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Division 500 — Structures

509Prestressing Concrete by Post Tensioning

GA · 2021 Standard Specifications✓ Full text on BuildSpecBook pages 733–752 Save this section

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SECTION 509 — Prestressing Concrete by Post Tensioning

509.1General Description

This work consists of prestressing concrete by post-tensioning cast-in-place concrete. The work includes furnishing, placing, and tensioning prestressing steel according to the plan details and these specifications. 509.1.01 Definitions Working Force and Working Stress: The force and stress remaining in the prestressing steel after the following losses: • Creep and shrinkage of concrete • Elastic compression of concrete • Creep of steel • Loss in post-tensioned prestressing steel from the sequence of stressing • Friction and anchor set (see Subsection 509.3.05.J, Post-Tension the Tendons, steps 18 to 19) • Other losses peculiar to the method, technique, or system of prestressing (see Subsection 509.3.05.J, Post- Tension the Tendons, step 20) 509.1.02 Related References

A.Standard Specifications
SECTION 501 — Steel Structures
SECTION 535 — Painting Structures
B.Referenced Documents

AASHTO LRFD Bridge Design Specifications ASTM C 109 ASTM A 416 ASTM A 722 ASTM C 939 Post Tensioning Institute (PTI) Specification for Grouting of Post-Tensioned Structures 509.1.03 Submittals

A.Coupler Use and Location

The use and location of couplers in bars entering into the prestressing work is subject to the Engineer’s approval.

B.Alternate Stressing or Anchorage Block Drawings and Calculations

When using stressing or anchorage blocks not shown on the Plans, submit shop drawings and calculations for the blocks to Bridge and Structural Design when submitting the prestressing system calculations and shop drawings.

C.Design Calculations

Submit to the Engineer all design calculations for the proposed post-tensioning system for review and approval. Submission should be made electronically in a portable document format (pdf) and include an index. Present calculations to fit 8.5 in. x 11 in. (216 mm x 297 mm) paper. The submission shall be prepared and stamped by the Design Engineer who shall be registered as a Professional Engineer in the State of Georgia. The Engineer will forward the calculations to the Bridge Engineer for review. Calculations for the size and spacing of the reinforcing around the ducts, as shown in Figure 1 shall include the following: 723 723 723 723 723 723

SECTION 509 — Prestressing Concrete by Post Tensioning

• Required jacking force and elongation of tendons during tensioning Using the initial jacking force, design the reinforcing to prevent ducts from pulling out because of the effects of web curvature and slope. • Stresses in anchorages and distribution plates Ensure that the calculations account for reinforcing to prevent the peeling of anchorages from the top and bottom slab. See Figure 2 for minimum reinforcing requirements for tying ducts to the deck reinforcing. • Stress-strain curves typical of the prestressing steel to be furnished • Seating losses • Temporary overstresses • Reinforcing in the concrete to resist tensioning loads Determine bearing offsets and expansion joint gaps and adjust for construction sequence, prestress shortening, and temperature. FIGURE 1 724 724 724 724 724 724

SECTION 509 — Prestressing Concrete by Post Tensioning

FIGURE 2

D.Certificates of Compliance

The Department will accept certificates of compliance for cements to be used. The Department reserves the right, however, to sample and test the cement before its use and at any time during the progress of the work.

E.Certified Mill Test Reports

Submit certified mill test reports for high tensile prestressing steel to the Project Engineer.

F.Shop Drawings

Submit to the Engineer shop drawings for review and approval. Submission should be made electronically in a portable document format (pdf) and include an index. Format all drawings to fit 11 in. x 17 in. (279 mm x 432 mm) paper.” The submission shall be prepared and stamped by the Design Engineer who shall be registered as a Professional Engineer in the State of Georgia. The Engineer will forward the shop drawings to the Bridge Engineer for review. Place a title block in the lower right-hand corner of the drawings that includes the following: • Project identification number (PI XXXXXXX) • Sheet numbering for the Shop Drawings • Structure name • Contractor and fabricator names The Shop Drawings shall include the following:

1.Fully dimensional views showing all projections, recesses, notches, openings, blockouts, and pertinent

design details

2.Details of mild steel reinforcing showing size, spacing, and location, including special reinforcing required as

determined by the design calculations but not shown on the Plans

3.Details of ducts for post-tensioning tendons showing size, type, and horizontal and vertical profiles
4.Details of duct supports, grout tubes, and vents showing size, type, and location

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SECTION 509 — Prestressing Concrete by Post Tensioning
5.Details of the relative positions of reinforcing steel, ducts, and anchorages
6.Details of the anchorage systems for the proposed post-tensioning system
7.A table giving jacking sequence, jacking forces, and initial elongation of the tendons at each erection stage for

post-tensioning

8.Details and a complete description of the post-tensioning system to be used for permanent tendons
9.Details of the prestressing, including:

• Method, sequence, and procedure for prestressing and securing tendons • Procedure for releasing tendons • Equipment supplier and type • Tendon size and properties • Anchorage plates and assemblies

10.Information on grouting, including:

• Grout mix design • Method of mixing and placing the grout • Type and capacity of grouting equipment

11.Working drawings and bar schedules for each prestressing system
12.Details of reinforcing or coil ties under anchorage plates
13.Details for usage of high-strength steel bar (furnished by the bar manufacturer)
14.Friction factors used in the prestressing system of deformed bars
G.Ram Calibration Charts

Before using rams in the work, furnish the Engineer with a certified chart from the calibration for each ram.

