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

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.

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Table of Contents

Chapter 1 - Introduction ............................................................................................................. 1

1.1 Objective ...................................................................................................................... 1
1.1.1 Benefits of Post-Tensioning .................................................................................. 1
1.1.2 Principle of Prestressing ....................................................................................... 1
1.1.3 Post-Tensioning Operations................................................................................. 2
1.1.4 Post-Tensioning Systems ..................................................................................... 3
1.2 Permanent Post-Tensioned Applications ..................................................................... 6
1.2.1 Cast-in-Place Bridges on Falsework ..................................................................... 6
1.2.2 Post-Tensioned AASHTO, Bulb-T, and Spliced Girders ........................................ 6
1.2.3 Precast Segmental Balanced Cantilever Bridges .................................................. 8
1.2.4 Cast-in-Place Segmental Balanced Cantilever Bridges ........................................16
1.2.5 Precast Segmental Span-by-Span Bridges ..........................................................18
1.2.6 Precast Segmental Progressive Cantilever Bridges .............................................21
1.2.7 Transverse Post-Tensioning of Superstructures ..................................................22
1.2.8 Post-Tensioning of Substructures ........................................................................25
1.3 Temporary Longitudinal Post-Tensioning (Bars) – Typical Applications ......................31
1.3.1 Erection of Precast Cantilever Segments .............................................................31
1.3.2 Closure of Epoxy Joints in Span-by-Span Erection ..............................................33
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

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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

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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

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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

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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

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

B.2.3 Lead Inspector ...................................................................................................... 2
B.2.4 Inspector ............................................................................................................... 2
Appendix C – Bibliography ......................................................................................................... 1

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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

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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

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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
Figure 5.11 – Possible Detail for Embedded Face Anchor ........................................................14

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Table of Tables

Table 3.1 - Example 1 Tendon Force and Elongation Calculation .............................................. 8

Table 3.2 - Example 2 Tendon Force and Elongation Calculation .............................................13

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Chapter 1 - Introduction
1.1 Objective
One of the major advancements in bridge construction in the United States in the second half of
the twentieth century was the development and use of prestressed concrete. Prestressed
concrete bridges offer a broad range of engineering solutions and a variety of aesthetic
opportunities. The objective of this Manual is to provide guidance to individuals involved in the
design, installation, grouting and inspection of post-tensioning tendons for prestressed concrete
bridges.

1.1.1 Benefits of Post-Tensioning

The tensile strength of concrete is only about 10% of its compressive strength. As a result,
plain concrete members are likely to crack when loaded. Reinforcing steel can be embedded in
the concrete members to accept tensile stresses which plain concrete cannot resist. Reinforcing
is selected assuming that the tensile zone of the concrete carries no load and that tensile
stresses are resisted only by tensile forces in the reinforcing bars. The resulting reinforced
concrete members may crack, but it can effectively carry the design loads (Figure 1.1).

Figure 1.1 - Reinforced Concrete Beam Under Load

Although cracks occur in reinforced concrete, the cracks are normally very small and well
distributed. Cracks in reinforced concrete can reduce long-term durability. Introducing a means
of precompressing the tensile zones of concrete members to offset anticipated tensile stresses,
reduces or eliminates cracking to produce more durable concrete bridges.

1.1.2 Principle of Prestressing

The function of prestressing is to place the concrete structure under compression in those
regions where load causes tensile stress. Tension caused by applied loads will first have to
cancel the compression induced by the prestressing before it can crack the concrete. Figure
1.2 (a) shows a plainly reinforced concrete simple span beam and fixed cantilever beam
cracked under applied load. Figure 1.2(b) shows the same unloaded beams with prestressing
forces applied by stressing post-tensioning tendons. By placing the prestressing low in the
simple-span beam and high in the cantilever beam, compression is induced in the tension
zones; creating upward camber.

