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
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.
This Page Intentionally Left Blank.
Table of Contents

Chapter 1 - Introduction ...................................................... Error! Bookmark not defined.

1.1 Objective .................................................................. Error! Bookmark not defined.
1.1.1 Benefits of Post-Tensioning ............................... Error! Bookmark not defined.
1.1.2 Principle of Prestressing .................................... Error! Bookmark not defined.
1.1.3 Post-Tensioning Operations .............................. Error! Bookmark not defined.
1.1.4 Post-Tensioning Systems................................... Error! Bookmark not defined.
1.2 Permanent Post-Tensioned Applications .................. Error! Bookmark not defined.
1.2.1 Cast-in-Place Bridges on Falsework .................. Error! Bookmark not defined.
1.2.2 Post-Tensioned AASHTO, Bulb-T, and Spliced GirdersError! Bookmark not
defined.
1.2.3 Precast Segmental Balanced Cantilever Bridges Error! Bookmark not defined.
1.2.4 Cast-in-Place Segmental Balanced Cantilever BridgesError! Bookmark not
defined.
1.2.5 Precast Segmental Span-by-Span Bridges ........ Error! Bookmark not defined.
1.2.6 Precast Segmental Progressive Cantilever BridgesError! Bookmark not
defined.
1.2.7 Transverse Post-Tensioning of Superstructures. Error! Bookmark not defined.
1.2.8 Post-Tensioning of Substructures ...................... Error! Bookmark not defined.
1.3 Temporary Longitudinal Post-Tensioning (Bars) – Typical Applications ........... Error!
Bookmark not defined.
1.3.1 Erection of Precast Cantilever Segments ........... Error! Bookmark not defined.
1.3.2 Closure of Epoxy Joints in Span-by-Span ErectionError! Bookmark not
defined.

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

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 Installation ......................................................................................................17
3.3.1 Anchorages .........................................................................................................17
3.3.2 Local Zone Reinforcement ...................................................................................17
3.4 Duct Installation ..........................................................................................................19
3.4.1 Alignment .............................................................................................................19
3.4.2 Duct Supports ......................................................................................................23 3.4.3
Splices and Connections .....................................................................................24
3.4.4 Grout Inlets and Outlets .......................................................................................25
3.4.5 Size of Pipes for Grout Inlets, Outlets and Drains ................................................25
3.4.6 Positive Shut-Offs ................................................................................................25
3.4.7 Protection of Ducts during Concrete Placement ...................................................26
3.4.8 Protection of Ducts after Concrete Placement......................................................29
3.5 Tendon Installation......................................................................................................30

3.5.1 Tendon Types ......................................................................................................30

3.5.2 Proving of Internal Post-Tensioning Ducts ...........................................................30
3.5.3 Installation Methods .............................................................................................30
3.5.4 Aggressive Environments ....................................................................................31
3.5.5 Time to Grouting and Temporary Tendon Protection ...........................................32
3.6 Jacks and Other Stressing Equipment ........................................................................32
3.6.1 Types ...................................................................................................................32
3.6.2 Calibration ...........................................................................................................35
3.7 Jacking Methods .........................................................................................................37
3.7.1 Single (Mono) Strand Stressing ...........................................................................37
3.7.2 Multi-Strand .........................................................................................................38
3.7.3 Bar Tendons ........................................................................................................41
3.8 Stressing Operations ..................................................................................................41
3.8.1 Personnel and Safety ...........................................................................................41
3.8.2 Jacking Force ......................................................................................................41
3.8.3 Measuring Elongations on Strand Tendons .........................................................42
3.8.4 Measuring Elongations on PT Bars ......................................................................43
3.8.5 Field Variables .....................................................................................................43
3.8.6 Final Force ...........................................................................................................45
3.8.7 Strand End Cut-Off ..............................................................................................45
3.8.8 Lift-Off ..................................................................................................................45
3.9 Stressing Records.......................................................................................................46
3.10 Stressing Problems and Solutions ..............................................................................46
3.10.1 Strand Slip ...........................................................................................................46
3.10.2 Wire Breaks .........................................................................................................47
3.10.3 Elongation Problems ............................................................................................47
3.10.4 Breaking Wedges ................................................................................................48
Chapter 4 – Grouting of Post-Tensioning Tendons .................................................................... 1
4.1 Grouting Plan ............................................................................................................... 1
4.2 Grout Testing ............................................................................................................... 2
4.3 Grouting Operations ..................................................................................................... 2
4.3.1 Verification of Post-Tensioning Duct System Prior to Grouting .............................. 2
4.3.2 Grouting Equipment .............................................................................................. 3

