45 SECTION 4 CONCRETE WORKS

4/34.6 Sand shall be natural sand or crushed natural stone or a combination of both as
specified in BS 1200: 1976.

4/35 EXTENT OF POURS

4/35.1 The limit of individual pours and the height of lifts shall be as approved. The
sequence of pours shall be arranged to minimize thermal and shrinkage strains.

4/35.2 For walls, the length of panel placed at one time shall not exceed 6 m,
adjacent panels shall not be placed within 2 days, but shall be placed as soon
as practicable thereafter. Subsequent vertical lifts shall not be poured within 2
days.

4/35.3 Bridge decks, floors, roofs and ground slabs shall be placed in an approved
sequence of panels. 'Chequerboard' placing shall be avoided. Adjacent panels
shall not be placed within 3 days, and then only provided that the concrete in
the first pour has cooled down to below 38 degrees centigrade or ambient
temperature. Placing of adjacent panels shall take place as soon as practicable
after the above criteria have been satisfied. Panels shall be 5 m x 5 m and any
pour exceeding 25 m2 will only be considered for approval if substantiated by
calculations.

4/36 POST-TENSIONED CONCRETE WORKS

4/36.1 General

This work includes, but not by way of limitation, supplying and fixing formwork,
falsework and temporary works; supplying, testing and placing prestressing
steel with all accessories, metal ducts and anchors; supplying concrete of the
class as indicated on the Drawings or specified herein and transporting and
placing it in prepared forms; tamping, vibrating, finishing and curing the
concrete; pointing and jointing with cement mortar; post-tensioning prestressing
steel; pressure grouting ducts; all in accordance with the specifications and
Contract Documents. Post-tensioned concrete work shall be as indicated on the
Drawings, as specified herein and/or included in the Bills of Quantities.

4/36.1.1 Standards and Codes

Standards and codes shall be as specified in Section 4, Concrete Works of the

General Specifications, and the following in their latest edition shall apply and
govern all works related to post tensioned concrete.

ASTM: American Society for Testing and Materials

A416: Uncoated Stress-Relieved Strands

4/36.1.2 Submittals

1. Shop Drawings - Shop drawings shall be submitted to the Engineer for

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 46 SECTION 4 CONCRETE WORKS

approval in accordance with Section 4/9 of General Specifications and as

specified herein. All submissions must be thoroughly checked by the Contractor
for numerical and conceptual errors before submitting to the Engineer for
approval.

Supplementing the requirements for shop drawings specified in Section 4/9, the
Contractor shall include with the shop drawings a description of the equipment
to be used and the procedure for constructing post-tensioned concrete work.
The type and size of ducts and method of holding the ducts in position, tendon
sizes, jack clearances and procedures, stressing sequences, grout connections
and vents, anchorage details and bonding and grouting procedures shall also
be indicated.

Any delays in the Engineer granting his approval consequent to incomplete,

late, inadequate or unchecked submissions shall be entirely the Contractor’s
responsibility.

2. Certificates - Certificates from the manufacturers shall be furnished to the

Engineer certifying that the materials and equipment to be provided comply with
the requirements of these specifications.

3. Test Reports - The Contractor shall furnish to the Engineer six (6) copies of
test reports and certificates as specified herein, unless otherwise directed by
the Engineer.

4/36.1.3 Quality Assurance

1. In the event the Contractor proposes to perform the post-tensioned concrete

work with his own forces, the Contractor shall submit all details of his
qualifications as specified herein and as required by the Engineer for approval
by the Engineer of the Contractor to perform the work.

2. In the event the Contractor is unable to provide acceptable and adequate

information of his qualifications to perform this work and is rejected by the
Engineer for the post-tensioned concrete work, the Contractor will be required
by the Engineer/Employer to subcontract such works.

3. The Contractor will be required to submit to the Engineer for review and
approval, the following information regarding his qualifications or those of the
proposed subcontractor:

a) The Contractor shall submit the name and address of the proposed
organization or subcontractor, along with a complete and detailed
description of their qualifications and experience in the performance of
post-tensioned concrete work.

b) The named proposed organization or subcontractor shall submit

evidence acceptable to the Engineer that the organization or
subcontractor is experienced in the field of prestressing systems. Further,
the Contractor or proposed subcontractor shall submit data acceptable to
the Engineer that they have, within the last five years, performed such
construction or work comparable to the post-tensioned concrete works as
specified in these Particular Specifications and indicated on the
Drawings. The Contractor shall confirm this experience

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 47 SECTION 4 CONCRETE WORKS

by citing a minimum of two projects comparable to the current projects

which have been successfully accomplished.

c) Approval by the Engineer of the Contractor’s organization or the

subcontractor for the performance of the post-tensioned concrete works
shall not relieve the Contractor of overall responsibility for such work.

d) In the event the Contractor or an approved subcontractor demonstrates

an inability to perform the work as specified in this Section for Post-
Tensioned Concrete Works subsequent to the approval by the Engineer,
the Engineer reserves the right to rescind such approval and require that
the Contractor submit the name of another subcontractor to perform the
work. All re-submittals shall comply with the requirements specified
herein and all Contract Documents.

4/36.1.4 Sampling and Testing

1. Concrete - Concrete sampling, testing and frequency of testing shall be in

accordance with Section 4, Part 1, Concrete Works, and as amended in
Clause 4/17.

2. Prestressing Steel - All reels of prestressing steel shall be accompanied

by an inspection and test certificate furnished by the supplier indicating the
number of reels in the shipment represented by the certificate, modulus of
elasticity, stress/strain curves, tensile strength, relaxation test results and
strand chemical composition.

For each certificate furnished, a sample, as described herein, shall be

furnished to the Engineer for testing purposes.

