Post-Tensioning Tendon Installation and Grouting Manual Version 2.0 May 2013 FHWA-NHI-13-026 This Page Intentionally Left Blank. Technical Report Documentation Page 1. Report No. FHWA-NHI-13-026 2. Government Accession No. 3. Recipient’s Catalog No. 4. Title and Subtitle Post-Tensioning Tendon Installation and Grouting Manual 5. Report Date May 2013 6. Performing Organization Code: 7. Author(s) John Corven, P.E. and Alan Moreton, P.E 8. Performing Organization Report No. 9. Performing Organization on Name and Address Ideation, Inc. 14150 Parkeast Circle Chantilly, VA 20151 10. Work Unit No. (TRAIS) 11. Contract or Grant No. DTFH61-11-D-00026 12. Sponsoring Agency Name and Address Office of Bridge Technology, HIBT-10 Federal Highway Administration 400 7th Street, SW Room 3203 Washington, DC 20590 13. Type of Report and Period Covered Final Document 14. Sponsoring Agency Code 15. Supplementary Notes 16. Abstract: This Manual includes state-of-the-art information relative to materials, post-tensioning systems, construction practices and grouting of post-tensioning tendons for bridges. The Manual is targeted at Federal, State and local transportation departments and private company personnel that may be involved in the design, inspection, construction, or maintenance of bridges that contain post-tensioning tendons. This Manual will serve as a reference and guide to designers, inspectors and construction personnel for post-tensioning materials, installation and a grouting of bridge tendons. The document is part of the Federal Highway Administration’s national technology deployment program and may serve as a training manual. 17. Key Words Bridges, post-tensioning, tendons, grout, grouting, strands, bars, protection, ducts, inlets, outlets, tests, prestressed concrete, pretensioning, stressing, post-tensioning operations, prestressing steel, concrete, bleed. 18. Distribution Statement This manual can be obtained from the Office of Bridge Technology, Federal Highway Administration, 400 7th Street, SW, Room 3203, Washington, DC 20590. 19. Security Classification (of this report) Unclassified 20. Security Classification (of this page) Unclassified 21. No of Pages 184 22. Price Form DOT F 1700.7 (8-72) Reproduction of completed page authorized Federal Highway Administration Post-Tensioning Tendon Installation and Grouting Manual Federal Highway Administration Post- Tensioning Tendon Installation and Grouting Manual Preface This Manual includes state-of-the-art information relative to materials, post-tensioning systems, construction practices and grouting of post-tensioning tendons for bridges. The Manual is targeted at Federal, State and local transportation department and private company personnel that may be involved in the design, inspection, construction or maintenance of bridges that contain post-tensioning tendons. This Manual will serve as a reference and guide to designers, inspectors and construction personnel for post-tensioning materials, installation and grouting of bridge tendons. The document is part of the Federal Highway Administration’s national technology deployment program and may serve as a training manual. Version 2.0 May 2013 Page i Federal Highway Administration Post-Tensioning Tendon Installation and Grouting Manual This Page Intentionally Left Blank. Version 2.0 May 2013 Page ii Federal Highway Administration Post-Tensioning Tendon Installation and Grouting Manual Table of Contents Chapter 1 - Introduction ............................................................................................................. 1 1.1 Objective ...................................................................................................................... 1 1.1.1 Benefits of Post-Tensioning .................................................................................. 1 1.1.2 Principle of Prestressing ....................................................................................... 1 1.1.3 Post-Tensioning Operations ................................................................................. 2 1.1.4 Post-Tensioning Systems ..................................................................................... 3 1.2 Permanent Post-Tensioned Applications ..................................................................... 6 1.2.1 Cast-in-Place Bridges on Falsework ..................................................................... 6 1.2.2 Post-Tensioned AASHTO, Bulb-T, and Spliced Girders ........................................ 6 1.2.3 Precast Segmental Balanced Cantilever Bridges .................................................. 8 1.2.4 Cast-in-Place Segmental Balanced Cantilever Bridges ........................................16 1.2.5 Precast Segmental Span-by-Span Bridges ..........................................................18 1.2.6 Precast Segmental Progressive Cantilever Bridges .............................................21 1.2.7 Transverse Post-Tensioning of Superstructures ..................................................22 1.2.8 Post-Tensioning of Substructures ........................................................................25 1.3 Temporary Longitudinal Post-Tensioning (Bars) – Typical Applications ......................31 1.3.1 Erection of Precast Cantilever Segments .............................................................31 1.3.2 Closure of Epoxy Joints in Span-by-Span Erection ..............................................33 Chapter 2 – Post-Tensioning System Materials and Components .............................................. 1 2.1 Prestressing Steel ........................................................................................................ 1 2.1.1 Strands and Bars .................................................................................................. 1 2.1.2 Shipping, Handling and Storage............................................................................ 3 2.1.3 Acceptance ........................................................................................................... 3 2.2 Anchorages and Associated Hardware ........................................................................ 5 2.2.1 Anchorages .......................................................................................................... 5 2.2.2 Post-Tensioning Bars Anchor Systems ................................................................. 7 2.2.3 Permanent Grout Caps ......................................................................................... 8 2.3 Ducts ........................................................................................................................... 8 2.3.1 Duct Size .............................................................................................................. 9 2.3.2 Ducts for Tendons ................................................................................................ 9 2.3.3 Shipping, Handling and Storage of Ducts .............................................................15 Version 2.0 May 2013 Page iii Federal Highway Administration Post-Tensioning Tendon Installation and Grouting Manual 2.3.4 Acceptance of Duct Materials ..............................................................................15 2.3.5 Acceptance of Post-Tensioning System ...............................................................15 2.4 Grout...........................................................................................................................16 2.4.1 Purpose ...............................................................................................................16 2.4.2 Cement and other Pozzolans for Grout ................................................................16 2.4.3 Admixtures ...........................................................................................................17 2.4.4 Pre-bagged Grouts ..............................................................................................17 2.4.5 Thixotropic vs. Non-Thixotropic Grout ..................................................................18 2.4.6 Laboratory Tests ..................................................................................................18 2.4.7 Shipping, Handling, Storage and Shelf-Life ..........................................................22 2.4.8 Acceptance ..........................................................................................................22 2.4.9 Field Mock-Up Tests ............................................................................................23 2.5 Other PT System Qualification Tests ..........................................................................23 Chapter 3 – Post-Tensioning Duct and Tendon Installation ........................................................ 1 3.1 Shop Drawings ............................................................................................................ 1 3.1.1 Drawings and Details ............................................................................................ 1 3.1.2 Stressing Calculations .......................................................................................... 4 3.2 Tendon Testing On Site ..............................................................................................14 3.2.1 Friction .................................................................................................................14 3.2.2 Modulus of Elasticity ............................................................................................16 3.3 Anchor