Prestressing Methodology Girder Casting Methodology
Prestressing Methodology Girder Casting Methodology
Prestressing Methodology Girder Casting Methodology
00 10-09-2011
Rev Date Prepared by Reviewed by Approved by
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LARSEN & TOUBRO LIMITED
ENGINEERING, CONSTRUCTION AND CONTRACTS
PROJECT QUALITY PLAN
SITE: SAMAKHIALI GANDHIDHAM ROAD PROJET
FROM 306.800 TO 362.420
QUALITY MANAGEMENT
1.0 OBJECTIVE
The objective of this method statement is to describe in detail all the
operations connected with the Post Tensioning work involved in the
construction of PSC Girder for VUP, Flyovers, ROB, Major Bridges etc.,
2.0 SCOPE OF WORK
The scope of work is post tensioning of superstructure as per section 1800 of
MoSRT&H, which consists of following operations at site:
a. Cutting of H.T Strand, laying and profiling of tendons.
b. Stressing of tendons.
c. Grouting of tendons.
These are dealt in detail in the following sections in this method
statement.
2.1 H.T Strands
H.T Strands of appropriate size and length as per the approved drawing
shall be procured and shall be tested to check for the compliance with the
specification.
3.0 EQUIPMENTS & ACCESSORIES
3.1 Equipment’s and Accessories Required for Stressing
a) Multi pulling Hydraulic Jack
b) Hydraulic Pumps
c) Bearing plate
d) Permanent wedges
e) Master wedges
f) Calibrated pressure gauges
g) High-pressure hose pipes
h) Low-pressure hose pipes
i) Tube Unit
3.2 Equipment’s and Accessories required For Grouting
a) Electric Grouting pump machine
b) Grout mixture with agitators
c) Calibrated pressure gauge
d) Water tank.
e) Grouting hose pipe
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4.0 CONSTRUCTION METHODOLOGY
In this section detailed methodology of carrying out post tensioning
operations of the superstructure is described.
4.1 H.T Strands Cutting, Identification and Transportation
a) The H.T Strand shall be brought to site in the form of coils. Each coil is
unloaded at site and stored off the ground under cover.
b) On receipt of coils, engineer shall check for its proper packing and
identification tags against the delivery challan.
c) The test certificates for each coil furnished by the manufacturer.
d) An area for cutting nearer to the site will be identified for Strand cutting.
e) The requisite number of cut Strands shall be bundled together and tied at
intervals with a binding wire. An identification tag is attached to each
bundle.
Indicating therein-span nos./tendon number for which this is formed.
These tags shall be removed from the bundle at the time of insertion into
the concerned duct. The Strand bundles with tags shall be kept free of
dust and sand.
4.2 Erection and Alignment of End Blocks
a) The Tube unit is fixed to the end block shutter with the aid of fasteners.
b) The end blocks are erected and aligned to the correct position and
supported firmly.
4.3 Tendon Laying and Profiling
a) The lengths of ducts are calculated as per the cutting length of the
tendons. GI Sheathing pipe are joined together by couplers.
b) GI Sheathing pipe of different lengths shall be jointed using
250mm coupler in such a way that there will be an equal lap on
either sides of joint.
c) The joints in Sheathing pipe are wrapped well by insulation tapes
so as to prevent slurry entry while concreting.
d) Chairs shall be welded at every 1m to the existing rebar in order to
maintain the cable profile as per the approved drawing.
e) The Sheathing pipe are laid on the welded chairs and secured by
binding wires properly.
4.4 Final Profiling Check and Concreting
Once the H.T Strands are inserted into the Sheathing ducts, the following
final checks are to be made by the site Engineer before concreting:
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a) The trumpet and Sheathing ducts connection is taped properly such that
concrete slurry can be prevented from flushing out.
b) Final profile checking is done and the same is to be cleared by the Engineer
before concreting.
c) During concrete make sure that the sheathing are in form position as per
profile.
4.5 Insertion of Anchor Head
a) After concreting, preparations shall be done for stressing. The stressing
operation shall be carried out after the concrete achieves the required
compressive strength.
Threading of H.T Strands, Insertion of Anchor Head
a) The threading method adopted is ‘Push-Through’ method. In this method
the H.T Strands are individually or few nos inserted in the duct.
b) The protruding strands are cleaned. This is done to remove dust; grease
or oil stains on the Strands.
c) The anchor head is cleaned well to remove anti corrosive oil, which is
applied before dispatch. The taper holes shall also be cleaned to remove
any dust / oil stains sticking on to the taper holes.
d) The H.T Strands shall be inserted one by one into the anchor head and
they shall be secured firmly by wedges.
4.6 Stressing Operations for Tendons
a) Stressing of Tendons shall be carried out after the concrete attains the
required strength.
b) Before stressing, the followings points shall be checked:
1. Calculate the maximum pressure required as per the jack details and
apply correction factors depending on the calibration certificate of the pressure
gauge and the jack.