H.Designs and Details of Distribution Reinforcing Steel

The Department plans for anchorages show only a minimum amount of distribution reinforcing steel. Design and detail the reinforcement needed to prevent bursting, peeling, and splitting. Submit the designs and details to the Engineer for review and approval.

I.Gauge Readings and Elongations

Keep a record of gauge pressures or readings and elongations at the end of each jacking operation and submit it to the Engineer for review and approval.

J.Grouting Operations Plan

Submit to the Engineer a grouting operation plan at least 6 weeks in advance of any scheduled grouting operations. The Engineer will forward the grouting operations plan to the Office of Materials and Testing for approval. Written approval of the grouting operations plan by the Office of Materials and Testing is required before any grouting of the permanent structure takes place. At a minimum, the plan will address and provide procedures for the following:

1.Provide names and proof or experience/training for the grouting crew and the crew supervisor.
2.Type, quantity, and brand of materials used in grouting including all certifications required.

Type of equipment furnished, including capacity in relation to demand and working condition, as well as back-up equipment.

3.General grouting procedures.
4.Duct cleaning methods prior to grouting.
5.Mixing and pumping procedures.
6.Direction of grouting.

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SECTION 509 — Prestressing Concrete by Post Tensioning
7.Sequence of use of the inlets and outlets pipes.
8.Procedures for handling blockages.
9.Procedures for possible post grouting repair.

509.2Materials

Ensure that materials meet the requirements of the following Specifications: Material Section Steel Wire Strand 853 Structural Steel for Anchorage Devices, Distribution Plates, and Incidental Parts Required to Be of Steel 501 Grout 509 Water 880

A.Steel

Do not use strands from more than one source within the same tensioning operation. Strands that differ in size from ASTM A 416 are to be submitted for prior approval. High strength steel bars shall meet ASTM A 722 Type II, and S1 throughS# supplemental requirements and have manufacturers details for their use. Ensure all bars within any member are of same grade. Bar couplers and locations are to be approved prior to use and shall have tensile strength not less than manufacturers minimum for strength of bar. Allow the Department 60 calendar days before installing prestressing steel to test the steel and approve the materials furnished. Use the anchor devices and distribution plates recommended by the manufacturer of the prestressing system.

B.Post-Tensioning Grouts

Use only post-tensioning grouts meeting the requirements of this subsection. Submit to the Engineer a written certification from the manufacturer that the product meets the requirements of this subsection. The Engineer may request that the manufacturer also submit certified test reports from an independent laboratory audited by the Cement and Concrete Reference Laboratory (CCRL) which shows the material meets all the requirements specified herein. 727 727 727 727 727 727

SECTION 509 — Prestressing Concrete by Post Tensioning
1.The grout shall not contain aluminum or other components which produce hydrogen, carbon dioxide or

oxygen gas.

2.The grout shall meet or exceed the specified physical properties stated as determined by the following

standard and modified test methods. Conduct all grout tests with grout mixed to produce the minimum time of efflux. Establish the water content to produce the minimum and maximum time of efflux. Property Test Value Test Method Total ChlorideIons Max. 0.08% by weight of cementitious material ASTM C 1152 Volume Change 0.0% to +0.1% at 24 hours <+0.2% at 28 days ASTM C 1090 Expansion ≤2.0% for up to 3 hours ASTM C 940 Compressive Strength at 28 days ≥5000 psi (35 MPa) ASTM C 942 Wet Density – Laboratory Report maximum and minimum obtained test value lbs/ft3 ASTM C 185 Initial Set Min. 3 hours Max. 12 hours ASTM C 953 Time of Efflux(1)

(a)Immediately after mixing Min. 20 seconds

Max. 30 seconds ASTM C 939 or Min. 9 seconds Max. 20 seconds ASTM C 939(2)

(b)30 minutes after mixing with

remixing for 30 seconds Max. 30 seconds ASTM C 939 or Max. 30 seconds ASTM C 939(2) Bleeding @ 3 hours Max. 0.0% ASTM C 940(3) Permeability at 28 days Max. 2,500 coulombs at 30 V for 6 hours ASTM C 1202 1) Adjustment to flow rates will be achieved by strict compliance with the manufacturer’s recommendations. The time of efflux is the time to fill a one liter container placed directly under the flow cone. 2) Modify ASTM C 939 test by filling the cone to the top instead of to the standard level. 3) ASTM C 940 modified per PTI Specification subsection 4.4.6.1, Wick Induced Bleed Test. 728 728 728 728 728 728

SECTION 509 — Prestressing Concrete by Post Tensioning

Have the Engineer approve grout for filling recesses or encasing anchoring devices. Use a type recommended by the manufacturer for highly stressed steel. 509.2.01 Delivery, Storage, and Handling

A.Protect Prestressing Steel

Protect prestressing steel against physical damage, rust, and corrosion. Reject all damaged, rusted, or corroded prestressing steel. See Subsection 509.3.06, Quality Acceptance.

