POST–TENSIONED SLAB/BEAM/RAFTER–METHODOLOGY BY M/s.
SPS
1. INTRODUCTION
Post–Tensioning of the slabs/Beam/Rafter be carried out in accordance with:
The Post – tensioning bonded Flat Slab system shall consist of High Tensile strands of 12.9 mm Dia and contained in a duct. Each strand is anchored by means wedge/grip and individually stressed by means of a mono-strand jack. The pre-stressing force is transferred to the concrete by anchorage.
2. Strands
12.9mm size of seven-wire stress-relieved strand is recommended.
Nominal diameter 12.9 mm
Nominal Area 100 mm2
Nominal weight 0.775-0.786 kg/m
Min. Ultimate strength 1860 N/mm2
Modules of elasticity 195 kN/mm2
Certificates Mill Certificate for each shipment
Strand quality in accordance with IS 14268
3. Ballooning procedure for fixed end
Strand at the fixed end is ballooned by means of mechanical device (Jack). Compressive force up to 2.0/ 3.0 Metric Tonne is applied at 250/300 mm length of strand end to develop an onion shape of dead end.
Fixed length i.e. the length between the bulb and the end of sheathing shall be as per the drawing. Anti-bursting ring shall be provided at the end of sheathing as shall be shown in the drawing. Minimum fixed length, however, shall be 900 mm.
4. Sheathing
The ducts shall be of the spiral – corrugated type. Unless otherwise specified, the material shall be galvanized steel CRCA Strips.
5. Anchorage System:
In Post-Tensioning systems for bonded tendons, the following anchorage systems are available:
Test certificates- physical as well as chemical; for the anchorages materials (anchor cones and anchor heads) shall be submitted by the contractor. Parent material for any anchor cone shall be Cast Iron
No damaged anchorage shall be used. Steel parts shall be protected form corrosion at all times.
All bearing surfaces of the anchorage shall be cleaned prior to concreting and tensioning. Un-tensioned steel reinforcement and anchorage shall conform to details of pre-stressing system and as shown on the drawing.
6. Post – Tensioning
Pre–stressing tendon shall be accurately profiled and maintained in position, both vertically and horizontally, as per drawings. Tendon shall be so arranged that they have a smooth profile without sudden bends and kinks. The positioning of pre-stressed cables shall be such as to facilitate easy placement and vibration of concrete in between the tendons, at stressing end and dead anchorages. The minimum spacing between the tendons and edge distance shall be as per recommendation of the system supplier and / or as per drawings.
Sheathing shall be placed in correct position and profiles suitable ladders / chairs made from 8 or 10 mm dia rod may be provided at required intervals on slab soffit. Sheathing shall be tied rigidly with such ladders / chairs bars so that they do not get disturbed during concreting. The method of supporting and fixing shall be such that profile of cables is not disturbed during vibrations, by pressure or wet concrete, by workmen or by construction traffic. Wherever possible tendons shall be handled with care to avoid damage or contamination to either the tendon or the sheathing.
7. General Working Procedures
Storage and Handling
All materials shall be stored appropriately and in orderly manner.
All materials shall be periodically examined, say at monthly intervals.
Care shall be taken during handling to avoid mechanical damages.
SIDDHESH PROJECTS & SERVICES
Office No.702,Vantage Tower, Bavdhan , Pune-411021. Placing of Post – Tensioning Material.
General Sequence of works should adhere to the following guidelines:
a. Place bottom layer of rebars in slabs and beams/rafter on completion of
Bottom Shuttering.
b. Lay post-tensioning tendons to correct profiles.
c. Place top layer of rebar’s in slabs and beams/rafter.
NB: For edge beams where tendons are anchored, open links be used. Top longitudinal rebars and closing links are to be placed tendons are installed.
It is of paramount importance that the Main Contractor and the Owner’s authorized representative shall ensure that the placement of rebar is does not interfere with tendon profiling. Should there be any conflict, priority should be given to correct tendon placement.
Placement Procedure of Tendons
The tendons are usually assembled on site. The procedure is as follows:-
Positioning and fixing of block-outs for stressing anchorages to the edge formwork or construction joint formwork
Cut hole to the edge formwork for each anchorage to accommodate protruding strands (by Main Contractor)
Place tendons according to tendon layout.
Anchorage fixing at active end/stressing end.
Anti-bursting reinforcement fixing at active end and dead end.
For effective water tightness joint will be sealed by masking tape.
