By Marc Friedheim and the Post

Tensioned Concrete Committee

January 2013

Reasons for changes/Problem Statement

PTI M55.1-12
Voids in ducts
Excessive bleed
Improved corrosion protection
Uniformity of product
Less room for error
Consistency with other DOTs
Construction, SP&I, PTI, and ASBI behind the changes

Benefits of well grouted tendons:

Corrosion protection
Bonding of strand within the duct and therefore integral behavior

Test Samples needed on each project to verify grout still

complies with AML properties previously tested

50-1.01C(4) Test Samples

Submit test samples for the materials to be used as shown in the following table:
Material
Uncoated stranda
Epoxy-coated strand:
Uncoated stranda
Coated stranda
Epoxy powder
Epoxy patching
material

Number of test
samples
1
1
4
1
1

Bara
Bar couplera

1
1

assembliesa
Prepackaged grout

1
1

aRandomly

Test sample description

4-foot-long sample from each reel or pack
4-foot-long sample of uncoated strand removed from each
reel or pack before coating
5-foot-long sample from each reel or pack of coated strand
8-ounce sample from each batchb
8-ounce sample from each batchb
7-foot-long sample of each size for each heat
Coupler from each lot of couplers with two 4-foot-long
barsc
assembly from each lot of anchorage assemblies
1 -60lb bag with a manufacturers date within 6 months of
planned placement in the bridge

selected by the Engineer.

in an airtight container and identified with the manufacturer's name and batch number.
cSubmit coupler and bar samples assembled. The bars must be from the same bar heats to be used in
the work.
bPackaged

Authorized Material List (AML) PT grout

Needed to maintain quality assurance
In-house in depth testing

50-1.01D Quality Control and Assurance

50-1.01D(1) General
The following items must be on the Authorized Material List:
1. Post-tensioning prestressing systems
2. Organic zinc-rich primer
3. Prepackaged grout

Minimum personnel qualifications

50-1.01D(1) General
The Department rejects any unidentified prestressing steel, anchorage assemblies, or bar couplers received at
the job site or casting site.
The contractor for post-tensioned concrete must have at least one person present during all operations who is
currently certified as a PTI Level 2 Bonded PT Field Specialist. In addition to the previous certification, the
foreman for each grouting crew must be an ASBI certified grouting technician. Proof of these certifications must
accompany the grouting plan.

Require a Grouting plan

Additional QA/QC

50-1.01D(4) Grouting plan

At least 4 weeks prior to the start of grouting tendons, the contractor is required to submit to the Engineer a written
grouting procedure for approval. This procedure must include the following elements:
a. Type, quantity, and brand of materials used in grouting, including all certifications required.
b. Type of equipment to be used, including provisions for backup equipment and spare parts.
c. Types and locations of inlets and outlets.
d. Types and sizes of grout hoses and connections.
e. Duct cleaning methods and equipment prior to grouting.
f. Mixing and pumping procedures.
g. Direction of grouting.
h. Sequence of use of the inlets and outlets.
i. Procedures for handling blockages.
j. Procedures for possible regrouting;
k. Names of persons in charge of grouting operations as well as names of personnel who will
perform the grouting operation, including their relevant experience, skill, and certifications.
The Engineer has 2 weeks to approve the grouting plan. If issues need to be addressed in the grouting plan, the
contractor must suspend grouting operations until all issues are resolved at least 2 weeks prior to grouting.

Criteria for rejection based on observations of rust

50-1.02B Prestressing Steel

The Engineer may reject prestressing steel that has
developed visible rust or other results of corrosion.
Prestressing steel will be rejected if surface rust either
cannot be removed with a fine steel wool pad, or once
removed, pits larger than 0.002 in. remain.

Grout Material Criteria

Prepackaged grout with thixotropic properties has zero bleed
Better flow properties within the duct
50-1.02C Grout
Unless specified by the Engineer, grout shall be Class C prepackaged grout as defined by the Post-Tensioning
Institute (PTI) Specification for Grouting of Post-Tensioned Structures. If grout is to be used in tendons longer
than 300ft, grout must have thixotropic properties. Grout may be stored onsite no longer than 1 month. Grout
must be mixed and placed within 6 months of the manufactured date printed on the packaging.