B.Package Prestressing Steel

Package prestressing wire or strand in containers or shipping forms to protect steel from physical damage and corrosion during shipping and storage. Comply with these packaging requirements:

1.Place a corrosion inhibitor to protect against rust and corrosion as follows:
a.Place the inhibitor in the package or form.
b.Incorporate the inhibitor in a carrier-type packaging material.
c.Apply the inhibitor directly to the steel.

Ensure that the corrosion inhibitor does not damage the steel, grout, or bond strength of the steel to the grout.

2.Immediately replace or restore to original condition damaged packaging or forms.
3.Clearly mark the shipping package or form with the following:

• A statement that the package contains high-strength prestressing steel

• Handling instructions

• The type, kind, and amount, of corrosion inhibitor used, including the date placed, safety orders, and

instructions for use

Ducts

1.Place all prestressing steel tendons in openings or ducts.
2.Use corrugated polyethylene or polypropylene ducts meeting requirements of Post Tensioning Institute (PTI)

Specification for Grouting of Post-Tensioned Structures.

3.Align ducts to match roadway alignment and/or tendon profile.
C.Grout

Grouts shall be prepackaged in moisture proof containers. Store grout in a location that is both dry and

convenient to the work. Storage in the open must be on a raised platform and with adequate waterproof covering.

Grout bags shall indicate the following:

1.Type of application
2.Date of manufacture
3.Lot number
4.Mixing instruction

Provide to the Engineer the manufacturer’s Quality Control Data Sheet for each lot number and shipment sent to

the job site. Materials with a total time from manufacture to usage in excess of six (6) months shall be retested and

certified by the supplier before use or removed and replaced. 729729729729729729

SECTION 509 — Prestressing Concrete by Post Tensioning

509.3Construction Requirements

509.3.01 Personnel

A.Representative of the Post-Tensioning System Supplier

If the Engineer requires, provide a representative of the post-tensioning system supplier at no additional cost to

the Department.

Provide a representative who:

• Is skilled in using post-tensioning systems

• Supervises or provides surveillance of the work

• Provides information about the post-tensioning system to the Engineer as needed

• Grouting Supervisor

Ensure the supervisor has verifiable documentation of three years of experience in construction of grouted

post tensioned structures and has successfully completed training in a grouting technician certification program,

such as, the American Segmental Bridge Institute’s grouting certification program or an approved equal

training program.

509.3.02 Equipment

A.Prestressing Equipment

Provide the following equipment for construction and prestressing:

1.Tensioning Jacks

Use tensioning jacks equipped with the following:

• Long enough stroke to perform stressing in a minimum number of strokes

• Provide a positive means of marking each elongation increment where two or more strokes are required

• Ports or windows to exam and measure tendon movement

• Slow stress release capability to allow the jack to relax from overstress to the proper seating force

2.Tensioning Equipment

Use tension prestressing tendons equipped with the following:

• Equipment that allows direct elongation measurement

• Hydraulic ram that determines the tensioning force applied

Measure the tensioning force applied by the ram using either of the following gauges:

a.Gauge that measures either the internal hydraulic pressure in the ram or the force exerted by the ram
b.Spring-type dynamometer used with the tensioning force applied directly

Convert the readings from either of these gauges to actual tensioning forces using calibrated values from

a calibration chart.

Use gauges with a diameter of at least 6 in. (150 mm) that allow accurate readings of load increments of

one percent of the total capacity of the ram used, not to exceed two percent of the tensioning force used.

3.Load Cell

Ensure that the range of the load cell does not use the lower 10 percent of the manufacturer’s rated capacity

to determine the jacking stress.

B.Sampling and Inspecting Prestressing Steel

The Department will identify, sample, test, and approve all prestressing steel as follows:

1.Identification
a.Assign a lot number to all strand and all bars of each size from each mill heat shipped to the jobsite.
b.Tag the lots so that each such lot can be positively identified at the job site.

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SECTION 509 — Prestressing Concrete by Post Tensioning
c.Assign and tag each lot of anchorage assemblies and bar couplers.
d.The Engineer or Department inspector will reject all unidentified prestressing steel, couplers, or anchorage

assemblies received at the site, and any items without positive identification.

2.Sampling
a.Give to the Engineer samples from each size and each heat of prestressing bars and prestressing steel

strand, and from each lot of anchorage assemblies and bar couplers.

b.Submit with each sample of prestressing strand or bar the manufacturer’s certification stating the

minimum guaranteed ultimate tensile strength of the sample furnished.

c.Submit enough samples to make up two assembled test units from each heat, complete with end fittings

and anchoring devices. Test units shall be at least 8 ft. (2.4 m) long.

d.If the Engineer’s tests indicate the necessity of retests, submit twice the number of previous specimens

without cost to the Department. Identify the samples by heat number.

e.Submit samples to the Engineer in ample time to allow for testing, tabulating results, and, in case of

unsatisfactory findings, to call for and test substitute samples.

f.The Department will not pay the Contractor additional compensation because of the delay while waiting

for approval of the material furnished for testing.