Lay tendons to correct profiles with support bars and chairs.
Grout Pipe fixing.
Checking for alignment and straightness of tendons.
SIDDHESH PROJECTS & SERVICES
Office No.702,Vantage Tower, Bavdhan , Pune-411021. Important
All tendon profiles shall be measured from formwork level
Do not damage ducts with tie bars or formwork.
Avoid stepping on ducts placed.
Check visually the axis of ducts and fixation at supports before concreting.
Repair any damage with tapes.
Pour concrete carefully and avoid any damage or duct and profile by vibrators.
8. Alignment & jointing of Beam/Rafter precast components.
Precast beam/rafter components place on a level pedestal/Platform according
to the design profile. After alignment, insert the tendon as per profiles and numbers according to the sequence mentioned above. Mix the Sikadur®-31 SBA S-02 IN – Part A(Resin) & Part B (Hardener) as per technical data sheet/Manufacture’s instruction. (Ref product TDS) Apply ( Sikadur®-31 SBA S-02 IN) mixed adhesive to the (Rafter/Beam surface) prepared surface with a spatula, trowel, notched trowel or with hands protected by gloves. After applying adhesive, join the components according to the exact profile within the pot life. After jointing the rafter/beam components, follow the tendon stressing and further process as per the sequence below mentioned.
9. Stressing
Stressing can commence after the concrete has attained minimum cube strength of 28 N / mm2 or otherwise stated in the drawing, whichever is greater.
10. Cutting of Strands
After completion of stressing works and approval of the stressing records by the Authorized Representative/Consultant, excess length of strands are to be cut-off by means of a
SIDDHESH PROJECTS & SERVICES
Office No.702,Vantage Tower, Bavdhan , Pune-411021. grinding disc or fiber cutter minimum 20 mm from the edges where the tendon will be gripped by the anchorage.
11. Tendon Stressing Report
Stressing results for each tendon shall be recorded during the stressing operation. Copies of the records shall be given to authorized representative or Consultant who shall approve or comment on these records. Stressing time: After seven days or on receipt of strength 70% i.e (28 MPa)
12. Interpretation of Tendon Stressing Report
A perfect log/record to be maintained for all the stressing operations and difficulties encountered, if any, in particular in approved formats for each Tendon.
13. Safety Precautions :
Special precaution shall be taken when working near tendons, which have been tensioned or are in the process of being tensioned. Use of PPE during stressing operations is a must. Principal Contractor shall provide adequate platform of minimum 400 mm beyond the edge of the slab/beam/rafter for stressing purposes.
Do not stand behind the jack during all stressing operation.
Fosroc Cebex 100 or equivalent : 225 gm per cement bag
Mixing Time : Minimum 2 minutes
Mixing Sequence : Water-cement-additive
ii) Grouting of Tendons
After all tests have been done and the suitable mix is determined, preparation for grouting of tendons may proceed
Prior to grouting, anchorage block-outs shall be patched by Main Contractor as
specified in the drawings. (Unless, otherwise stated)
Grout vents are fitted to the ducts at the alternate high points, each tube cone and dead end of ducts Grouting methodology is effective up to 45 degree Celsius beyond 45 degree atmospheric temperature ice to be used.
Start injecting grout form the anchorage end. When regular grout outflow appears at the vents, close vents consecutively in the direction of flow.
Grout must flow from the outlet until any residual flushing water or entrapped air has been removed. When regular grout outflow appears at outlet, lock the grout vent and maintain the working pressure for approximately 1 minute, the pressure should be constant before stopping the operation.
Pressure should be duly controlled so as not to cause segregation of grout.
After 24 hrs of the grouting, the grout hoses left out for injection of grout are cut-off flush to the slab/beam level
Grouting of the rafter will be done after rafter is placed at its final position / place.
v) Interruption of Grouting Operation
In case of an interruption (more than hour), the grout shall be flushed with water. Maintain a perfect record of the w/c ratio, admixture concentration, pump Pressure and lock pressure for each set of cables in specific format for all operations.
15. Breakage of Anchorage
During concreting care will be taken. However in case of breakage of anchorage the same should be replaced by new anchorage. The weak area of concrete and damaged anchor shall be removed by mechanical device .Then new anchor shall be fixed and remaining area to be filled by GP2. After three to four days the new anchor shall be stressed In case of slippage & breakage of strand as per codal provision in bridges, 2% breakage of strand area of a cable is permissible.