Cement and water grout is currently used and has the following
potential variations
HRWR agents (more bleed)
Water, must be carefully monitored
Plasticizers
Glenium 7500 (accelerates early strength)
Common prepackaged thixotropic grouts:
Masterflow 1205
Euco Cable Grout PTX
Sika Grout 300PT
Masterflow 1341

Prepackaged Grout used so far on segmental and vertical

applications:
Devils slide
Confusion Hill
SFOBB Skyway
Benicia Martinez
Antlers
Otay River Bridge
Pitkens Curve
Laural Street Overcrossing

Prepackaged grouts require the use of a high shear colloidal mixer

Water
tank with
overflow
Mixing
hopper

Holding hopper
with cont. feed to
pump

Superior mixing
compared to the
vane (paddle
type) mixers

Acknowledgment of
prepackged grout issues and
resolution:
Chlorides
Testing is now required to
confirm chloride ion
content
Soft Grout
Inclined tube test
Limit on filler content
(inert materials such as
limestone)
Limit on grouting
pressure
Limit on grouting speed
New PTI addendum in
March

Admixture special requirements

50-1.02C Grout
Admixtures must comply with section 90, except admixtures (1) must not result in chloride ions in excess of 0.08
percent by weight of mixed grout and (2) must already be present in the prepackaged grout.

Grout mixing requirements

50-1.02C Grout
Mix the grout as follows:
1. Add water to the mixer followed by prepackaged grout.
2. Mix the grout with a high-shear colloidal mixer.
3. Retempering of grout is not allowed.
4. Agitate the grout continuously until the grout is pumped.

Grout must be placed within 30 min of adding the first water to the mixture.

Grout testing for prequalification to AML

50-1.02C(1) Testing of grout

The following tests must be performed in order to prequalify a prepackaged grout with METS:
1. Setting time test according to ASTM C953: Set time must be between 3hrs and 12hrs.
2. Permeability test in accordance with ASTM C1202: Test values of 2500 Coulombs or less
after a 6hr test using 30V input is acceptable. Grout is to be tested at 28 days.
3. Inclined tube bleed test: Grout bleed must not exceed 0.3% of the initial volume of grout after
3 hours. This test must be performed in accordance with EN 445, Grout for Prestressing
tendons Test Methods, American National Standards Institute, Washington DC, 2010.
4. Volume change test: If an expansive agent is used in the mix design, this test must be
performed to demonstrate the vertical height change of no more than 0.2% at 28 days. This test
is to be performed in accordance with ASTM C1090.
5. Strength test: Grout cubes must be tested according to ASTM C942. 7 day strength must be
at least 3000psi. 28 day strength must be at least 5000psi
6. Flowability testing: Modified flow cone tests according to CTM 541. Efflux time must be
between 5 and 30 seconds. Additionally, grout must be allowed to stand for 30 minutes, be
remixed for 30 seconds, and demonstrate an efflux time less than 30 seconds.
7. Chloride ion test: Chloride ion content (Cl-) of the mixed grout must not exceed 0.08% by
weight as measured by ASTM C1152.

Grout testing during on-site production

50-1.02C(1) Testing of grout
The following tests must be performed on-site during grouting operations:
1. Grout cubes must be obtained once per day for strength testing by METS according to ASTM
C942. 7 day strength must be at least 3000psi. 28 day strength must be at least 5000psi
2. Modified flow cone tests according to CTM 541 at the inlet and furthest outlet. Efflux time
must be between 5 and 30 seconds. Efflux time of grout sampled at the outlet shall be remixed
for 30 seconds and must be within 10 seconds of the inlet efflux. This test must be performed
once every 2 hours during grouting operations.
3. Schupack pressure bleed test (See PTI M55.1-12 article 4.4.6.2) performed a least
once per day.
4. Wet density test, also known as the mud balance test, (See PTI M55.1-12 article
4.4.8) performed at least twice per day.
5. Chloride ion test: Chloride ion content (Cl-) of the mixed grout must not exceed 0.08% by
weight as measured by ASTM C1152.

Grout temperature limitations

50-1.02C(1) Grout temperature limitations

The temperature of the grout mixture must not exceed 90 degrees Fahrenheit. Measures must be incorporated
on hot days to control flash set and must be included on the grouting plan submitted by the contractor. Cold
climate conditions exist when the outside air temperature is 40 degrees Fahrenheit and falling. In such conditions,
planned grouting operations must be suspended.

Vents
Specify locations to prevent voids, especially at high points
More vents than currently used, larger diameter
50-1.02E Vents
Vent all ducts having a vertical duct profile change of 6 inches or more. Place vents at the following locations:
1. At the anchorage areas at both ends of the tendon.
2. At all high points.
3. At locations 4ft upstream and downstream of each high point.
4. At each low point.
5. At any location where there is a change in the cross section of the duct.
6. At any other location recommended by the Engineer.
Vents must:
1.Be at least 3/4-inch-diameter standard pipe or suitable plastic pipe.
2.Be connected to ducts using metallic or plastic structural fasteners. Plastic
components must not react with the concrete or enhance corrosion of the
prestressing steel and must be free from water soluble chlorides.
3.Be mortar tight and taped as necessary.
4.Provide a means for injection of grout through the vents and for sealing the
vents.
5. Be left open at low points in order to allow drainage of any water that may
have accumulated within the duct before grouting the duct.