3.Tendon Modulus of Elasticity
a.Submit to the Engineer for approval the apparatus and test methods you propose to use to determine the

modulus of elasticity.

b.Run bench tests on two samples of each size and type of longitudinal strand and/or wire tendon prior to

stressing the initial tendon.

c.Stress the tendon at an anchor assembly with the dead end consisting of a load cell.
d.Apply 80 percent of the ultimate tension to the test specimen in 10 increments and record the gage

pressure, elongation and load cell force for each increment.

e.Detension the test specimens back to 0 in 10 increments, and record the gage pressure, elongation, and

load cell force for each increment.

f.Submit the test data to the Engineer.
g.Re-evaluate and correct, as necessary, the theoretical elongations shown on the post-tensioning working

drawings based on the results of the tests.

h.Submit any revisions to the theoretical elongations to the Engineer.
i.After the initial testing, the Engineer may require five more tests. Space these tests evenly throughout the

duration of the contract.

4.In-Place Friction Test
a.Submit to the Engineer for approval the apparatus and test methods you propose to use to measure the

in-place friction.

b.After receiving approval for the apparatus and method, test the first draped continuity strand and/or wire

tendon in place of each size and type.

c.Apply 80 percent of the ultimate tension to the test specimen in 10 increments and record gage pressure

elongation and load cell force for each increment.

d.Detension the tendon back to 0 in 10 increments, and record the gage pressure, elongation, and load cell

force for each increment.

NOTE: You only need to run one friction test for each type and size of a tendon for the project.

e.Submit the results of the tests (loss due to friction and modulus of elasticity) to the Engineer.

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SECTION 509 — Prestressing Concrete by Post Tensioning
C.Grouting Equipment

Provide grouting equipment consisting of measuring devices for water, a high-speed shear colloidal mixer, a

storage hopper and a pump with all the necessary connecting hoses, valves, and pressure gauge.

Provide pumping equipment with sufficient capacity to ensure continuous grouting of the largest tendon on the

Project in 20 minutes.

1.Mixer and Storage Hopper

Provide a high-speed shear colloidal mixer capable of continuous mixing producing a homogeneous and

stable grout free of lumps and undispersed cement. The grout machinery will have a charging tank for

blending and a holding tank.

• The blending tank must be equipped with a high shear colloidal mixer.

• The holding tank must be kept agitated and at least partially full at all times during the pumping

operation to prevent air from being drawn into the post-tensioning duct.

Add water during the initial mixing by use of a flow meter or calibrated water reservoir with measuring

accuracy of ± 1.0 ounces (30 ml) or better.

2.Grout Pumping Equipment

Provide pumping equipment capable of continuous operation which will include a system for circulating the

grout when actual grouting is not in progress.

• The equipment will be capable of maintaining pressure on completely grouted ducts and will be fitted

with a valve that can be closed off without loss of pressure in the duct.

• Grout pumps will be positive displacement type, will provide a continuous flow of grout and will be

able to maintain a discharge pressure of at least 145 psi (1 MPa).

• Pump seals adequate to prevent oil, air, or other foreign substances out of the grout and to prevent

loss of grout or water.

• Pressure gauge with a maximum full scale reading of 300 psi (2 MPa) installed at some point in the

grout line between the pump outlet and the duct inlet to establish grout pressure at the pump.

• Screen with 0.125 in. (3 mm) maximum clear openings to screen the grout before it is introduced into

the grout pump. 732732732732732732

SECTION 509 — Prestressing Concrete by Post Tensioning
D.Grouting Equipment

Provide grouting equipment consisting of measuring devices for water, a high-speed shear colloidal mixer, a

storage hopper and a pump with all the necessary connecting hoses, valves, and pressure gauge.

Provide pumping equipment with sufficient capacity to ensure continuous grouting of the largest tendon on the

Project in 20 minutes.

1.Mixer and Storage Hopper

Provide a high-speed shear colloidal mixer capable of continuous mixing producing a homogeneous and

stable grout free of lumps and undispersed cement. The grout machinery will have a charging tank for

blending and a holding tank.

• The blending tank must be equipped with a high shear colloidal mixer.

• The holding tank must be kept agitated and at least partially full at all times during the pumping

operation to prevent air from being drawn into the post-tensioning duct.

Add water during the initial mixing by use of a flow meter or calibrated water reservoir with measuring

accuracy of ± 1.0 ounces (30 ml) or better.

2.Grout Pumping Equipment

Provide pumping equipment capable of continuous operation which will include a system for circulating the

grout when actual grouting is not in progress.

• The equipment will be capable of maintaining pressure on completely grouted ducts and will be fitted

with a valve that can be closed off without loss of pressure in the duct.

• Grout pumps will be positive displacement type, will provide a continuous flow of grout and will be

able to maintain a discharge pressure of at least 145 psi (1 MPa).

• Pump seals adequate to prevent oil, air, or other foreign substances out of the grout and to prevent

loss of grout or water.

• Pressure gauge with a maximum full scale reading of 300 psi (2 MPa) installed at some point in the

grout line between the pump outlet and the duct inlet to establish grout pressure at the pump.

• Screen with 0.125 in. (3 mm) maximum clear openings to screen the grout before it is introduced into

the grout pump.