4.3.3 Batching and Mixing.............................................................................................. 7

4.3.4 On-Site Tests of Production Grout ........................................................................ 7
4.3.5 Injection of Grout .................................................................................................. 9
4.3.6 Grout Injection of Superstructure Tendons ............................................................ 9
4.3.7 Grout Injection of Vertical Tendons ......................................................................10
4.3.8 Post-Grouting Inspection .....................................................................................11
4.3.9 Filling Voids by Vacuum Grouting ........................................................................12
4.3.10 Sealing of Grout Inlets and Outlets ......................................................................14
4.3.11 Protection of Post-Tensioning Anchorages ..........................................................14
4.3.12 Grouting Report ...................................................................................................15
4.4 Grouting Problems and Solutions ................................................................................15
4.4.1 Interruption of Grout Flow ....................................................................................15
4.4.2 Too High Grouting Pressure ................................................................................16
4.4.3 Incomplete Grouting.............................................................................................16
4.4.4 Unanticipated Cross-Grouting ..............................................................................16
4.4.5 Production Grout Fluidity Unacceptable ...............................................................16
4.5 Examples of Grouting Procedures ..............................................................................16
4.5.1 Example 1: Two-Span Spliced Ι-Girder (Figure 4.3) .............................................16
4.5.2 Example 2: Four-Span Spliced Ι-Girder (Figure 4.4) ............................................17
4.5.3 Example 3: Cantilever and Drop-In Spliced 3-Span Ι-Girder (Figure 4.5) .............18

4.5.4 Example 4: Cast-in-Place on Falsework (Figure 4.6) ...........................................18

4.5.5 Example 5: Cantilever or Top Continuity Post-Tensioning (Figure 4.7) ................19
4.5.6 Example 6: Bottom Continuity Tendon in Variable Depth Cantilever (Figure 4.8) .20
4.5.7 Example 7: End Span External Tendon in Span-by-Span Structure (Figure 4.9) ..20
4.5.8 Example 8: Inlet and Outlet Connections to Bottom External Tendon (Figure 4.11)
21
4.5.9 Example 9: Lateral Tendons in Hammerhead Pier Cap (Figure 4.12) ..................22
4.5.10 Example 10: Vertical Post-Tensioning in Pier (Figure 4.13) .................................23
4.5.11 Example 11: Cantilever C-Pier (Figure 4.14) .......................................................24
Chapter 5 – Corrosion Protection of Post-Tensioning Tendons .................................................. 1
5.1 Corrosion Protection .................................................................................................... 1
5.1.1 Background .......................................................................................................... 1
5.1.2 Corrosion Protection of Post-Tensioning Tendons ................................................ 2

