DUCT FILLER FOR POST-TENSION ED STRUCTURES
938-1 Description.
This Section covers filler materials used to fill voided areas within ducts to protect post - tensioning steel. Grout applications are differentiated into three applications: horizontal, vertical and repair. There is no differentiation for flexible fillers.
938-2 Approved Product List.
Only post -tensioning grouts and flexible filler material listed on the Department’s Approved Product List (APL) shall be used. Ma nufacturers seeking evaluation of their product shall submit an application in accordance with Section 6 and include certified test reports from an independent AASHTO R18 or ISO 9001 approved laboratory showing that the material meets all the requirements specified herein. A written certification from the manufacturer that the product meets the requirements of this Section must be submitted. Any change of materials or material sources requires new testing and certification of the conformance of the grout w ith this Specification. Grout products will be qualified by application (horizontal, vertical or repair).
938-3 General Requirements.
938-3.1 Grout: Grouts shall exhibit thixotropic properties and shall be prepackaged in
clearly labeled moisture proof co ntainers. The containers shall indicate application type, date of manufacture, LOT number and mixing instructions. The manufacturer’s Quality Control Data Sheet for each lot number and shipment sent to the job site shall be provided to the Contractor and submitted to the Engineer.
938-3.2 Flexible Filler - Microcrystalline Wax: The flexible filler shall be a petroleum
based microcrystalline wax delivered to the project site in clearly labeled prepackaged containers and stored in accordance with the manufac turer’s recommendations as applicable for the particular project. The manufacturer’s Quality Control Data Sheet for each shipment sent to the job site shall be provided to the Contractor and submitted to the Engineer.
938-4 Grout.
938-4.1 Mixing: The material shall be mixed in accordance with the manufacturer’s
recommendations except when additional water is indicated for particular tests .
938-4.2 Grout Physical Properties:
938-4.2 1 Gas Generation: The grout shall not contain aluminum or other
components which produce hydrogen, carbon dioxide or oxygen gas.
938-4.2 2 Laboratory Testing: The grout shall meet or exceed the specified
physical properties stated herein as determined by the following standard and modified ASTM and FM test methods co nducted at normal laboratory temperature (65°F -90°F) and conditions. Prepare all laboratory test specimens using 110 percent of the maximum water allowed by the manufacturer unless otherwise noted in Table 938-1. Tests A, B, N, and O will be conducted by the Department. FY 2023-24 Return to Table of Contents Table 938-1 Test ID Property Test Value Test Method A Total Chloride Ions Max. 1.0 lb/yd3 FM 5-516 (1) B Total Sulfate Ions Max. 30 ppm FM 5-618 (1) C Gradation 99% passing the No. 50 95% passing the No. 100 90% passing the No. 170 ASTM C136(2) D Hardened Height Change @ 24 hours and 28 days 0.0% to + 0.2% ASTM C1090 E Expansion ≤ 2.0% for up to 3 hours ASTM C940 F Wet Density - Laboratory Report maximum and minimum obtained test value lb/ft3 ASTM C138 G Wet Density - Field Report maximum and minimum obtained test value lb/ft3 ASTM C138 or ASTM D4380 H Compressive Strength 28 day (Average of 3 cubes) ≥7,000 psi ASTM C942 I Initial Set of Grout Min. 3 hours Max. 12 hours ASTM C953 J Time of Efflux immediately after mixing Max. 12 seconds ASTM C939(3) K Bleeding @ 3 hours 0.0 percent ASTM C940(4) L Pressure Induce d Bleeding 0.0 percent ASTM C1741 M Surface Resistivity@ 28 days ≥16 kOhms-cm AASHTO T 358 N Relative Viscosity, RV f, determined from Dynamic Sheer Rheometry < 1.15 FM 5-605 O Inclined Tube Test FM5-619 Amount of Bleed ≤ 0.0% Allowable Difference in Moisture ≤ 2.0% Penetration at 500 psi ≤ 1 mm
1.Obtain test sample from upper vent of inclined tube test specimen after 7 days curing.
2.Use ASTM C117 procedure to determine the percent passing after washing the sieve.
3.The time of efflux is the time to fill a one liter container placed directly under the flow cone. Modify the ASTM C939 test by filling t he cone to the top instead of to the standard level. Use the midrange of the water content indicated in the manufacturer’s technical data sheet to produce the time of efflux.
4.Use ASTM C940 to conform with the wick induced bleed test as modified by the Post-Tensioning Institute specification PTI M55.1 -12.
938-4.3 Accelerated Corrosion Test Method (ACTM): Perform the ACTM as outlined
in Appendix B of the Specification for Grouting of Post -Tensioning Structures published by the FY 2023-24 Return to Table of Contents Post-Tensioning Institute. Report the time to corrosion for both the grout being tested and the control sample using a 0.45 water-cement ratio neat grout. A grout that shows a longer average time to corrosion in the ACTM than the control sample and the time to corrosion exceed 1,000 hours is considered satisfactory.