The Contractor shall make arrangements with the vendor to furnish the
Engineer, samples as selected at random from the lot of reels represented
by each certificate. Samples shall be not less than 1.20m in length.

All samples submitted shall be accompanied by a certification from the

vendor certifying that the samples were taken from and are representative
of, the lot of reels to be furnished.

All of the above samples shall be tested by an approved laboratory well in

advance of the anticipated date of use. The Contractor shall make no claim
for additional compensation if his work is delayed awaiting approval of the
materials testing.

4/36.1.5 Scheduling of Post-Tensioned Concrete Works

The scheduling of all post-tensioned concrete work shall be such that

construction of each individual superstructure unit can be completed within
a 90-day period commencing with the first concrete pour through completion
of the post-tensioning and duct grouting operations unless otherwise
indicated on the Drawings, or directed by the Engineer.

The Contractor shall have sufficient materials on hand prior to commencing

work on any given superstructure unit to ensure completion of the unit within
the specified 90-day period.

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 48 SECTION 4 CONCRETE WORKS

4/36.1.6 Materials, Delivery, Storage and Handling

Prestressing steel shall be protected from physical damage and corrosion

at all times from manufacture to grouting or encasing in concrete. Physically
damaged post-tensioning steel will be rejected by the Engineer. The
development of visible rust or other results of corrosion will be cause for
rejection by the Engineer.

Prestressing steel shall be packaged in containers or shipping forms for the

protection of the steel from physical damage and corrosion during shipping
and storage. The manufacturer shall place a corrosion inhibitor, which
prevents rust or other results of corrosion directly to the steel, and in the
package or form, or shall use a corrosion inhibitor carrier type packaging
material. Corrosion inhibitor shall have no deleterious effect on steel or
concrete or bond strength of steel to concrete.

Shipping packages shall be clearly marked with a statement that the

packages contain high-strength post-tensioning steel, and that care is to be
used in handling; and that shows the type, kind and amount of corrosion
inhibitor contained, including the date packaged and safety instructions for
use. Reel identification tags showing all the relevant details for the reel shall
be securely placed both on the inside and outside of the packaging.

4/36.2 Concrete and Materials

The concrete and other materials to be furnished and included in the

construction of all Post-Tensioned Concrete Works shall be as specified
herein.

4/36.2.1 Post-Tensioning Systems

1. Post-tensioning systems for concrete box girders shall be of

internationally recognized types acceptable to the Engineer, as indicated
on the Drawings, and as specified in these Particular Specifications.
a) All the anchorage devices must be certified and have been tested
according to the acceptance test requirements for highly
aggressive environments as given in AASHTO Division II –
Construction Part 10.
b) Strands shall be uncoated, seven wire, high-tensile, cold drawn,
low relaxation complying with ASTM A416, Grade 270.
c) Wire shall be uncoated, stress-relieved, cold drawn, round, high
tensile steel, complying with ASTM A421:2006, and having a
minimum tensile strength of 1,650 x 106 N/m2. Wire shall not be
oil tempered.
d) Anchorage assemblies, jacks, gauges, grout fittings, and other
related equipment and accessories shall be standard with the
system manufacturer and approved by the Engineer.
e) Ducts for bonded post-tensioning strand shall be flexible,
galvanized, interlocked, mortar and grout tight, and fabricated of
not

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 49 SECTION 4 CONCRETE WORKS

lighter than 28 gauge steel. Ducts shall be at least 6 mm larger than

the nominal diameter of the strand or wire bundles and the cross
sectional area shall be at least twice that of the net steel area. The
ducts shall have grout openings at each end, and shall be vented at
high points of the ducts at piers.
f) Epoxy bonding agent: complying with the national and
international standards and specifications (latest edition).
g) Bituminous protective coating complying with the national and
international standards and specifications (latest edition).

2. Post-tensioning systems of other manufacturers which are comparable and

equal in all respects to the specified systems may be used, provided the
proposed alternative post-tensioning systems have the prior approval of the
Engineer. The Engineer will be the sole judge as to whether or not any
proposed alternative system of post-tensioning is comparable and equal to
the specified systems.

4/36.2.2 Concrete

Concrete for post-tensioned concrete work shall be Class 45/20 (unless

otherwise indicated on the Drawings) specified in Section 4, Concrete
Works, of these General Specifications.

4/36.2.3 Reinforcement Steel

Reinforcement steel shall comply with the requirements of Section 4,

Concrete Works, of these Standard Specifications and where specifically
indicated on the Drawings or directed in the Particular Specifications.

4/36.2.4 Duct Grout Materials

1. Grout admixture shall be a balanced blend of expanding, fluidifying,

and water-reducing agents containing no calcium chloride, nitrates or
other chemicals causing steel corrosion.

2. Portland cement shall be as specified in Section 4 of General

Specifications.

3. Water shall comply with the requirements of Section 4, Concrete

Works, of these General Specifications.

Properties of Grout - Duct grout shall comply with the requirements given in
the relevant sections of the Specifications with regard to the following:

• fluidity and bleeding in the plastic condition

• volume change when hardening
• strength when hardened
The tests are specified in Section4, Clause 4/36.2.5.

Fluidity - The fluidity of grout during the injection period shall be

sufficiently high for it to be pumped effectively and adequately to fill

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 50 SECTION 4 CONCRETE WORKS

the duct without excessive segregation, but sufficiently low to expel

the air and any water in the duct.

When tested by the methods given in Section PS 4/36.2.5 the grout

shall have the values given in Table 4-11.

Table 4- 11: Fluidity Test Requirements

FLUIDITY(S)
30 min. after mixing or at
Test Immediately end of injection period At duct
Method After Mixing (see Note 1) Outlet
Immersion > 30 < 80 > 30
Tube
Cone < 25 < 25 > 10
Note1: Mixing time shall be measured from the point when all the
materials are in the mixer.

