Post-Tensioning Tendon Installation and Grouting Manual

List of Figures and Tables

Chapter 1

Figure 1.1 Reinforced concrete beam under load
Figure 1.2 Comparison of Reinforced and Prestressed Concrete Beams
Figure 1.3 Typical Post-Tensioning Anchorage Hardware for Strand Tendons
Figure 1.4 Typical Post-Tensioning Bar System Hardware
Figure 1.5 Typical Post-Tensioning Bar System Hardware
Figure 1.6 Cast-In-Place Post-Tensioned Construction in California
Figure 1.7 Spliced Haunched I-Girder of Main Span Unit
Figure 1.8 Erection Sequence and Temporary Supports for Spliced I-Girder
Figure 1.9 Cast-In-Place Segmental Construction using Form Travelers
Figure 1.10 Foothills Parkway, Tennessee
Figure 1.11 Precast Segmental Balanced Cantilever Construction
Figure 1.12 Typical Balanced Cantilever Segment
Figure 1.13 Bottom Continuity Tendons for Balanced Cantilever Construction
Figure 1.14 Span-By-Span Construction
Figure 1.15 Interior Span Post-Tensioning for Span-By-Span Construction
Figure 1.16 Post-Tensioning in Hammerhead Piers
Figure 1.17 Post-Tensioning in Straddle Bents
Figure 1.18 Post-Tensioning in Cantilever Piers
Figure 1.19 Precast Hollow Segmental Piers, Linn Cove Viaduct, North Carolina
Figure 1.20 Precast I-Piers
Figure 1.21 Natchez Trace Parkway Arches, Tennessee
Figure 1.22 Temporary PT Bars for Segment Erection

Chapter 2

Figure 2.1 Standard and Modified ASTM C939 Flow Cone Test
Figure 2.2 Wick Induced Bleed Test
Figure 2.3 Bleed Under Pressure Test (Gelman Filtration Funnel)
Figure 2.4 Spiral Wound Steel Duct and Rigid Steel Pipe
Figure 2.5 Corrugated Plastic Duct
Figure 2.6 Basic Anchor Plate
Figure 2.7 Multi-plane Anchor
Figure 2.8 PT-Bar Anchor Plate
Figure 2.9 Permanent (Plastic) Grout Cap to Anchor
Table 2.1 Permissible Bleed Under Pressure
Table 2.2 Physical Properties Required for Shrink Sleeves

Chapter 3

Figure 3.1 Typical Shop Drawing Approval Process for Post-Tensioning
Figure 3.2 Tendon Profile in Four-Span I-Girder
Figure 3.3 Calculated Tendon Force after Losses
Figure 3.4 External Deviated Tendon in End Span
Figure 3.5 External Tendon Force after Friction and Wedge Set
Figure 3.6 On-Site Friction Test
Figure 3.7 On-Site Bench Test for Modulus of Elasticity
Figure 3.8 Basic Anchor Bearing Plate
Figure 3.9 Multi-Plane Anchor
Figure 3.10 Anchor Plate for PT-Bar
Figure 3.11 General and Local Anchor Zone in End of I-Girder
Figure 3.12 Local Zone Reinforcing for Edge Anchor in Thin Slab
Figure 3.13 Duct Spacing and Clearance in Post-Tensioned Precast Girders
Figure 3.14 Check Longitudinal and Transverse Duct Alignments
Figure 3.15 Anchor Recess and Checking of Duct Alignment
Figure 3.16 Unacceptable Duct Connections and Mistakes
Figure 3.17 Duct Supports in Post-Tensioned Precast I-Girders
Figure 3.18 A Possible Result of Poorly Supported and Connected Ducts
Figure 3.19 Connections for Secondary, Vacuum Grouting, Operations
Figure 3.20 Unintentional Excess Wobble
Figure 3.21 Excess Wobble Due to Rebar and Duct Conflict
Figure 3.22 Duct Size in Post-Tensioned Girders
Figure 3.23 Placing Concrete in Box Segments
Figure 3.24 Use of Internal Vibrators for Consolidation of Concrete
Figure 3.25 Steel Wire Sock for Installing Multi-Strand Tendon
Figure 3.26 Monostrand Jack
Figure 3.27 Typical Multi-Strand, Center Hole, Stressing Jack
Figure 3.28 Prestressing Bar Jack
Figure 3.29 Jack Calibration
Figure 3.30 Calibration Chart for Pressure Gauge and Jack Force
Figure 3.31 Alternate End Stressing
Figure 3.32 Stresses Along Tendon for Different Modes of Stressing
Figure 3.33 Anchor Set or Wedge Set
Table 3.1(a) Example 1: Elongation of Profiled Tendon in Four-Span Girder (Fig. 3.2)
Table 3.1(b) Example 1 continued: Elongation of Profiled Tendon in Four-Span Girder (Fig. 3.3)
Table 3.2 Example 2: Elongation of External Deviated Tendon in End-Span (Fig. 3.4)
Table 3.3(a) Stressing Report - Example 1: Profiled Tendon in Four-Span Girder (Fig. 3.2 and 3.3)
Table 3.3(b) Stressing Report - Example 1 continued: Profiled Tendon in Four-Span Girder(Figs 3.2 and 3.3)