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Figure 1.2(c) shows the two prestressed beams under the action of post-tensioning and applied
loads. The loads cause both the simple-span beam and cantilever beam to deflect down,
creating tensile stresses in the bottom of the simple-span beam and top of the cantilever beam.
The designer balances the effects of load and prestressing in such a way that tension from the
loading is compensated by compression induced by the prestressing. Tension is eliminated
under the combination of the two and tension cracks are prevented. As a result, durability is
increased and more efficient, cost effective construction is realized.

Figure 1.2 - Comparison of Reinforced and Prestressed Concrete Beams

Prestressing can be applied to concrete members in two ways, by pretensioning or post-

tensioning. In pretensioned members the prestressing strands are tensioned against restraining
bulkheads before the concrete is cast. After the concrete has been placed, allowed to harden
and attain sufficient strength, the strands are released and their force is transferred to the
concrete member. Prestressing by post-tensioning involves installing and stressing
prestressing strand or bar tendons after the concrete has been placed, hardened and attained a
minimum compressive strength for that transfer.

1.1.3 Post-Tensioning Operations

Compressive forces are induced in a concrete structure by tensioning steel tendons comprised
of strands or bars placed in ducts embedded in the concrete. The tendons are installed after
the concrete has been placed and sufficiently cured to a prescribed initial compressive strength.
A hydraulic jack is attached to one or both ends of the tendon and pressurized to a
predetermined value while bearing against the end of the concrete beam. This induces a
predetermined force in the tendon and the tendon elongates elastically under this force. After
jacking to the full required force, the force in the tendon is transferred from the jack to the end
anchorage.

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Tendons made up of strands are secured by steel wedges that grip each strand and seat firmly
in a wedge plate. The wedge plate itself carries all the strands and bears on a steel anchorage.
The anchorage may be a simple steel bearing plate or may be a special casting with two or
three concentric bearing surfaces that transfer the tendon force to the concrete. Bar tendons
are usually threaded and anchored by means of spherical nuts that bear against a square or
rectangular bearing plate cast into the concrete. For an explanation of post-tensioning
terminology and acronyms, see Appendix A.

The protruding “tails” of strands or bars of permanent tendons are cut off using an abrasive disc
saw or plasma cutting after stressing. Flame cutting should not be used as it negatively affects
the characteristics of the prestressing steel. Tendons are then grouted using a cementitious
based grout. This grout is pumped through a grout inlet into the duct by means of a grout pump.
Grouting is done carefully under controlled conditions using grout outlets to ensure that the duct
anchorage and grout caps are completely filled. After grouting, anchorages are protected by
multiple levels of protection appropriate to the environmental demand on the structure. See
Chapter 5 for details regarding corrosion protection of tendons.

Materials other than cementitious grout, such as wax, have been used to fill ducts after the
installation and stressing of tendons. These materials are not commonly used in the United
States and are not addressed in this Manual. Post-tensioning and grouting operations require
certain levels of experience and certification, as outlined in Appendix B.

1.1.4 Post-Tensioning Systems

Many proprietary post-tensioning systems are available. Several suppliers produce systems for
tendons made of wires, strands or bars. The most common systems found in bridge
construction are multi-strand systems for permanent post-tensioning tendons and bar systems
for both temporary and permanent situations. Refer to manufacturers’ and suppliers’ literature
for details of available systems. Key features of three common systems (multiple-strand and
bar tendons) are illustrated in Figures 1.3, 1.4 and 1.5.

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Figure 1.3 - Typical Post-Tensioning Anchorage Hardware for Strand Tendons

Figure 1.4 - Typical Post-Tensioning Bar System Hardware

(Courtesy of Dywidag Systems International)

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Figure 1.5 - Typical Post-Tensioning Bar System Hardware

(Courtesy of Williams Form Engineering Corporation)

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1.2 Permanent Post-Tensioned Applications

1.2.1 Cast-in-Place Bridges on Falsework
Bridges of this type have a superstructure cross-section of solid or cellular construction. They
are built on-site using formwork supported by temporary falsework (Figure 1.6). Formwork
creates the shape of the concrete section and any internal voids or diaphragms. Reinforcement
and post-tensioning ducts are installed in the forms and then the concrete is placed,
consolidated and cured. When the concrete attains sufficient strength, post-tensioning is
installed and stressed to predetermined forces.