Bleeding - The bleeding of the grout shall be sufficiently low to prevent

excessive segregation and settlement of the grout materials, when tested
by one of the methods given below in Section4, Clause 4/36.2.5.

The grout shall not be subject to bleeding in excess of 2% after 3 hours or

4% maximum when measured at 18C in a covered cylinder approximately
100mm diameter with a height of grout of approximately 100mm, and the
water shall be reabsorbed by the grout during the 24 hours after mixing.

Volume Change - The volume change assessed may be either increased

or decreased. When tested in accordance with the methods given in Section
4, Clause 4/36.2.5 the volume change of the grout shall be within the range
0% and +3%. For grouts with expanding agents there shall be no decrease
in volume.

Strength - The compressive strength of grout may be assessed using either

of the specimen shapes and sizes given in Table 4-12 and using the
corresponding procedure given in the same table.

In either case the compressive strength shall be not less than the
compressive strength of the surrounding concrete at 7 and 28 days.

Table 4- 12: Compressive Strength Specimens

Specimen Shape Specimen Dimensions (mm) Test Procedure

Prism 40 x 40 x 160 PS 4/36.2.5
Cylinder 100 dia x 80 height PS 4/36.2.5

Batching and Mixing of Grout - The proportions of materials used in the

mix may be selected on the basis of prior documented experience with
similar materials and equipment, and under comparable field conditions

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 51 SECTION 4 CONCRETE WORKS

(weather, temperature, etc.) and shall be verified by tests made on the grout
before grouting begins.

The water content shall be the minimum necessary to obtain the required
workability for proper placement and under no circumstances shall the
water/cement ratio exceed 0.44. The water content of any admixtures shall
be taken into account when calculating the water/cement ratio. The
materials shall be batched by weight with an accuracy of +2% for cement
and admixtures and +1% for water.

All materials shall be batched by mass except in the case of water which
may be batched by mass or volume.

Mixing shall be carried out mechanically to obtain a homogeneous and

stable grout with the plastic properties given in the Specification.

Depending upon environmental or material influences (eg. Temperature,

configuration of the tendon and the properties of the cement use), the w/c
ratio shall be kept as low as possible having regards to the required plastic
properties of the grout.

A sufficient amount of material shall be batched to ensure complete grouting

of a duct making due allowance for overflow. The grout shall be mixed in a
machine capable of producing a homogenous grout and after mixing,
keeping the grout in slow continuous agitation, until it is ready to be pumped
into the duct, Water shall be added to the mixer first, followed by the cement
and if agreed by the Engineer, admixtures. The batch quantities of cement
and admixtures may be added as a whole or in part in sequence until the
total quantities are added.

Temperature at Grouting - Records shall be kept of the maximum and

minimum air temperatures and the temperature of the members to be
grouted.

Ambient temperature during grouting shall not be above 35Co.

Grout temperature at duct inlet and outlet shall not be above 32oC during
mixing or pumping. If necessary cold water shall be used for grout mixing to
maintain recommended temperature.

4/36.2.5 The Testing of Grout

The following tests, listed below, shall comply with the requirements of the
following standards:

a) UAE & DMs Standards, if any

b) International Standards “ISO, BS, ASTM, etc.)

1. General Conditions - The grouts shall be tested by competent

personnel experienced in the subject, and in laboratory conditions of
temperature and humidity as follows:

Temperature (20 ± 2) oC

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 52 SECTION 4 CONCRETE WORKS

Humidity > 65% R.H.

The grout for the tests shall be made from the materials specified in
and mixed in accordance with the requirements of these Specifications. The
temperature of the freshly mixed grout is to be given in all test reports.

2. Fluidity Test - Immersion Method (BS EN-445:2007)

Principle - The tests consists of measuring the time a plunger

needs to drop through a defined amount of grout in a tube.
Apparatus
a) Calibrated immersion equipment according to Figure 4-2.
b) Wooden measuring rod according to Figure 4-2.
Calibration Procedures - The immersion equipment shall be calibrated
with glycerol (analytical grade) having a density of 1.23 T/M3 at 20oC. The
temperature of the room, immersion equipment and glycerol shall be (20 +
1) oC during the calibration.
The cylinder shall be filled with about 1.9 litres of glycerol up to
approximately 250mm below the rim. After filling the immersion equipment
the glycerol shall be allowed to rest for about 1 hour. The plunger then shall
be immersed to expel any air bubbles from the glycerol, which may have
been introduced during the filling of the cylinder.

After one hour the plunger shall be positioned so that its stop on the tail rod
lies on the spacer placed at the top of the tube. The spacer shall then be
pulled away to allow the plunger to sink to the top of the tube. The immersion
time (the time taken for the plunger to sink) shall be recorded in seconds to
the nearest second.

The calibration shall be repeated at least 3 times.

The mean value of all measured immersion times shall be (34 + 1)s. If the
mean value deviates for this figure, the weight of the plunger shall be
increased where t > 35s or reduced where t < 33s. This is done by varying
the quantity of the lead pellets in the plunger. Repeated calibration
procedures shall be delayed for at least 30 minutes to ensure expulsion of
any air bubbles that may be have been introduced during a preceding
calibration procedure.

Test Procedure

Preparation - The immersion equipment shall be calibrated before it is

used. Calibration of the immersion equipment shall be performed
subsequently once a year and/or after any damage.Directly before the test,
the inside of the tube and the plunger shall be slightly wetted.

Procedure - The cylinder shall be filled with approximately 1.9 liter of grout
up to approximately 260mm below the rim, so that on introduction the
plunger is fully immersed when its stop on the tail rod lies on the spacer
placed at the top of the tube. The spacer should be pulled away to allow the
plunger to sink to the stop on the tube. Thereafter the plunger should be
raised back to its initial position, the spacer inserted and again pulled away.