Chapter 4

Figure 4.1 Grout Mixing and Pumping Equipment
Figure 4.2 Vacuum Grouting Equipment
Figure 4.3 Grouting Details for a Two-Span Spliced Girder Duct System
Figure 4.4 Grouting Details for a Four-Span Spliced Girder Duct System
Figure 4.5 Grouting Details for a Three-Span, Drop-In and Spliced Girder Duct System
Figure 4.6 Grouting Details for Cellular Box, Voided or Solid Slab Duct System
Figure 4.7 Grouting of Cantilever (at Top Continuity) Tendons
Figure 4.8 Grouting Bottom Continuity Tendons in Variable Depth Box Girders
Figure 4.9 Grouting Details for End Span, External Tendon
Figure 4.10 Grouting Vent Locations at Pier Segments in Span-By-Span Bridges
Figure 4.11 Possible Grout and Drainage Connections for Bottom External Tendons
Figure 4.12 Grouting Details for Lateral Tendons in Hammerhead Pier Cap
Figure 4.13 Grouting and Anchor Details for Vertical Tendons in Piers
Figure 4.14 Grouting Details and Anchor Protection for Vertical and Lateral Tendons in C-Pier

Appendix C

Figure C.1 Cantilever Post-Tensioning Tendons Anchored on End Faces
Figure C.2 Cantilever Post-Tensioning Tendons Anchored in Top Blisters
Figure C.3 Bottom Continuity Tendons for Balanced Cantilever Construction
Figure C.4 Top Continuity Tendons for Balanced Cantilever Construction
Figure C.5 Bottom Continuity Tendons Near Expansion Joint at a Support
Figure C.6 In-Span Hinges in Balanced Cantilever Construction
Figure C.7 Expansion Joint Span Post-Tensioning for Span-By-Span Construction
Figure C.8 External/Internal Tendons
Figure C.9 Construction of the Linn Cove Viaduct
Figure C.10 Transverse Post-Tensioning in the Top Slab of Box Girder
Figure C.11 Transverse Post-Tensioning in Diaphragms
Figure C.12 Vertical Post-Tensioning in Diaphragms
Figure C.13 Transverse Post-Tensioning in Deviation Ribs
Figure C.14 Vertical Post-Tensioning in Webs

Appendix D

Figure D.1 Levels of Protection for Corrosion Protection
Figure D.2 Levels of Protection to Internal Tendons
Figure D.3 Levels of Protection to External Tendons
Figure D.4 Sealing of Inlets and Outlets along Internal Tendons
Figure D.5 Sealing of Inlets and Outlets along External Tendon
Figure D.6 Anchor Protection Details at End Anchorages
Figure D.7 Anchor Protection Details at Top Anchorages
Figure D.8 Anchor Protection at Interior Piers
Figure D.9 Anchor Protection for Cantilever Tendons Anchored in Blisters
Figure D.10 Protection of Individual Anchorages at Expansion Joints
Figure D.11 Protection of a Group of Anchors at an Expansion Joint Segment
Figure D.12 Anchorage Protection at Expansion Joints
Figure D.13 Possible Detail for Embedded Face Anchor