3.Vacuum Grouting Equipment

Provide vacuum grouting equipment at the jobsite concurrently with all pressure grouting operations.

• The equipment will be the volumetric measuring type with the ability to measure a void and supply a

measured volume of grout to fill the void.

4.Standby Equipment

Provide flushing equipment capable of pumping 300 psi (2 MPa) gauge and flushing out partially-grouted

ducts.

• A different power source for the flushing equipment than the grouting equipment.

D.Rams

Twenty days before using rams and their gauges or reading devices in the work, have them calibrated by an

approved laboratory.

Recalibrate the equipment every three months during the work or when the Engineer observes erratic results. For

each calibration, furnish a calibration chart, certified by the laboratory, to the Engineer.

The Engineer may extend the 3-month interval if there are no performance changes. However, recalibrate at least

every 6 months. 733733733733733733

SECTION 509 — Prestressing Concrete by Post Tensioning

509.3.03 Preparation

A.Test Tendon Modulus of Elasticity

To determine the tendon elongations while stressing, bench test two samples of each size and type of longitudinal

strand and/or wire tendon using the following procedure:

1.Propose apparatus and methods used to perform these tests for approval by the Engineer.
2.Stress the tendon at an anchor assembly with the dead end consisting of a load cell.
3.Tension the specimen to 80% of ultimate in 10 increments.
4.Detension the specimen from 80% of ultimate to 0% in 10 increments.
5.Record the gage pressure, elongation, and load cell force for each increment. Provide this data for

the Engineer.

6.Reevaluate the theoretical elongations shown on the post-tensioning working drawings using the results of the

tests. Correct the results as necessary.

7.Submit revisions to the Engineer for approval.
8.Perform five more tests after the initial testing (if required by the Engineer). Space these tests evenly

throughout the duration of the contract.

B.Test Friction

To accurately determine the friction loss in a strand and/or wire tendon, test, in place, the first draped continuity

tendon of each size and type using the same procedure described for the modulus of elasticity test. Only one

friction test for each type and size of a tendon is required for the project. Submit the results of the tests to

the Engineer.

C.Test Anchorages

Before construction, test prestressing anchorage blocks of the type indicated in Figure 2 using the proposed

jacking system as follows:

1.Construct and test anchorage test blocks for the following:

• Each different radius of bend of the duct into the anchorage

• Each different number of strands per duct arrangement

2.If anchorages (reinforcing, anchorage geometry, anchor plate, and duct bend radius) are the same within a

project or bridge, test only the anchorage with the largest jacking force.

3.Assemble a test block with these features:

• Same concrete dimensions of the structure cross section at the points of anchorage in the proposed

system

• Tendon geometries, anchor plates, and anchorage reinforcing steel proposed for use in the structure

4.Place the tendons.
5.Stress the tendons to the full force required by the design using the proposed jacking system and

stressing procedures.

Anchorages are acceptable to the Department if no concrete cracks wider than 1/100 in (0.25 mm) develop within

3 days under full force.

509.3.04 Fabrication

General Provisions 101 through 150.

509.3.05 Construction

A.Contractor Options

The Contractor may choose from these options when constructing the structure according to the

Department plans: 734734734734734734

SECTION 509 — Prestressing Concrete by Post Tensioning
1.Alternative Prestressing Systems

The Contractor may use post-tensioning systems other than those shown on the plans. The alternative system

may use wires, bars, or strands anchored with friction grips or bearings.

Unless the plans allow, do not use prestressing systems that incorporate dead-end anchorages.

Choose alternative systems that can be stressed from either end unless the construction staging does not

allow room to stress tendons from both ends. In this case, use anchorage systems with compression plates or

fittings to seat anchor wedges.

2.Alternative Stressing or Anchorage Blocks

Stressing or anchorage blocks for the structure may deviate from those shown on the plans.

Alternate stressing or anchorage blocks must be located inside the box. Place the blocks in any of the

following locations:

• At the juncture of the bottom of the top slab

• At the juncture of the top of the bottom slab and the web walls

• Within fillet areas in reinforced stressing blocks

• In partial depth diaphragms

Permanent or temporary stressing blockouts are allowed in the top of the top slab when post-tensioning ducts

do not have a moisture-retaining low point.

B.Install the Ducts
1.Support ducts at intervals of no more than 2 ft. (600 mm).

The horizontal tolerance for longitudinal ducts in the top or bottom slab is plus or minus 1 in. (25 mm). The

vertical tolerance for longitudinal ducts is plus or minus ¼ in. (6 mm).

2.Detail splices and connections in shop drawings. All splices, vents and connections are to be watertight.

Pressure test ducts for leaks to ensure grout will not enter duct prior to placement of concrete.

3.Stagger splices in ducts to prevent splices in same location in a row of ducts. Stagger the splices to give a

3 ft. (900 mm) longitudinal spacing from row to row.