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 53 SECTION 4 CONCRETE WORKS

Figure 4- 2: Immersion equipment for determining the immersion time

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 54 SECTION 4 CONCRETE WORKS

The immersion time shall be measured, i.e. the time it takes for the plunger
to sink to the point where its tail stop touches on top of the tube. The
immersion times of the grout shall be measured immediately after the mixing
process and after a further 30 minutes. For the latter test, unused grout from
the same mix as that used for the former immersion test shall be used. The
grout is to be kept in motion while carrying out all tests. Each test shall be
carried out three times in succession with the same filling.

Reporting the Results - The result shall be reported as the average of the
immersion times to the nearest second of the second and third immersion,
i.e ignoring the first immersion time.

3. Fluidity Test - Cone Method

Principle - The fluidity of grout, expressed in seconds, is measured by the

time necessary for a stated quantity of grout to pass through the orifice of
the cone, under stated conditions.

Apparatus - The following apparatus is required for the test:

a) Cone - A cone of dimensions shown in Figure 4-3. The cone shall be

robust and manufactured from materials not reactive with any duct
grout materials specified in these Specifications. The volume of the
cone (excluding the cylindrical portions at top and bottom) shall be
1.7 liters + 10%.
b) Sieving Medium - The sieving medium aperture shall be 1.5mm
and the medium shall be fitted as shown in Figure 4-3.
c) Stopwatch
d) Container of 1 litre capacity.

Test Procedure

Preparation - The cone shall be mounted with its axis vertical and its largest
diameter uppermost. The sieving medium shall be fixed at the position
indicated in Figure 4-3. During the test the cone shall be prevented from
vibrating. The container under the cone outlet. All surfaces of the cone shall
be clean and slightly moistened. Close the lower cone orifice.

Procedure - Pour 1.5 liters of the grout through the sieving medium into the
cone sufficiently slowly to prevent the build-up of air in the grout in the cone.
Open the lower cone orifice and at the same time, start the stopwatch.
Measure the time taken to the nearest 0.5s to fill the container. The
presence of lumps on the sieving medium shall be reported. Two tests shall
be carried out, the first immediately after the grout is mixed and the second
30 minutes thereafter or alternatively at the end of the grouting period.

Reporting of Results - Report the time taken to the nearest 0.5s. Report
also the presence of lumps.

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 55 SECTION 4 CONCRETE WORKS

Figure 4- 3: Cone for Fluidity Test

4. Bleeding Tests

Principle - The test consists in measuring the quantity of water remaining

on the surface of the grout which has been allowed to stand protected from
evaporation.

Apparatus - A transparent I00 ml cylinder 25mm in diameter and 250mm

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 56 SECTION 4 CONCRETE WORKS

in height graduated in ml. Alternatively a transparent cylinder 50mm in

diameter and 200mm in height graduated in mm.

Procedure

Preparation - Place the cylinder on a surface free from shocks or vibration.

The grout used may be from the same batch as that used for the fluidity test.

Procedure for 25mm diameter cylinder

Pour 95ml to l00mI of grout into the cylinder. Note the precise level of the
grout (v) ignoring the meniscus. After 3 hours, measure the quantity of water
on top of the grout (vl) taking appropriate measures to prevent evaporation.
The test is carried out on one sample of grout.

Procedure for 50mm diameter cylinder

Pour grout into the cylinder to a height of approximately 150mm. Note the
height to the top of the grout (h) ignoring the meniscus.
After 3 hours, measure the height of water on top of the grout (hl) taking
appropriate measures to prevent evaporation. The test is carried out on one
sample of grout.

Reporting of Results - Bleeding at the end of 3 hours is given by:

vl /v x I00% for 25mm diameter cylinder, and

hl/h x 100% for 50mm diameter cylinder

where
vl is the volume of water on the surface of the grout after 3
hours (in ml)
v is the initial volume of grout (in ml)
hl is the height of water on the surface of the grout after 3
hours (in mm)
h is the initial height of grout (in mm)

The report shall state the temperature at the time of test.

5. Volume Change Test

Principle - Testing shall be in accordance with the FIP (Federation

International de La Precontrainte) Guide for Good Practice Procedures. The
volume change is measured as a percentage of the volume of grout between
the start and the end of the test. The test measures mainly the volume
change caused by segregation or expansion. The grout used in this test may
have been used for the bleeding test (see Test 4).

Cylinder Method

Apparatus - A transparent cylinder 50mm in diameter and 200mm in

height as required for test 4.

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 57 SECTION 4 CONCRETE WORKS

Procedure - Place the cylinder on a surface free from shocks and vibration.
Fill it with the grout to a height (h). Twenty four hours after filling the cylinder
measure the height (h2) to determine the change in volume.

Reporting of Results - The volume change at the end of 24 hours is

given by:

(h2 – h)/h x 100%

where
h = is the initial height of grout (in mm)
h2 = is the height of grout after 24 hours (in mm)

Can Method
Apparatus
a) Three cans, 120mm high and approximately 100mm in diameter,
with lids capable of preventing the loss of moisture.
b) Measuring rod or sliding calipers
c) Plates
• Stop plate for placing on the can with a diameter of 120mm
(see Figure 4-4)
• Stop plate for placing on the grout with a diameter of 96mm
(see Figure 4-5)
d) Filling gauge 100mm high

Procedure - Place the cans on a surface free of vibration and heat radiation
and store for 24 hours. Immediately after mixing pour the grout into each
can using the filling gauge, to a depth of 100mm. The measurement of the
distance from the top edge of the can to the top of the grout is to be taken:

• immediately after the containers are filled and

• 24 hours after the containers are filled by one of the following methods:

a) Measurement with the Stop Plate on the Can - immediately after

the cans have been filled with grout, measure the distance between
the surface of the grout and the stop plate on the can in at least six
places with the depth gauge (first measurement). The marking must
coincide with the top edge of the can (reference point). Then the
cans are sealed by covering with the lid weighted with approximately
300g until the second measurement is carried out 24 hours after the
filling of the cans.

b) Measurement with the Stop Plate on the Grout - Immediately after

filling the cans, put the stop plate (Figure 4-5) on the fresh grout and
measure with the depth gauge the distance between this plate and
the top edge of the can in at least six places (first measurement).
Then the cans are sealed. The second measurement shall be carried
out 24 hours after the filling of the cans. In the second measurement
the distance between the stop

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 58 SECTION 4 CONCRETE WORKS

plate and the top edge of the can is measured at the same places
as for the first measurement. After the second measurement the
cans are sealed as before, and used as necessary for the
compression strength tests (6).

Figure 4- 4: Plate on the Can

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 59 SECTION 4 CONCRETE WORKS

Figure 4- 5: Plate on the Grout

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 60 SECTION 4 CONCRETE WORKS

Reporting of Results - The difference of the average values between first

and second measurement(s) in mm corresponds at I00mm grout level to
the volume change in percent and is reported as the percentage change in
volume. Report the percentage change in volume as the average of the
three containers to the nearest 0.1 %. Report increase of volume as (+)
and decrease
as (-).

6. Compression Strength Test

a) Compression Strength Test - Prism

Principle of the test - The compression strength of grout in this test

(which is an adaptation to grouts of the mechanical tests described in BS
EN 196-1: 2005) is determined on the broken halves of prisms.

Apparatus
i) Mixer for grout in accordance with the requirements of these
Specifications for hatching and mixing of grout.
ii) Air conditioned cabinet at (20 + 1) oC and (95 ± 5) % relative
humidity.
iii) Test machine and the device in accordance with 4.7 and 4.8 of B.S.
EN 196-1: 2005.
iv) Metal molds in accordance with 4.5 of BS EN 196-1: 2005.
v) Metal straight edge in accordance with figure 3 of BS EN 196-1:
2005.

Procedure

Moulding of the Test Specimens - File moulds and accessories shall

be prepared and the specimens made in accordance with BS EN 196-
1, with the exception noted below.

Each mould (fitted with a hopper) shall be filled with the prepared
grout. As an exception to the procedure in B.S. EN 196-1: 2005 and in
view of the liquidity of the grout the test specimens shall not be
subjected to any vibration or shock so as to prevent rapid deterioration
of the grout (loss of grout, drying out, bleeding or sedimentation).

Remove the hopper gently. Immediately strike off the excess grout
with the metal straight edge held almost vertically and moved slowly,
with a transverse sawing motion once in each direction. Smooth the
surface of the specimens using the same straight edge held almost
flat.
Label or mark moulds to identify the specimens.
Curing of Test Specimens - The curing of test specimens shall be
carried out in accordance with BS EN 196- 1: 2005, until they are
tested.

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 61 SECTION 4 CONCRETE WORKS

Compression Test - The compression tests shall be carried out in

accordance with BS EN 196- 1: 2005. The compression strength shall
be measured on six test specimens from three prisms broken in
flexure.
Reporting of Results - The report shall provide all the results of the
compression tests, in MPa. The value obtained for each test shall be
the mean of the individual results.

b) Compression Strength Test - Cylinders

Principle - The compressive strength of grout in this test is determined
on the three cylinders used in the volume change test given in Test 5.

Apparatus

i) The cans as described in Test 5.

ii) An air conditioning cabinet as described in Test 6.
iii) A compression test machine as described in BS EN 196-1: 2005
iv) Implements for sawing and grinding test specimens.

Procedure
After measuring the volume change (see 5.) the three cylinders shall be
stored in the air conditioning cabinet at (20 + 1) oC until they are to be
prepared for test. Immediately prior to test the specimens shall be
carefully demolded.
Each specimen is prepared for test by sawing through the cylinder near
the upper surface and then grinding both circular surfaces of the cylinder
until the disc to be loaded in the test has a thickness of 80mm.

Each specimen shall then be placed in the compression test machine

and loaded, at a uniform rate of 0.5 MPa/s, on its ends until the maximum
load (Fc) is reached.

Reporting of Results - The compressive strength Rc is calculated in

MPa from:

Rc = Fc/A
where

Fc = is the failure load,

A = is the cross sectional area and shall be measured on three
specimens, the mean value of which shall be reported as
the compressive strength.

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7. Frequency of Testing - The testing of the grout made from certified

or otherwise quality assured materials shall be carried out prior to the
start of grouting operations and at the following minimum of testing in
the course of grouting.

Bleeding: 2 tests per day. One sample is to be taken at the

mixer and one sample at the duct outlet when the
grout there has a satisfactory fluidity value.

Volume Change: 1 test per day.

Strength: 1 test per 7 days or a minimum of two tests per

grouting operation whichever is greater.

Fluidity: To be tested at outlet and inlet for each duct

during grouting operation.

4/36.2.6 Built-In Materials

The Contractor shall furnish and install all built-in materials and items as
indicated on the Drawings, as specified herein and as directed by the
Engineer.

Built-in materials shall include, but not by way of limitations, all inserts,
hardware or similar items as indicated on the Drawings or specified in the
Particular Specifications.

4/36.3 Construction

The construction of all Post-Tensioned Concrete Works shall be as specified

herein.

4/36.3.1 Post-Tensioned Method Statement

The Contractor shall submit, to the Engineer for review, complete details of
the method, materials and equipment he proposes to use in the prestressing
operations, including any additions or rearrangement of reinforcement steel
from that indicated on the Drawings.