5.1.3 Post-Tensioning System Tendon Protection Levels .............................................. 4

5.2 Corrosion Protection Materials ..................................................................................... 4
5.2.1 Concrete Cover ..................................................................................................... 4
5.2.2 Ducts .................................................................................................................... 4
5.2.3 Grout .................................................................................................................... 5
5.2.4 Other Considerations ............................................................................................ 5
5.3 Corrosion Protection along a Tendon ........................................................................... 6
5.3.1 Internal Tendons ................................................................................................... 6
5.3.2 External Tendons .................................................................................................. 6
5.4 Sealing Intermediate Inlets and Outlets ........................................................................ 7
5.4.1 Internal Tendons ................................................................................................... 7
5.4.2 External Tendons .................................................................................................. 8
5.5 Corrosion Protection at Anchorages ............................................................................ 8
5.5.1 Anchorage Protection Considerations ................................................................... 9
5.5.2 Permanent Grout Caps ......................................................................................... 9
5.5.3 Anchor Protection Details ..................................................................................... 9
5.5.4 Post-Tensioning Anchorage Protection Installation ..............................................15
5.6 Temporary Protection during Construction ..................................................................16
5.7 Watertight Box Girder Bridges ....................................................................................16
Appendix A – Terminology ......................................................................................................... 1
A.1 Post-Tensioning Systems ............................................................................................ 1 A.2
Post-Tensioning Grout Related Definitions .................................................................. 3 A.3
Contract Administration Definitions .............................................................................. 5 A.4
Abbreviations and Acronyms ....................................................................................... 6
Appendix B – Personnel Qualifications ...................................................................................... 1
B.1 Contractor’s Personnel ................................................................................................ 1
B.1.1 Project Engineer ................................................................................................... 1
B.1.2 Project Superintendent / Manager ......................................................................... 1 B.1.3
Foreman ............................................................................................................... 1
B.1.4 Crews for Tendon Installation and Stressing ......................................................... 1
B.1.5 Crews for Tendon Grouting ................................................................................... 2
B.2 Construction Engineering and Inspection (CEI) ............................................................ 2
B.2.1 Resident Engineer or Senior Project Engineer ...................................................... 2

B.2.2 Project Engineer ................................................................................................... 2 B.2.3

Lead Inspector ...................................................................................................... 2
B.2.4 Inspector ............................................................................................................... 2
Appendix C – Bibliography ......................................................................................................... 1
Table of Figures

Figure 1.1 - Reinforced Concrete Beam Under Load ................................................................. 1