2. Note the stressing sequence of the tendons as per drawing. This is
recorded in the stressing format.
c) The wedges shall be cleaned to remove dust or oil traces from the threads
of the wedges.
d) The grip lengths of the H.T Strands shall be cleaned to remove dirt or oil
traces.
e) The wedges shall be inserted on to the Strands and assembled by a
wedge-seating tool to seat properly on the tapered holes of the anchor
heads.
f) The hydraulic jack with wedge seating device shall be assembled over the
Anchor Head.
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g) A stressing head and lock nut shall be inserted on the Strands and bears
against the ram face of the jack. Master Wedges secures the stressing
head.
h) Master Wedges shall be seated properly by wedge seating tool and
secured in place by a stressing plate, which shall be fastened to the
stressing head by fasteners.
i) The hydraulic jack and wedge-seating device shall be connected to a
hydraulic pump by high and low-pressure hoses.
j) The stressing operations shall begin after aligning the hydraulic jack and an
initial force shall be given to remove any slackness in the tendon. Ram
movement shall be noted from this stage. The pressure shall be
increased slowly in stages up to the maximum required pressure. Ram
movement shall be noted for each increment of pressure.
k) Zero correction shall be calculated by drawing a graph from the pressure
and elongation readings recorded so far. The total elongation shall be
observed from these readings.
l) If elongation values correspond with calculated values (within tolerance),
the wedges shall be locked by wedge seating device. The draw-in of the
wedges at both the stressing ends shall be measured.
m) After wedges locking the jack shall be released and shifted to another
tendon as per stressing sequence. All observations will be recorded in the
Stressing Report.
4.7 Grouting Procedures
The purpose of Grouting is to provide permanent protection to the post-
tensioned tendon against corrosion and to develop a bond between the
pre stressing Strand and the surrounding concrete.
4.7.1 Materials Required For Grouting
Cement grout shall be prepared at site by mixing cement, water and
admixture as per the approved mix design.
4.7.2 Pre Grouting Operations
a) Grouting shall be carried out for the tendon after stressing. This shall be
done as soon as possible but not later than two weeks after completion of
stressing of the tendon.
b) The protruding Strands shall be cut with a disc cutter not closer than 25
mm from the face of the Anchor Head.
c) A Grout Cap shall be fixed to the anchor head by fasteners.
d) The tendon duct shall be washed well with water and then this water shall
be flushed by compressed air.
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e) Compressive Strength: Grout cubes of size 100 mm x 100 mm x 100 mm
shall be made to check the compressive strength at 7 days.
4.7.3 Grouting Operations
a) Grouting operations shall be started after completion of stressing.
b) Grout shall be injected into the tendon in a continuous manner without
any interruption.
c) Grouting shall be started with a low pressure. As the grout fills up and
flows forward, the pressure increases and allows flow of grout through
outlet till good consistency come out.
d) At this stage, pumping is stopped .The outlet is closed and the pumping
is resumed. The pressure increases and is allowed to buildup 5 Kg / Sq.
Cm. This pressure is maintained for about 1 min.
e) After this the inlet is closed and grout pipe is shifted to another tendon.
5.0 SAFETY
The following measures will be taken observed in addition to safety
precautions taken at construction sites, while carrying out post tensioning
operations.
5.1 General
a. Trained and experienced personnel shall be entrusted with carrying out
these operations.
b. Personnel should wear safety shoe, safety gloves and protective helmets
during stressing operations.
c. During grinding, cutting and grouting operations protective eye goggles should
be worn.
d. All hauling and supporting equipment for the pre-stressing jacks should
be checked
5.2 Safety Measures during Stressing
a. Check whether concrete in the vicinity of anchorage is free from cracks or
unsound pockets.
b. During stressing, no personnel should stand in the line of jack or in the
line of the corresponding fixed anchorage.
c. The personnel should always place themselves in a location offering
maximum safety in the event of failure of concrete, anchorage or H.T
Strand.
d. Hydraulic hoses should be checked before stressing operations.
e. Pressure gauges should be checked
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f. During stressing, the force and extension should be checked and
compared with theoretical values. Maximum values of force / extension
should not be exceeded.
g. Worn out electrical cables and damaged connections should be
immediately repaired.
j. Jacks will be secured in such a manner that they will be held in position,
should they loose their grip while tensioning is in progress.
5.3 Safety precautions during Grouting
a. All personnel engaged in operations where the danger of grout spray is
present e.g. Mixing Grout should wear protective eyeglasses.
b. If the Grout enters in the eye it should be washed out with clean water
and the patient to be taken immediately to an eye Doctor.
d. Grouting hose connections should be checked before grouting for any
signs of damage.
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