4.Use grout inlets, grout outlets, valves and plugs made of ASTM a 240 Type 316 stainless steel, nylon or

polyolefin materials. For products made of nylon, the cell class of nylon shall be S-PA0141 (weather resistant),

S-PA0231 or S-PA0401 (ultimate strength not less than 10,000 psi with UV stabilizer), according to ASTM

D5989. Products made from polyolefin shall contain antioxidant(s) with a minimum Oxidation Induction Time

(OIT)according to ASTM D 3895 of not less than 20 minutes.
5.Place continuous-draped longitudinal ducts in the web in one vertical row at the center of the web.
6.Tie the ducts securely to the saddles, which shall hold the duct in position during concrete placement

and hardening.

7.Ensure that the clear distance between the ducts is 1-1/2 times the maximum size aggregate in the concrete

mix or 1 in. (25 mm) whichever is greater.

8.Do not bundle ducts.
9.See Figure 3 below for an illustration of how to tie duct support saddles.
10.If needed, place ducts in the top or bottom slab in one of these ways:

• Horizontally at the variable spacings

• In closely and uniformly spaced groups

The minimum horizontal clear spacing between ducts must be 3 in. (75 mm).

11.Install at least one more continuity duct than needed in each web throughout the length of the structure. This

duct will be used during blockage and excessive prestress losses during construction.

12.Position the ends of the additional ducts to use anchorage blocks if necessary.

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SECTION 509 — Prestressing Concrete by Post Tensioning
13.Vent continuity ducts over each intermediate support or high point along tendon. Provide additional vents 3 to

6 ft. from high point on downslope.

14.Provide vents at the low point of every duct to drain off water in the duct.
15.Immediately before installing the prestressing steel, demonstrate to the Engineer that ducts are unobstructed

and free of water and debris.

16.After installing ducts in the forms, keep the duct ends sealed to keep out water and debris.
17.After post-tensioning the steel, fill ducts with or without strands full of grout.
18.After the grout has set, remove the ends of the vents flush with the concrete surface.

FIGURE 3: PARTIAL WEB VIEW

C.Install Reinforcing Steel

Fabricate reinforcing steel and place it according to the Plans and Shop Drawings.

Do not cut and remove reinforcing steel to align stressing ducts properly. Replace bars that cannot be fabricated

to clear the ducts with bars with an adequate lap length.

Where bars are extended by the use of couplers, the assembled units shall have a tensile strength of not less than

the manufacturer’s minimum guaranteed ultimate tensile strength of the bar. 736736736736736736

SECTION 509 — Prestressing Concrete by Post Tensioning

Submit revised drawings indicating the proposed bar to the Engineer for review and approval.

D.Install Anchorages

Secure post-tensioned prestressing steel at the ends using permanent anchoring devices recommended by the

prestressing steel manufacturer and meeting the requirements herein.

Use anchoring devices that hold the prestressing steel at a load producing a stress of at least 95 percent of the

guaranteed minimum tensile strength of the prestressing steel.

E.Install Distribution Devices

Distribute the load from the anchoring device to the concrete using devices that conform to the following:

• The final unit compressive stress on the concrete directly underneath the plate or assembly does not

exceed 3,000 psi (20 MPa) or 0.9 (f”ci), whichever is less.

• Bending stresses in the plates or assemblies induced by the pull of the prestressing steel do not exceed

the yield point of the material or distort the anchorage plate as determined by the Engineer when 100

percent of the load is applied.

The Contractor may omit steel distribution plates or assemblies when furnishing large anchoring devices used with

a steel grill embedded in concrete to distribute the compressive stresses to the concrete.

Install distribution devices as follows:

1.Place steel distribution plates, if used, inside the end surface of the member.
2.Recess anchoring devices so that the ends of the prestressing steel and all of the anchoring devices are

embedded in concrete.

3.After post-tensioning and grouting the duct, clean foreign and loose material off the surfaces of the concrete.

Do not clean the concrete until the duct grouting operations are complete.

4.Fill anchoring device recesses with an approved, non-shrink grout.
5.Cover the anchoring devices and ends of the prestressing steel with at least 2 in (50 mm) of grout, unless the

plans specify more.

F.Have the Engineer Inspect

Have the Engineer inspect and approve the placement of reinforcement, ducts, and anchorages before pouring

concrete into the forms.

G.Pour the Concrete

Pour concrete according to Section 500.

H.Install the Tendons

Install tendons in the ducts after pouring the top deck or when the Engineer approves.

Before installing the tendons, demonstrate to the Engineer that the ducts are unobstructed and free of water.

Install the tendon in the duct as approved by the Engineer.

I.Follow Weld Restrictions

The Engineer will not allow welds or welding equipment grounds on the forms or near the prestressing steel after

the steel has been installed.

J.Post-Tension the Tendons

Post-tension the tendons as follows:

1.Before post-tensioning tendons, ensure that the deck slab thickness and deck reinforcement cover comply

with the Plan requirements. 737737737737737737

SECTION 509 — Prestressing Concrete by Post Tensioning
2.Unless otherwise noted on the Plans or approved by the Engineer, wait to prestress cast-in-place concrete

until the compressive strength of all the concrete placed reaches the required 28-day strength and the

concrete is at least 14 days old.

If the Engineer approves, the Contractor may apply a portion of the prestressing force to a member with a

concrete strength less than the value shown on the Plans.

Even with this partial prestressing, the Contractor must successfully construct the members.