Figure 1.2 - Comparison of Reinforced and Prestressed Concrete Beams ................................. 2
Figure 1.3 - Typical Post-Tensioning Anchorage Hardware for Strand Tendons ........................ 4
Figure 1.4 - Typical Post-Tensioning Bar System Hardware ...................................................... 4
(Courtesy of Dywidag Systems International) ............................................................................. 4
Figure 1.5 - Typical Post-Tensioning Bar System Hardware ...................................................... 5
(Courtesy of Williams Form Engineering Corporation) ................................................................ 5
Figure 1.6 - Cast-In-Place Post-Tensioned Construction in California ........................................ 6
Figure 1.7 - Spliced Haunched I-Girder of Main Span Unit ......................................................... 7
Figure 1.8 - Erection Sequence and Temporary Supports for Spliced I-Girder ........................... 8
Figure 1.9 - Precast Segmental Balanced Cantilever Construction ............................................ 9
Figure 1.10 - Typical Balanced Cantilever Segment ..................................................................10
Figure 1.11 - Cantilever Post-Tensioning Tendons Anchored on End Faces .............................11
Figure 1.12 - Cantilever Post-Tensioning Tendons Anchored in Top Blisters ............................12
Figure 1.13 - Bottom Continuity Tendons for Balanced Cantilever Construction ........................13
Figure 1.14 - Top Continuity Tendons for Balanced Cantilever Construction .............................14
Figure 1.15 - Bottom Continuity Tendons near Expansion Joint at a Support ............................15
Figure 1.16 - In-Span Hinges in Balanced Cantilever Construction ...........................................16
Figure 1.17 - Cast-In-Place Segmental Construction using Form Travelers ..............................17
Figure 1.18 - Typical Construction Stages for Cast-In-Place Balanced Cantilever Construction 17
Figure 1.19 - Span-By-Span Construction .................................................................................18
Figure 1.20 - Typical Span Post-Tension for Span-By-Span Construction .................................19
Figure 1.21 - Expansion Joint Span Post-Tensioning for Span-By-Span Construction ..............20
Figure 1.22 - External/Internal Span-By-Span Tendons ............................................................21
Figure 1.23 - Progressive Construction of the Linn Cove Viaduct ..............................................22
Figure 1.24 - Transverse Post-Tensioning in the Top Slab of Box Girder ..................................23
Figure 1.25 - Transverse Post-Tensioning in Diaphragms .........................................................24
Figure 1.26 - Vertical Post-Tensioning in Diaphragms ...............................................................24
Figure 1.27 - Transverse Post-Tensioning in Deviation Ribs .....................................................25
Figure 1.28 - Vertical Post-Tensioning in Webs .........................................................................25
Figure 1.29 - Post-Tensioning in Hammerhead Piers ................................................................26
Figure 1.30 - Post-Tensioning in Straddle Bents .......................................................................27
Figure 1.31 - Post-Tensioning in Cantilever Piers .....................................................................28
Figure 1.32 - Precast Hollow Segmental Piers, Foothills Bridge No. 2 ......................................29
Figure 1.33 - Precast I-Piers .....................................................................................................30
Figure 1.34 - Natchez Trace Parkway Arches, Tennessee ........................................................31
Figure 1.35 - Applying Epoxy between Precast Segments ........................................................32 at
the Foothills Parkway Bridge No. 2 .......................................................................................32 Figure
1.36 - Stressing Temporary Bar in Bottom Slab .............................................................32 of the
Foothills Parkway Bridge No. 2 .......................................................................................32 Figure 2.1
- Basic Bearing Plate Anchorage System .................................................................. 5 Figure 2.2 -
Multi-Plane Anchorage System (Courtesy of VSL) .................................................. 6 Figure 2.3 -
Anchorage System for Flat Duct Tendon (Courtesy of DSI) .................................... 6
Figure 2.4 - Post-Tensioning Bar Anchorage System (Courtesy of DSI)..................................... 7
Figure 2.5 - Permanent Plastic Grout Caps (Courtesy of VSL) ................................................... 8
Figure 2.6 - Corrugated Metal Duct ...........................................................................................10
Figure 2.7 - Corrugated Plastic Duct .........................................................................................11
Figure 2.8 - Grout Vents at Center of a Precast Segmental Pier Segment ................................12
Figure 2.9 - Duct Coupler for Precast Segmental Internal Tendons...........................................13
Figure 2.10 - Duct Couplers in Precast Segmental Construction ...............................................13
Figure 2.11 - Pressure Distribution: Diabolos vs. Steel Pipe......................................................14
Figure 2.12 - Reusable Diabolo Inserts at Deviation Segment ..................................................15
Figure 2.13 - Standard and Modified ASTM C939 Flow Cone Testing ......................................19
Figure 2.14 - Wick-Induced Bleed Test .....................................................................................20
Figure 2.15 - Bleed Under Pressure Test (Gelman Filtration Funnel) ........................................21
Figure 3.1 - Typical Shop Drawing Approval Process for Post-Tensioning ................................. 4
Figure 3.2 - Frictional Losses Related to Friction and Wobble .................................................... 5
Figure 3.3 - Four-Span Girder .................................................................................................... 7
Figure 3.4 - Tendon Geometry ................................................................................................... 7