Such details shall outline the method and sequence of stressing and shall
include complete specifications and details of the prestressing steel and
anchoring devices, working stresses, anchoring stresses, type of ducts, and
all other data pertaining to the prestressing operation, including the
proposed arrangement of the prestressing steel in the members, pressure
grouting materials and equipment.

The Contractor shall not cast any member to be prestressed before the
detailed shop drawings are complete and approved by the Engineer.

4/36.3.2 Formwork and Falsework

1. Formwork, shoring, and removal of forms shall be as specified in

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 63 SECTION 4 CONCRETE WORKS

Section 4, Concrete Works, of the General Specifications and as

further specified herein.

2. Formwork shall be marine plywood for all superstructure concrete

work. Treated commercial plywood may be used for internal vertical
and inclined web surface. Treatment of plywood shall be by way of 3
coats of polyurethane varnish or similar approved materials

3. The deck slab forms and all related formwork for concrete box girder
construction, including all supporting falsework, shall be designed and
constructed in order to facilitate removal of all formwork materials from
within the cells of the concrete box girders. The deck forms shall be
suspended from the girder stems which shall be stripped of all forms
prior to placing the deck forms. The deck slab forms shall in no way
interfere with the required concrete bond between the deck slab and
the girder stems.

Stay-in-place deck forms will be permitted for the deck slab of concrete
box girder construction, provided they are galvanized steel or other
non-combustible material acceptable to the Engineer which will not
deteriorate in any way. Further, such stay-in-place deck forms shall
not increase the volume of concrete, the depth of the deck slab or
reduce the dimension of concrete coverage over the reinforcement
steel.

The Contractor shall submit samples of the proposed form material

and all details and design for the use of stay-in-place deck forms. The
decision of the Engineer shall be final for acceptance or rejection of
stay-in-place forms.

A 3cm slip joint shall be placed transversely in the deck forming

between each diaphragm to eliminate resistance of the deck forms to
deck shortening during prestressing.

The Contractor shall submit shop drawings and design calculations for
the forms, and falsework to the Engineer for approval prior to
commencing work.

Prior to erecting falsework for the deck superstructure the Contractor

shall confirm by way of testing the bearing capacity and expected
amount of settlement of the supporting ground.

4. Falsework and forms shall be set to provide the structural camber

indicated in the Drawings for long-term deflection, falsework
settlement, and shall comply with the required lines and grades.

5. Where indicated on the Drawings, the Contractor shall include all

formwork required to produce the concrete surface ornamental pattern
on the vertical surface of the box section of the post- tensioned
concrete Works as indicated on the Drawings, as specified herein and
as approved by the Engineer. The marine plywood forms supporting
the bottom slab of the box girder shall be arranged in a regular brick
pattern as approved by the Engineer.

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 64 SECTION 4 CONCRETE WORKS

The Contractor shall include in his shop drawing submittal all details
and a full description of all formwork proposed by the Contractor to
produce the concrete surface ornamental pattern. All details and
proposed methods and formwork material shall be subject to approval
by the Engineer.

The construction of all formwork required to produce the concrete

surface ornamental pattern shall comply with the applicable
requirements of Section 4, Concrete Works, of these Standard
Specifications and as specified herein. All formwork shall produce a
smooth, even surface with clean, straight, true and unbroken lines at
the concrete surface ornamental pattern.

4/36.3.3 Placing Post-Tensioning Systems

1. Anchorage devices, ducts, tendons and other appurtenant post-

tensioning equipment and accessories shall be accurately positioned
in the forms and secured in place as indicated on the drawings and
approved shop drawings. Installation of the post-tensioning system
shall be coordinated with the placement of reinforcing steel and
embedded items as specified elsewhere in these Standard
Specifications. Care shall be exercised to keep ducts and tendons free
of form coating compounds and other substances which might break
or reduce the concrete bond.

2. Field measurements of vertical locations of centers of gravity of the

tendons shall not vary by more than 6 mm from the dimensions
indicated on the Drawings.

4/36.3.4 Concrete Box Girders - The sequence for placing concrete for the cast-
in-place, multi-cell, concrete box girders at bridges shall be as follows:

1. First, the bottom slab, the exterior and interior web portions and the
diaphragm portions shall be placed monolithically as indicated on the
Drawings and as specified herein;

2. Second, the roadway or top slab shall be placed.

Vertical construction joints in all portions of the multiple cell box girders shall
be minimized and, where proposed, shall preferably be placed 0.2 of the
span length on either side of supporting pier. Dependent upon the volume
of the concrete, additional vertical construction joints may be used all subject
to the approval of the Engineer.

A concrete pour sequence plan shall be prepared by the Contractor for each
superstructure and submitted to the Engineer for approval prior to
commencing any bridge superstructure work. The pour sequence plan shall
show the locations of all construction joints which shall be bonded joints as
specified herein. Concrete pours within each element shall be alternated to
eliminate shrinkage to the greatest extent possible.

The placing of concrete in each pour shall start at the low point and shall
proceed upgrade, unless otherwise permitted by the Engineer.

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4/36.3.5 Mixing and Placing Concrete

1. Concrete work for box girder superstructure construction shall comply

with the applicable provisions of Section 4, Concrete Works, of these
General Specifications and the Particular Specifications, herewith.

2. Prior to placing concrete, tendon profiles shall be rechecked to ensure

that proper location and concrete cover will be maintained. Any ducts
found to be damaged shall be repaired or replaced as directed by the
Engineer.

3. Prior to placing forms for box girder deck slabs, the Contractor shall
demonstrate, to the satisfaction of the Engineer, that either the
prestressing steel is free and unbonded in the duct or, in the event
prestressing steel has not yet been placed, that all ducts are
unobstructed.

