operation, work from central

UML

Page 13 of 21

MC

strand first, outward symmetrically.

5.8

Lock off each strand after it is stressed to 100% of specified

stressing load & release the jack.

UML / CL / SC

5.9

Record the distance of the mark on each strand from the face
of the respective wedge. The extension achieved is calculated
by necessary interpolation.
Submit extension records for approval from consultant/client
prior to cutting of stands for grouting.

UML

After stressing, if there is any delay for grouting operation,

cover the strands.

UML / MC / CL

5.12
5.13

UML

* CL Client, MC Main Contractor, SC Structural Consultant, UML Usha Martin Ltd.

SL. No.

DESCRIPTION

RESPONSIBILITY

6.0
6.1

METHOD OF GROUTING:
Cut strands 25 mm clear of wedge face using abrasive cutter UML
after at least 12 hours ( preferably 24 hours ) from the time
of stressing.

6.2
6.3

Thoroughly clean the anchorage end if any rust/oil.

Fill anchorage pocket/box outs with non-shrink epoxy based
mortar & allow curing.

MC
MC

6.4

Flush the ducts by water for cleaning as well as for making

the surface wet.

UML

6.5

Blow out the water in the duct with compressed air in case
compressor is available at the job site.

UML

6.6

Setup grout agitator & pump on the top of the slab.

UML / MC

6.7
6.8

Stack fresh bagged cement (OPC) close to the mixer.

Add measured volume of water and cement to the agitator
ensuring 0.4-0.45 ratio between water & cement and also add
admixture (FOSROC -Cebex or 100 Sika- Interplast NN) and
start mixing. There should be no lumps in the mixture.

CL / MC
UML

6.9

Mix batch for about 2 to 3 minutes prior to pumping.

UML

Page 14 of 21

6.10

Start pump & discharge grout through nozzle until a good

consistency of grout transpire.

UML

6.11

Connect grout nozzle to grout inlet & commence pumping

whilst keeping the mixer topped up.

UML

6.12

Seal/tie off grout vents in direction of the flow after air has
exited & consistent grout is apparent.

UML

6.13

When the mix reaches the opposite end of the tendon & good
consistent grout is evident & no air bubble, stop the pump
simultaneously with locking off the grout exit pipe.

UML

6.14

Lock off grout inlet pipe & continue with next tendon.

UML

6.15

Maintaining the records of grouting as agreed by the site in

charge representing the customer.

UML

* CL Client, MC Main Contractor, SC Structural Consultant, UML Usha Martin Ltd.

SL. No.

DESCRIPTION

RESPONSIBILITY

7.0
7.1

QUALITY ASSURANCE:
Necessary care to be taken to avoid contact of LRPC strand
with ground.

7.2

Unpacking of LRPC strand should be done only prior to cutting

& making of cables.

UML

7.3

Check the jacks and pressure gauges for calibration before

starting of stressing. Normally, calibration is carried out by the
manufacturer & calibration certificate is provided.

UML

7.4

Check hydraulic oil in the pump visually at times & replace if

necessary.

UML

7.5

During stressing operation, no one will be allowed to stand

behind the jacks to avoid any accident.

UML

7.6

Necessary safety guards/railing etc. should be arranged

before starting stressing operation
Apply pre-stressing force gradually & subsequently, load from
the stressing jack will also be transferred to the anchoring

CL / MC

7.7

Page 15 of 21

UML

UML

wedges gradually & steadily to avoid any impact load on the

wedges/ structure.
7.7

If the calculated elongation is reached before the

specified/calculated gauge pressure reaches, stressing will be
continued till attaining the specified/calculated gauge
pressure, provided that the elongation doesnt exceed 1.05
times the calculated/specified elongation. In case the
elongation exceeds 1.05 times, necessary investigation should
be done.

UML

7.8

If the necessary elongation doesnt reach at the

specified/calculated gauge pressure, stressing will be
continued until elongation is reached provided the gauge
pressure doesnt exceed 1.05 times the specified/calculated
gauge pressure. If the elongation doesnt even reach 1.05
times of specified/calculated gauge pressure, necessary
investigation to be done.

UML

7.9

Pressure gauges should be calibrated at the time of using

those for the first time in the job site and thereafter at a
predetermined interval.

UML

7.10

Check temperature of cement (20-30 oC) & examine for lumps.

Discard lumpy bags.

CL / MC / UML

* CL Client, MC Main Contractor, SC Structural Consultant, UML Usha Martin Ltd.

SL. No.

DESCRIPTION

RESPONSIBILITY
o

7.11

Check grout temperature regularly (below 35-40 C).

CL / MC / UML

7.12

Check flow-ability using standard flow cone. Also check if

grout mix appears visually thick.

CL / MC

7.13

Manufacture minimum three (3) cubes during the time of

grouting.

CL / MC

Page 16 of 21

* CL Client, MC Main Contractor, SC Structural Consultant, UML Usha Martin Ltd.