Possible Low Point Vent

Configuration

Flushing
No longer allow flushing
Water will get trapped in the corrugations and act as a mechanism
for corrosion

50-1.02F Flushing Water

Water is not permitted for flushing of ducts at any time. Use only oil-free compressed air to blow out ducts.

Duct Tie Spacing

Better QC on tying ducts to prevent movement during concrete
placement

50-1.03A(3) Ducts
Accurately place prestressing ducts. Securely fasten the ducts in place to prevent movement of the ducts during
concrete placement. Round metal ducts must be secured horizontally and vertically at a spacing not to exceed
4ft. HDPE round duct without strands must have a support spacing not to exceed 2ft. HDPE flat duct with strand
installed must have a support spacing not to exceed 2ft. HDPE flat duct without strand installed must have a
support spacing not to exceed 1ft.

Duct integrity
Pressure testing
Compressed air to remove water/debris
Torpedo to check for kinks/blockages
Purpose is to ID major leaks and fix prior to grouting
Check for cross-over
Evaluate function of vents and valves
50-1.03B Prestressing
50-1.03B(1) General
Prior to inserting strand into a duct, the duct must be pressure tested after stem and soffit concrete placement.
Pressurize ducts to 30 psi and record pressure loss for 1 minute. A loss of 50% is acceptable.
External ducts are to be pressure tested with compressed air by pressurizing to 15 psi and recording pressure
loss for 1 minute. A loss of 50% is acceptable.
After all concrete placement and just prior to inserting strand into the ducts, ducts must be cleared with the
application of compressed air into the duct to remove water or debris. After clearing the duct with compressed air,
a torpedo (or similar device) with a cross sectional area slightly smaller than the duct, must be passed through the
entire length of the duct.

Strand insertion method

More direction on push versus pull through methods

50-1.03B Prestressing
50-1.03B(1) General
Installation of prestressing strand in the ducts may be by the push or pull through methods. In the pull through
method, all strands within a duct must be pulled simultaneously. In the push through method, bullets must be
attached to the leading end of each strand prior to pushing the strand through.

Pumping pressures
Cap on allowable pump pressure to prevent blowouts
Procedure for handling blockages (alternative to flushing)

50-1.03B(3)(d) Bonding and Grouting

50-1.03B(3)(d)(i) General
Pump pressures must not exceed 75 psi. Once grout is wasted for at least 5 seconds at the outlet, close outlet
valve followed by inlet valve closure and stopping the pump. If a blockage is suspected or pressure exceeds 75
psi, close inlet valve and continue pumping from the next closest low point from which grout has already flowed
unimpeded.

Corrosion prevention measures

Limit the time between strand placement and grouting
Function of humidity
Final note on vibration protection
50-1.03B(3)(d) Bonding and Grouting
50-1.03B(3)(d)(i) General
Grout post-tensioned tendons within the limits in the following table. Detension tendons not grouted within the
following specified number of days after prestressing, as directed, to allow inspection of strand for corrosion.
Alternatively, corrosion protection measures may be used if approved by the Engineer.
Time limits for grouting after inserting strand into the duct:
Very damp atmosphere or over salt water (humidity>70%)
Moderate atmosphere (humidity 40 to 70%)
Very dry atmosphere (humidity<40%)

7 days
20 days
40 days

Do not allow traffic or loads on the structure until 24 hours after completion of grouting.

Vertical Grouting
Alert the contractor to use a special prepackaged mix

50-1.03B(3)(d)(ii) Vertical Grouting

Ducts grouted in the vertical position must use a prepackaged thixotropic grout specifically designed for this
application.

Safety
Provide some protections for the grout plant operators
Current specs are silent on this

50-1.03B(3)(e) Safety
Personnel involved in the grouting operation must be adequately protected. They must wear NIOSH approved
Tyvek suits, full-face dual cartridge respirators, earplugs, and eye protection. They are also required to wear
gloves which are impermeable to grout. The grout plant must be arranged such that the grout plant operator is
not required to move bags of prepackaged grout more than 30 vertically in order to place grout in the mixer.
During stressing, no personnel may stand next to, behind, or above the hydraulic jack. All personnel must be
located a safe distance away from the jack and the area around the jack. The end opposite to the stressing end
must be cordoned off.

Where might we go from here?

Physical testing on existing bridges to look for corrosion and
voids
Examine PT bridge tendons which are scheduled to be
demolished
Create an AML to begin allowing prepackged grouts with
performance criteria
Identify some pilot bridges currently in design for prepackaged
grout use and create a feedback loop on cost and construction
issues