Figure 3.5 - Tendon force Diagram for Stressing at End A ......................................................... 9
Figure 3.6 - Tendon Force Diagram after Anchor Set at End A .................................................10
Figure 3.7 - Tendon Force Diagram after Stressing from End B ................................................11
Figure 3.8 - Tendon Force Diagram after Anchor Set at End B .................................................11
Figure 3.9 - External Deviated Tendon in End Span .................................................................12
Figure 3.10 - Example 2: External Tendon Force after Friction and Anchor Set ........................13
Figure 3.11 - On-Site Friction Test ............................................................................................16
Figure 3.12 – On-Site Bench Test for Modulus of Elasticity .......................................................17
Figure 3.13 - General and Local Anchor Zone in End of I-Girder ...............................................18
Figure 3.14 - Local Zone Reinforcing for Edge Anchor in Thin Slab ..........................................19
Figure 3.15 - Duct Spacing and Clearance in Post-Tensioned Precast Girders .........................20
Figure 3.16 - Check Longitudinal and Transverse Duct Alignments ..........................................21
Figure 3.17 - Anchor Recess and Checking of Duct Alignment .................................................22
Figure 3.18 - Unacceptable Duct Connections and Mistakes ....................................................23
Figure 3.19 - Duct Supports in Post-Tensioned Precast I-Girders .............................................24
Figure 3.20 - A Possible Result of Poorly Supported and Connected Ducts ..............................25
Figure 3.21 - Connections for Secondary, Vacuum Grouting Operations ..................................26
Figure 3.22 - Excess Wobble Due to Rebar and Duct Conflict ..................................................27
Figure 3.23 - Duct Size in Post-Tensioned I-Girders .................................................................27
Figure 3.24 - Placing Concrete in Box Segments ......................................................................28
Figure 3.25 - Use of Internal Vibrators for Consolidation of Concrete ........................................29
Figure 3.26 - Steel wire sock for installing multi-strand tendon ..................................................31
Figure 3.27 - Monostrand Jack ..................................................................................................33
Figure 3.28 - Typical Multi-Strand, Center Hole, Stressing Jack ................................................34
Figure 3.29 - Prestressing Bar Jack ..........................................................................................35
Figure 3.30 - Jack Calibration ...................................................................................................36
Figure 3.31 - Calibration Chart for Pressure Gauge and Jack Force .........................................37
Figure 3.32 - Alternate End Stressing .......................................................................................39
Figure 3.33 - Stresses Along Tendon for Different Modes of Stressing .....................................40
Figure 3.34 - Anchor Set or Wedge Set ....................................................................................44
Figure 3.35 - Example Stressing Record Page 1 of 2 ................................................................49
Figure 3.36 - Example Stressing Record Page 2 of 2 ................................................................50
Figure 4.1 - Grout Mixing and Pumping Equipment .................................................................... 4
Figure 4.2 - Vacuum Grouting Equipment, Digital Volumeter (up (upper left), Void Volume
Measurement (upper right), Grout Pump (lower left), Vacuum Grout injection (lower right) . 6
Figure 4.3 - Grouting Details for a 2-Span Spliced Girder Duct System ....................................17
Figure 4.4 - Grouting Details for a 4-Span Spliced Girder Duct System ....................................17
Figure 4.5 - Grouting Details for a 3-Span, Drop-in and Spliced Girder Duct System ................18
Figure 4.6 - Grouting Details for Cellular Box Girder, Voided, or Solid Slab Duct System .........19
Figure 4.7 - Grouting of Cantilever Tendons (Top Continuity Tendons Similar) .........................19
Figure 4.8 - Grouting Bottom Continuity Tendons in Variable Depth Box Girders ......................20
Figure 4.9 - Grouting details for end span, external tendon .......................................................21
Figure 4.10 - Grouting vent locations at pier segments in span-by-span bridges .......................21
Figure 4.11 - Possible Grout and Drainage Connections for Bottom External Tendons .............22
Figure 4.12 - Grouting Details for Lateral Tendons in Hammerhead Pier Cap ...........................22
Figure 4.13 - Grouting Details for Vertical Tendons in Piers ......................................................23
Figure 4.14 - Grouting Details and Anchor Protection for Vertical and Lateral Tendons in C-Pier
..........................................................................................................................................24
Figure 5.1 – Levels of Protection for Corrosion Protection ......................................................... 2
Figure 5.2 – Levels of Protection to Internal Tendons ................................................................ 6
Figure 5.3 – Levels of Protection to External Tendons ............................................................... 7
Figure 5.4 – Sealing of Inlets and Outlets along Internal Tendons ............................................. 8
Figure 5.5 – Sealing of Inlets and Outlets along External Tendons ............................................ 8
Figure 5.6 – Anchor Protection Details at End Anchorages .......................................................10
Figure 5.7 – Anchor Protection Details at Top Anchorages .......................................................11
Figure 5.8 – Anchor Protection at Interior Piers .........................................................................12
Figure 5.9 – Anchorage Protection for Cantilever Tendons Anchored in Blisters .......................13
Figure 5.10 – Protection of Anchorages at Expansion Joints.....................................................13