3.Conduct the tensioning process so that the applied tension and the elongation can be measured.
4.Tension the prestressing steel using hydraulic jacks.
5.Tension the prestressing tendons in continuous post-tensioned members by jacking at each end of the

tendon. Jacking of both ends does not need to be done simultaneously.

6.When approved by the Engineer and if shown on the Plans, tension bent cap tendons by jacking from one

end only.

7.Tension the prestressing tendons in simple span post-tensioned members by jacking from one end only.
8.When tensioning from one end of the tendon only, tension half of the prestressing steel in each member from

one end and the other half from the opposite end of the span unless otherwise shown on the plans.

9.Unless allowed on the plans, do not use prestressing systems that incorporate dead-end anchorages.
10.Where construction staging does not allow room to stress tendons from both sides, use anchorage systems

with compression plates or fittings to seat anchor wedges.

11.Ensure that the prestressing steel force does not drop below the value shown on the Plans.
12.Ensure that the tendon force measured by gauge pressure is within 5 percent of the force calculated by

elongation movement.

13.If the measured elongation at the jacking stress varies more than 5 percent from the theoretical elongation, or

if the unbalanced force about the section center line exceeds 3 percent:

a.Check the entire operation and determine the error.
b.Correct the error to the Engineer’s satisfaction before proceeding with the work.
14.Do not allow the total force at each section to drop below the total prestressing force specified. However, the

prestressing force may vary plus or minus 5 percent per tendon.

15.Unless otherwise specified on the Plans, ensure that the average working stress in the prestressing steel does

not exceed 80 percent of the yield point stress of the prestressing steel.

16.To determine the amount of steel required, ensure that the maximum temporary tensile (jacking) stress in

prestressing steel does not exceed 80 percent of its specified minimum ultimate tensile strength unless the

Plans indicate a lower jacking stress.

17.Anchor the prestressing steel at stresses (initial stress) that will retain working forces at or higher than the

minimum values shown on the Plans or approved by the Engineer.

Do not allow the initial stress to exceed 70 percent of the specified minimum ultimate tensile strength of the

prestressing steel.

18.Check that the loss of elongation from anchor set agrees with the anticipated value used in the stress

calculations.

a.Adjust measured Elongation to account for the actual measured anchor set.
b.Maintain 5 percent agreement between the elongation and the stressing force.
19.Compute the prestress losses from friction, using the formulas in the AASHTO LRFD Bridge Design

Specifications, Section 5.9.3.2.2b. The total friction losses at any section will be the sum of the effects for

each tendon, depending on its anchorage location for each tendon. 738738738738738738

SECTION 509 — Prestressing Concrete by Post Tensioning
20.Compute other prestress losses, using the AASHTO LRFD Bridge Design Specifications, Sections 5.9.3.2,

and 5.9.3.3.

21.After stressing and anchoring tendons and after the Engineer approves, trim projecting tendons by sawing as

shown in the approved working drawings.

K.Mix the Grout

Maximum grout temperature will not exceed 90 °F (32.2 °C). Use chilled water and/or pre-cooling of bagged

material to maintain mixed grout temperature below the maximum allowed temperature.

Grouting operations are prohibited when the ambient temperature is below 40 °F (4 °C) or is 40 °F (4 °C) and

falling. Remove any standing water from ducts using compressed air, if freezing temperatures are forecast.

Grout for use with prestressing concrete bridge members includes a mixture of prepackaged material and water,

as follows:

• Prepackaged material―Use prepackaged material that meets the requirements of Subsection 509.2.01.D.

• The Department reserves the right to sample and test the prepackaged material before its use and at any

time during the work.

• Water―Use potable water or other water that meets the requirements of Subsection 880.2.01.

Mix the prepackaged material and water in accordance with the manufacturer’s recommendation and as follows:

1.Mix the grout with a metered amount of water.
2.When adding water, do not exceed the manufacturer’s recommendations.
3.The materials will be mixed to produce a homogeneous grout.
4.Continuously agitate the grout until it is pumped.
5.Do not add water to increase grout flowability that has decreased because grout use is delayed.

The Engineer may determine grout pumpability according to ASTM C 939. When using this method, efflux time for

the grout sample immediately after mixing will not be less than the efflux time as established in subsection

509.2.B.

L.Prepare Ducts for Grouting

Prepare the ducts for grouting by flushing the ducts with compressed air.

1.Clear ducts of water and debris at a pressure no greater than allowed for grouting the tendon.
2.Use oil-free compressed air to blow out ducts.
M.Grout the Duct

Bond prestressing steel to the concrete by filling the space between the duct and the tendon with grout. Grout

tendons in accordance with the Grouting Operations Plan.

Grout the duct as follows:

1.Open the grout and vent openings.
2.Unless approved otherwise by the Engineer, pump grout at a rate of between 16 linear feet (5 m) and 50 linear

feet (15 m) of duct per minute. Ensure that the pumping pressure at the grout inlet does not exceed 245 psi

(1.7 MPa).

3.Allow grout to flow from the first vent after the inlet pipe to remove residual flushing water or entrapped air.
4.Once water or air is removed, cap or otherwise close the vent. Close the remaining vents in sequence in the

same manner.