938-4.4 Variation in Testing for Specific Applications.
938-4.4 1 Horizontal Applications: Horizontal grout applications are defined as
grouting of all superstructure tendons and transverse substructure tendons in caps, struts, etc. All physical requirements defined in 938 -4.2 and 938 -4.3 are applicable for grouts used in horizontal applications.
938-4.4 2 Vertical Applications: Vertical grout applications are defined as
grouting of substructure column tendons. All physical requirements defined in 938 -4.2 and
938-4.3 are applicable for grouts used in vertical applicat ions.
938-4.5 Repair Applications: Repair applications are used to augment grouting
operations which did not completely fill the duct or anchorage. For new construction, repairs may be made with the same filler approved for use in the tendon as long as th e volume of the void is less 0.5 gal. In all other cases, use a non -sanded grout meeting the requirements of
938-4.2 and 938 -4.3.
938-5 Flexible Filler - Microcrystalline Wax.
938-5.1 Storage and Preparation: Store and prepare wax in accordance with Section
462. Reject wax that shows any sign of segregation or decomposition prior to application even though it conforms to these Specifications. Use equipment designed for pumping the wax in a fluid state to fill t he tendon ducts. Manufacturers shall include the recommended pumping temperature in the material technical data sheet.
938-5.2 Laboratory Testing: The wax shall meet the specified physical properties stated
herein as determined by the following standard a nd modified ASTM and FM test methods conducted at normal laboratory temperature (65°F -78°F) and conditions. Prepare and test all laboratory test specimens as noted in Table 938-2. Table 938-2 Property Test Value Test Method Salt Fog – 168 hours@35°C No corrosion ASTM B117(1) Chlorides ≤ 50 ppm (total) ASTM D512(2) Sulfate ≤ 100 ppm ASTM D516(2) Congealing Point ≥ 65°C ASTM D938 Cone Penetration at 25°C ≤ 260 d-mm ASTM D937 Bleeding at 40°C ≤ 0.5% ASTM D6184 Resistance to Oxidation 100 hours at 100°C ≤ 0.03 MPa ASTM D942 Kinematic Viscosity at 100°C 10 – 30mm2/s ASTM D445
1.Test sample consists of a 4 -inch x 6-inch steel panel blast cleaned to a NACE surface preparation SP5 or equivalent, with a 2 to 2.5 mil surface profile. The plate is covered with a layer of wax equivalent to 0.5 grams wax per square inch of panel.
2.Prepare sample in accordance with NF M07 -023, sections 6a through 6c or equivalent. Other analytical methods are acceptable as long as equiv alency to the above methods has been established by the Department. FY 2023-24 Return to Table of Contents DRAINAGE MATERIALS SECTION 942 PRECAST CONCRETE PIPE GASKETS
942-1 Round Rubber Gaskets for Pipe Joints.
Except where O -ring type gaskets are specified for special cases and for special type pipe, round rubber gaskets for use in concrete pipe joints shall meet the requirements of ASTM C443, with the additional requirements that the gasket used shall be of such cross sectional area and perimeter as to properly fit the space provided in the pipe joint in which it is to be used. Prior to use, the gasket shall be stored in as cool a place as practicable.
942-2 Cold Adhesive Preformed Plastic Gaskets (For Sealing Elliptical Conc rete Pipe
Joints).
942-2.1 General: Cold adhesive preformed plastic gaskets shall be of a material, shape
and size so as to effect a permanent water tight seal in joints of elliptical concrete pipe. A minimum of two pieces of gasket material shall be used in each joint. The gasket material shall be protected by a 2 -piece removable wrapper. To facilitate application, the 2 -piece wrapper shall be so designed that one -half may be removed longitudinally without disturbing the other half. The size of the ga sket shall be in accordance with the manufacturer ’s recommendation for the particular joint in which it is to be used. However, the minimum size for each of the gaskets used in a joint shall be in accordance with the following: Table 942-1 Pipe Size (Inches) Nominal Gasket Size (Inches) Minimum Cross -Section (In2) Up to 19 by 30 1-1/2 1.75 19 by 30 to 53 by 83 1-3/4 2.5 Over 53 by 83 2 3.25 The above minimum size requirements are based on a joint designed with a maximum taper of 10 degrees and an in -place annular space of approximately 1/4 inch.
942-2.2 Composition: The gasket sealing the joints shall be produced from blends of
refined hydro carbon resins and plasticizing compounds reinforced with inert mineral filler. The material shall contain no solvents and shall not produce irritating fumes or obnoxious odors. The gasket shall not depend on oxidizing, evaporation or chemical action for it s adhesive or cohesive strength. The chemical composition of the gasket material shall meet the following requirements: FY 2023-24 Return to Table of Contents
Source: Florida Standard Specifications for Road and Bridge Construction, 2024 Edition. Pages 1065–1067 of 1,299.