Figure 1.6 - Cast-In-Place Post-Tensioned Construction in California

Longitudinal post-tensioning typically comprises multi-strand tendons draped along the length of
the girder to a designed profile. In continuous spans, the tendon profile lies in the bottom of the
girder in the mid-span region and rises to the top of the section over interior supports. In simple
spans and at the expansion ends of continuous spans, post-tensioning anchors are arranged
vertically so that the resultant of the tendon anchor force passes close to the centroid of the
section. A draped profile of this type provides the most effective distribution of internal prestress
for this type of construction.

1.2.2 Post-Tensioned AASHTO, Bulb-T, and Spliced Girders

Precast, post-tensioned AASHTO and bulb-T girders are usually pre-tensioned sufficiently at the
precast plant to carry their own self weight for transportation to the site and erection. On site,
girders are first erected as simple spans. The girder segments are made continuous over
multiple spans (typically three or four spans) by cast-in-place joints that connect the girder ends
and are incorporated as a part of transverse diaphragms at the piers.

Post-tensioning ducts that are cast into the webs are spliced at the cast-in-place joints. The
ducts follow a smoothly curved, draped profile along each girder line, rising to the top of the
girders over the interior piers and draping to the bottom flange in mid-span regions. Before the

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deck slab is cast, some or all of the tendons running the full length of the multi-span unit are
installed and stressed, making each simple span I-girder into a series of continuous spans.
When the deck slab has been cast and cured, additional tendons may be installed and stressed
on the fully composite section. Tendons may be anchored in a variety of configurations at the
ends of each continuous unit.

Longer spans can be built using similar techniques. A variable depth girder section
cantilevering over a pier can be spliced to a typical precast girder in the main and side-spans.
An example is shown in Figure 1.7.

Figure 1.7 - Spliced Haunched I-Girder of Main Span Unit

Temporary supports are needed at the splice location in the side spans. The ends of girders
have protruding mild reinforcing to help secure the girder to the closure concrete and ducts that
splice with those of other girder segments to accommodate tendons over the full length of the
main unit. The variable depth girder sections are placed over the piers, aligned with the girders
of the side spans, and closures cast. Usually, temporary strong-back beams support the drop-in
girder of the main span while closures are cast.

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The sequence for erecting and temporarily supporting this type of I-girder construction is
illustrated in Figure 1.8. After all closures have been cast and have attained the necessary
strength, longitudinal post-tensioning tendons are installed and stressed. To maximize the
efficiency of the post-tensioning, phased stressing is necessary. Some of the longitudinal
tendons are stressed on the I-girder section alone (i.e. while it is non-composite). The
remaining tendons are stressed after the deck slab has been cast and act upon the full
composite section.

Figure 1.8 - Erection Sequence and Temporary Supports for Spliced I-Girder

1.2.3 Precast Segmental Balanced Cantilever Bridges

Precast segmental balanced cantilever construction involves the symmetrical erection of
segments about a supporting pier. When a segment is lifted into position, adjoining match-cast
faces are coated with epoxy and temporary post-tensioning bars are installed and stressed to
attach the segment to the cantilever. Typically, after a new, balancing segment, is in place on
each end of the cantilever, post-tensioning tendons are installed and stressed from one
segment on one end of the cantilever to its counter-part on the other. Consequently, as
segments are added, more top cantilever tendons are added.

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Figure 1.9 shows two typical methods of placing precast segments in balanced cantilever; using
cranes with stability towers at each pier and using an overhead launching gantry. When all
segments of a new cantilever have been erected and tendons stressed, a closure joint is made
at mid-span. Continuity post-tensioning tendons are installed and stressed through the closure
to make the cantilevers into continuous spans. Other methods of erecting the precast segments
are available, including deck mounted beam and winch systems and tire mounted segment
lifters.