OPERATION SEQUENCE FOR POST-TENSIONING IN BUILDING:

Erect soffit formwork
Erect edge boards
Attach anchorages to vertical edge boards
Place & secure bottom reinforcement
Place & secure anchorage zone reinforcement
Place & secure tendons (or sheaths)
Place & secure top reinforcement
Place concrete & cure
Remove edge boards & pocket formers
Test concrete cube or cylinder for strength required for stressing
Thread strands (for bonded system), if only sheaths were placed in step 6
Stress tendons
Strip formwork & back prop if required
Cut surplus strand lengths
Fill anchorage pockets by non-shrinking epoxy based mortar
Grout sheaths for bonded tendons

Page 17 of 21

Other than the specialist prestressing crew, the main workforce on a post-tensioned floor site
consists of three major categories: formwork erectors, steel fixers & concreting gang. For maximum
efficiency, the site operations would be so organized that the three crews have continuous work,
with no or minimum idle time. The site programme would, therefore, depend on a number of
factors, including the size & plan shape of the building. Table below shows a construction
programme consisting of a six days cycle, which may be adapted to suit the particular needs of the
project.
A Typical Programme Cycle:
Ref

1-2
3
4-7
8
9-10
12
13
14

Description
Columns formwork
Columns reinforcement
Concrete columns
Strip columns
Slab formwork
Fix anchorages
Steel & Tendons
Concrete floor
Strip edges
Stress tendons
Strip forms & backprop
Grout & finish
Columns formwork

Days
6

10

11

111111
11

111
111111
111
111

111
111111
111111
111111
111111
111111
111

1111
1111
11111

111111

PROCEDURE FOR QUALITY CONTROL:

Casting Approval:
1. UML will supervise the installation of PT works according to the approved drawings
following the standards.
2. UML will inspect the slab after completion of the installation works.
3. UML will submit a checklist to CL/SC for inspection.
4. CL/SC checks the works on site & issues approval.

Stressing Approval:
1. After concreting, the side shutters shall be removed to allow stressing operation.
2. UML will proceed with the stressing operation when concrete strength exceeds 25
MPa unless otherwise noted as per the project criteria.

Page 18 of 21

3. UML will measure & record the stressing results using the stressing result form &
send back to UML office in Kolkata.
4. UML Kolkata office will assess the results & send them to SC for their review &
approval and/or further submittal to client.
5. After reviewing the stressing results concerned engineer/consultant can issue the
stressing approval via letter/fax/e-mail to the site, after which the strands can be
cropped.

CONTROL OF INSPECTION, MEASURING & TEST EQUIPMENT:

Before stressing, the site foreman shall confirm the accuracy of the instrument/equipment
prior to use by carrying a quick check against the client supplied points, if any. Calibration
certificate should be available for all such instruments/equipments used.
Installation Inspection & Testing
Nominated personnel shall undertake verification of availability
inspection/test certificates as set out within the inspection test plan.

of manufacturers

SAFETY PLAN:
Following safety measures shall be taken at different stages of work:
a) Helmets & shoes will be provided to all our people.
b) During stressing operation, no one will be allowed to stand behind the jacks to avoid
accident. Also necessary shield will be provided behind the jacks.
c) Safety glasses to be used for welding and strand cutting.
d) Hand gloves should be used for material handling and also at the time of grouting.
e) Safety belts will be used wherever required.

ATTACHMENTS:
1.Stressing Report format
2. Strand Traceability Report with Revised Elongation format

STRESSING REPORT

Page 19 of 21

Project no.
SF Drawing No:
Usha Martin Limited

2 A Shakespeare Sarani, Mangal Kalash, 4th

Date (Measured):
Floor
Kolkata - 700 071; India
Document Revision
Project:
Prepared By:
Measured ext Filled by:

Strand Force
Friction Factor:
Wobble Factor:
Draw in:
Tendon
No.

Strands
Per
Tendon

Typical Comments

Date (Theoretical):

kN
0.2
0.004
6mm
Strand Extension
Length
(m)

Min. Target
(mm) (mm)

Max
(mm)

UML

SL

Single live end stress

DL
PAN
DLPAN
C

Double live end stress

Single top pan stress
Double live end stress with top pan
Cranked or curved tendon

Low
High

Average
Measured
Extension
(mm)

Measured Extensions
Comments Elongation Elongation
Elongation Elongation
Elongation Elongation
Elongation Elongation
Strand 1
Strand 2
Strand 3
Strand 4
(DL/SL)
at 25%
at 100%
at 25%
at 100%
at 25%
at 100%
at 25%
at 100%

Repulled/
% Var. Remeasu
red

Signat ure of L&T

Signat ure of USHA MARTIN LTD-

Page 20 of 21

Tendons/Strands Traceability Reports with Revised Elongation

PROJECT

DATE:

BUILDING
FLOOR
COLUMN GRID
REF. DWG. NO.

Sl No

Cable
ID

NO.OF
H.T.S.

Coil No

Actual Dia of Actual Area Modulus of

Elongation
Revised
Strands
of Strands
Elasticity (Given in Table)
Elongation (mm)
(mm)
(sq.mm)
(N/mm2)
(mm)

Signature for Usha Martin Ltd.

Signature for L&T

Page 21 of 21

Remarks