4. The Contractor shall exercise care during concrete placement to

prevent concrete from entering anchorage hardware. Concrete shall
be placed in such a manner that tendon alignment and reinforcement
positions are maintained, and concrete shall be vibrated with particular
attention at tendon anchorage locations to ensure optimum
compaction and penetration at these points.

5. Curing of concrete shall be in accordance with Section 4, Concrete

Works, of these General Specifications.

6. The Contractor shall keep a record showing the date and time of
placement of cast-in-place, post-tensioned concrete in each portion of
the structure. This record shall be available for examination at all times
by the Engineer. Upon completion of construction of each structure,
two copies of such records shall be submitted to the Engineer.

4/36.3.6 Stressing Operations

1. Post-tensioning of cast-in-place concrete shall be performed as soon

as the last placed concrete has attained a cube compressive strength
of 36 Newtons per square millimeter, or as specified on the Drawings,
or more based on the results of two cube tests.

2. The Contractor shall provide, at no additional cost to the Client, a

Team of one Engineer and two Technicians who are skilled in the post-
tensioning method to give such aid and instruction in the use of the
prestressing equipment and installation of the prestressing steel as
may be necessary to obtain the specified results.

3. Prestressing tendons in continuous span post-tensioned structures

shall be tensioned by jacking at each end of the tendon or at one end
of tendons as indicated on the Drawings. Prestressing tendons in
single span post-tensioned structures may be tensioned by jacking

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 66 SECTION 4 CONCRETE WORKS

from one end only as directed by the Engineer.

4. All post-tensioning shall be by means of hydraulic jacks equipped with

accurate reading calibrated hydraulic pressure gauges to permit the
stress in the prestressing steel to be computed at any time. A certified
calibration curve shall be furnished with each jacking system and
independently calibrated master gauge shall be provided on site. In
the event inconsistencies occur between the measured elongation and
the jack gauge reading, the jack gauge shall immediately be
recalibrated. In the event still further discrepancies occur, the cause
shall be determined and reported to the Engineer. An agreement
within five percent shall be satisfactory.

5. The Drawings indicate jacking locations of the tendons. Proper

allowance shall be made for friction losses and one tendon from each
bridge or each of tendons with similar configuration shall be checked
for friction loss at the very start of the post-tensioning.

a) In case the friction losses in tests exceed the computed losses,

all wires shall be relieved and lubricated with water-soluble oil
and retensioned.

b) Each tendon shall be stressed until either the required elongation

or the maximum force is reached. Elongation is the preferred
method of stress determination wherever possible. The tendons
shall be tensioned by jacking to the total forces indicated on the
Drawings.

6. The post-tensioned prestressing steel shall be anchored at an “initial

stress” that will result in the ultimate retention of working forces or
stresses of not less than those indicated on the drawings, but in no
case shall the prestressing steel be tensioned above 80 percent of the
ultimate tensile strength of the wire or strands.

7. Prior to post-tensioning any member, the Contractor shall demonstrate

to the satisfaction of the Engineer that the prestressing steel is free
and unbonded in the duct.

8. The Contractor shall keep records of the elongation and tension applied
to each tendon, and this record shall be submitted to the Engineer
promptly upon the completion of stressing of each member. At the time
of stressing the first member, the stresses in the individual tendons shall
be checked to establish a procedure for ensuring uniform results. At any
later time, a recheck may be ordered by the Engineer if it appears that
the design stresses are not being obtained. The Contractor shall have
written permission from the Engineer before capping any prestressing
anchorage.

9. The effective prestress force “Pf” indicated on the Drawings represents

the force required after all losses of prestress have occurred. The
prestress losses due to creep and shrinkage of concrete, relaxation of
prestressing steel and elastic shortening are assumed to be 227N per
sq. mm, and friction is accounted for using wobble and curvature

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 67 SECTION 4 CONCRETE WORKS

coefficients of k = 0.0017 per meter and  = 0.20. Losses due to an

anchor set of 6 mm have been added in case a grip type anchorage is
used.

4/36.3.7 Grouting of Tendons

1. General - After the tensioning of all tendons has been completed and
the total retained stress is equal to or exceeds that indicated on the
Drawings, for each member, and the steel strands or wires have been
anchored, the annular space between the conduit and the tendons
shall be grouted.

2. Grouting - Tendons shall be grouted within 7 days after tensioning but

not before 8 to 12 hours after tensioning. The tendons shall be
protected against corrosion by a plug at each end to prevent the
passage of air, and such plugs shall be left in place until the tendon is
grouted.

3. Grout Mixture - The grouting mixer and pump shall be in top

mechanical condition and of such size and capacity to ensure
continuous grouting of the largest tendon until it is completed and shall
be capable of grouting to a pressure of at least 1.07N per
sq. mm. The Contractor shall submit his mix design as per the
requirements of PS 4/16 and the recommendation of the admixture
manufacturer for the approval of the Engineer.

4. Equipment - The grouting equipment shall include a mixer capable of

continuous mechanical colloidal mixing which will produce a grout free
of lumps and undispersed cement. The equipment shall be able to
pump the mixed grout in a manner which will comply with all provisions
of these Standard Specifications. Accessory equipment which will
provide for accurate solid and liquid measures shall be provided to
batch all materials such as flow meter or similar approved method.