5.If the grouting pressure exceeds 245 psi (1.7 MPa) gauge, inject grout at a vent that has been or is ready to

be capped. 739739739739739739

SECTION 509 — Prestressing Concrete by Post Tensioning
a.Maintain a one-way grout flow while injecting.
b.Fit the vent used for injection with a positive shutoff.
c.If a one-way flow of grout cannot be maintained, immediately flush the grout out of the duct with water.
6.Pump grout through the duct and waste it continuously at the outlet pipe until the following happens:

• No visible slugs of water or air are ejected.

• The efflux time of the ejected grout is at least 11 seconds.

7.To ensure that the duct remains filled with grout:
a.Close the outlet.
b.Hold pumping pressure for an additional 1 minute and then close the inlet.
c.Do not remove or open plugs, caps, or valves used to close off the outlet or inlet until the grout has set.
N.Place Rust Inhibitor

If prestressing and grouting are not completed within 10 consecutive days after installing steel strands in the ducts

(or within 30 days in the case of bars), use rust inhibitor in the ducts.

Prestressing steel installed but not grouted within the specified number of consecutive days is subject to the limits

in Subsection 509.3.06.C, “Rust Limits.” If the Engineer directs, remove rejected tendons at no cost to the

Department.

Do not reuse prestressing steel that has been detensioned. Replace detensioned prestressing steel.

O.Paint Steel Parts

Paint steel parts exposed in the completed structure as follows:

1.Field clean the parts according to Subsection 535.3.03.A, “Clean New Steel Structures.”
2.Field paint the parts according to System IV of Section 535.
3.Paint the ends of strands according to System IV of Section 535.

509.3.06 Quality Acceptance

A.For Prestressing Concrete Bridge Members

Use grout that has a minimum compressive strength of 3,000 psi (20 MPa) at 28 days, as determined by

ASTM C 109.

B.Tendon Standards

Individual wires in a 7-wire strand or wires in a parallel wire tendon may fail if the total area of wire failure is not

more than 2 percent of the total cross-sectional area of tendons in any member.

Failure of an entire strand will be subject to structural review.

C.Rust Limits

Pre-stressing steel will be rejected when:

• The opened package (pak) of prestressing steel has an even coating of rust or rust film over the

entire pak.

• One or more wires in a strand are rusted throughout their length.

• A length of strand or bar contains clinging rust, pits, or other faults.

Pre-stressing steel will be accepted when:

• Rust film can be removed by light rubbing, leaving light streaks or spots but no pitting.

• Rust forms during the 10 consecutive days (or 30 consecutive days for bars) between the installation of

steel in the ducts and the prestressing and grouting. 740740740740740740

SECTION 509 — Prestressing Concrete by Post Tensioning
D.Tendon Grouting

At least 24 hours after completion of the grouting of tendon ducts, and no more than 7 days after grouting,

investigate the ducts for voids, as follows:

1.After the grout has cured, open grout injection and exit ports by drilling through the ports into the duct cavity

to probe for any void.

2.Sound all grout caps for voids. Unless grout caps are determined to have voids, do not remove or drill

the cap.

3.If voids are found, completely fill the void with grout by secondary grouting of the duct with vacuum grouting

process that determines the size of the void and measures filling of the void.

4.If no voids are found, clean and backfill the drilled hole with Type V epoxy selected from QPL 15―Epoxy

Resin Adhesives. Use an injection tube to extend to the bottom of the drilled hole.

During drilling operations use equipment that will automatically cut-off when steel is encountered.

509.3.07 Contractor Warranty and Maintenance

General Provisions 101 through 150.

509.4Measurement

Prestressing cast-in-place concrete is measured as an accepted lump quantity, complete in place.

The Contract Lump Sum price paid for prestressing cast-in-place concrete will be full compensation for the following:

• Furnishing labor, materials, tools, equipment, and incidentals

• Doing Work to furnish, place, and tension the prestressing steel in cast-in-place concrete structures complete

in place and as specified on the Plans and in these Specifications

509.4.01 Limits

A.Tests

Tests performed by the Contractor will not be paid for separately but will be considered incidental to the project.

No additional payment will be made for testing prestressing anchorage blocks. Costs associated with performing

the test, including materials, equipment, and labor, will be included in the bid price for prestressing.

B.Additional Compensation

No additional compensation will be made for the following:

• Furnishing and placing additional deformed bar reinforcing steel, ducts, anchoring devices, saddles,

distribution plates or assemblies, and incidental parts

• Furnishing samples for testing

• Performing testing

• Grouting recesses

• Pressure grouting ducts

Full compensation will be included in the Contract Lump Sum price paid for prestressing cast-in-place concrete.

509.5Payment

Payment will be made under:

Item No. 509 Pre-stressing cast-in-place concrete, Bridge No._____ Per lump sum 741741741741741741

SECTION 509 — Prestressing Concrete by Post Tensioning

509.5.01 Adjustments

General Provisions 101 through 150.. 742 742 742 742 742 742

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Source: Standard Specifications for Construction of Transportation Systems, 2021 Edition. Pages 733–752 of 2,050. View official source ↗

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