The pump shall be a positive displacement type and be able to

produce an outlet pressure of at least 10.5kg per sq. cm. The pump
shall have seals adequate to prevent introduction of oil, air or other
foreign substance into the grout, and to prevent loss of grout or water.

a) A pressure gauge having full scale reading of no greater than

2.15N per sq. mm shall be placed at some point in the grout line
between the pump outlet and the duct inlet.

b) The grouting equipment shall contain a screen having clear

openings of 3.2 mm maximum size to screen the grout prior to
its introduction into the grout pump. If a grout with a thixotropic
additive is used, a screen opening of 4.8 mm is satisfactory. This
screen shall be easily accessible for inspection and cleaning.

c) The grouting equipment shall utilize gravity feed to the pump

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 68 SECTION 4 CONCRETE WORKS

inlet from a hopper attached to and directly over it. The hopper
shall be kept at least partially full of grout at all times during the
pumping operation to prevent air from being drawn into the post-
tensioning duct.

d) Under normal conditions, the grouting equipment shall be

capable of continuously grouting the largest tendon on the
project in no more than 20 minutes.

e) The Contractor shall furnish and maintain back-up equipment

and such additional equipment to ensure continuous,
uninterrupted grouting of all tendons. Such back-up equipment
shall be equal to the main grouting equipment and shall be
prepared and ready to operate at the start of any grouting
operations. The Contractor shall submit a description of all
grouting equipment including back-up equipment for approval by
the Engineer prior to commencing work specified in this Section
of these Particular Specifications.

5. Mixing of Grout - Water shall be added to the mixer first, followed by

Portland cement and admixture, unless otherwise required by the
admixture manufacturer.

a) Mixing shall be of such duration as to obtain a uniform thoroughly

blended grout, without excessive temperature increase or loss of
expansive properties of the admixture. The grout shall be
continuously agitated until it is pumped.

b) Water shall not be added to increase grout flowability which has

been decreased by delayed use of the grout.

c) Proportions of materials shall be based on tests made on the

grout before grouting is begun, or may be selected based on
prior documented experience with similar materials and
equipment and under comparable field conditions (weather,
temperature, and similar factors). The water content shall be the
minimum necessary for proper placement.

6. Grouting - Flushing of metal ducts shall be optional. Water used for

flushing ducts may contain slaked lime (calcium hydroxide) or quick-
lime (calcium oxide) in the amount of 12gm per liter.

7. Injection of Grout - All grout and high point vent openings shall be
open when grouting starts. Grout shall be allowed to flow from the first
vent after the inlet pipe until any residual flushing water or entrapped
air has been removed, at which time the vent shall be capped or
otherwise closed. Remaining vents shall be closed in sequence in the
same manner.

a) The pumping pressure at the tendon inlet shall not exceed 1.8N
per sq. mm.

b) If the actual grouting pressure exceeds the maximum

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recommended pumping pressure, grout may be injected at any

vent which has been or is ready to be capped, as long as a one-
way flow of grout is maintained. If this procedure is used, then
the vent which is to be used for injection shall be fitted with a
positive shutoff.

c) When one-way flow of grout cannot be maintained as outlined in

the above paragraph, the grout shall be immediately flushed out
of the duct with water.

d) Grout temperature shall be pumped through the duct and

continuously wasted at the outlet pipe until no visible slugs of
water or air are ejected and the efflux time of the ejected grout
shall not be less than the injected grout. To ensure that the
tendon remains filled with grout, the outlet and/or inlet shall be
closed. Plugs, caps or valves thus required shall not be removed
or opened until the grout has set.

e) Grout temperature at duct inlet and outlet shall not be above

32°C during mixing or pumping. If necessary, the mixing water
shall be cooled. Grouting shall not proceed when shade
temperature exceeds 35Co.

f) Grouted tendons or girders shall not be disturbed for 48 hours

after grouting and grouting test results shall be satisfactory as
per manufacturer recommendations before any further step.

4/36.3.8 Protection of End Anchorages

1. As soon as possible after tensioning and grouting is completed, clean

exposed end anchorages, wires and other metal accessories of rust,
displaced mortar, grout and other such materials, then apply to all such
dry metal surfaces a heavy, unbroken coating of epoxy bonding agent.

2. Install tight-fitting forms and hold in place securely against the

previously placed concrete.

3. After applying epoxy bonding agent, apply a patching mortar prepared

by mixing one part type V, Portland cement to three parts of clean
sand (ASTM C33: 2007) measured by volume, and sufficient water to
provide a stiff but workable consistency. Apply the patching mortar,
and manipulate, finish and cure as specified in Section 4, Concrete
Works. After mortar patches have cured, apply two heavy brush coats
of bituminous protective coating material, applied as recommended by
the manufacturer, including the recommended thickness.

4/36.3.10 Access Doors

Access doors shall be installed in post-tensioned box girders as located

and as detailed on the Drawings.

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All access doors shall be fabricated of steel shapes, plates and accessories
complying with Section 5/45 - Metal Works and Drawings. All steel shall be
galvanized. Access or cover shall be made of GRP to be mounted to steel
frame.

The furnishing and installing of access doors as indicated on the Drawings

and specified herein will not be measured or paid for separately but shall be
considered a subsidiary obligation to and included in the various concrete
Items of work included in the Bills of Quantities.

4/36.3.11 Vent Pipes

The Contractor shall include the unplasticized polyvinylchloride (PVC) vent

pipes in the cells of the concrete box girders as indicated on the Drawings.

The vent pipes shall be of the size as indicated on the approved shop
Drawings and shall be PVC extruded from one hundred percent virgin
materials. The pipe material shall be new and homogeneous throughout and
free from visible cracks, holes, foreign materials, blisters, wrinkles and
dents.

All vent pipes shall be anchored in an approved manner so as to prevent

displacement or movement during the placement of concrete. No separate
payment for vent pipes will be made by the Client.

4/36.3.12 Opening Bridges to Traffic

No equipment or vehicular traffic will be allowed on any bridge

superstructure until the post-tensioning and grouting operation is
completed, falsework has been removed, and all concrete has been cured
for the time required in these Particular Specifications, or as further directed
by the Engineer.

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