Figure 1.9 - Precast Segmental Balanced Cantilever Construction

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1.2.3.1 Typical Features of Precast Cantilever Segments

Figure 1.10 presents a perspective of a typical balanced cantilever segment showing various
features of the concrete shapes, post-tensioning tendon locations and post-tensioning
anchorage locations. The principal types of post-tensioning tendons in these bridges are
cantilever and continuity tendons. The cantilever tendons are stressed to resist the cantilever
dead load moments during construction and the effects of superimposed dead loads and live
loads on the continuous bridge. Continuity tendons are stressed to join adjacent cantilevers and
resist positive moments from superimposed dead loads, creep redistribution, and live loads.

Figure 1.10 - Typical Balanced Cantilever Segment

1.2.3.2 Cantilever Tendons

Longitudinal post-tensioning tendons for cantilever construction are contained within the top
slab, usually spaced in a single layer over each web. For long spans, a second layer of tendons
in the thickened haunch of the top slab may be required. The layout of the ducts is always the
same at each side of the match-cast joint, and ducts shift sideways or up and down within a
segment to make up the full tendon profile from an anchor at one end of the cantilever to that at
the other. Relative to each segment, cantilever tendons always anchor in the same location.
This may be in the end face of the segment or within an anchor block (or “blister”) on the interior
of the segment.

Cantilever tendons in the top slab of a box section counteract the bending effect from the self-
weight of the cantilever during construction. This bending induces a longitudinal tension stress
in the top, reaching a maximum over the pier. The top cantilever post-tensioning counters these
effects by inducing a compression stress of equal or greater magnitude at each cross section
along the cantilever.

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Figure 1.11 shows a typical layout for cantilever tendons that anchor on the end face of a
precast or cast-in-place segment. This feature requires special details to facilitate inspection of
the anchor head after tendon grouting and after additional segments have been erected on the
cantilever. (A possible detail for a face anchor to facilitate this inspection is shown in Chapter 5,
Figure 5.11).

Figure 1.11 - Cantilever Post-Tensioning Tendons Anchored on End Faces

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An alternate approach is to anchor cantilever tendons in blisters (anchor blocks) cast into the
segments at the intersection of the top slab and web as shown in Figure 1.12. Anchorages of
these tendons can be inspected at any time during and after construction.

Figure 1.12 - Cantilever Post-Tensioning Tendons Anchored in Top Blisters

1.2.3.3 Continuity Tendons between Cantilevers

To complete a span, the ends of two adjacent cantilevers are connected by a cast-in-place
closure pour at or near mid-span of interior spans. In end spans, the closure joint is usually
nearer to the end expansion joint. The length of the closure, which comprises the full cross
section of the superstructure box, may range from six inches to several feet. In order to align
and hold the cantilever tips while making the closure, a special device, referred to as a “closure
beam” or “strong-back”, is fastened across the tips of the cantilevers. Formwork is secured
around the closure, reinforcement and transverse post-tensioning is installed if necessary, and
the closure concrete is poured. When the closure concrete attains sufficient strength,
longitudinal post-tensioning (continuity) tendons are installed, tensioned and grouted. Figure
1.13 depicts typical locations and layouts for bottom continuity tendons at mid-span.

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When a closure is several feet long and weighs more than one half as much as a typical
segment, it may be necessary to place the closure concrete in a very specific sequence in order
to prevent the closure opening or cracking as the cantilevers deflect. It may also be necessary
to apply a small amount of post-tensioning (10% to 20% of two continuity tendons) as soon as
the bottom slab concrete has taken an initial set (i.e., within about 2 to 4 hours of casting) to
keep the closure tight, even as more concrete is added. These are project specific
considerations.

Figure 1.13 - Bottom Continuity Tendons for Balanced Cantilever Construction

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Top continuity post-tensioning tendons are also typically required in balanced cantilever bridges.
A bridge built in balanced cantilever has little, if any, self-weight stress at the location of the
closure joint in the center of the span. Midspan bottom continuity tendons, along with live loads
in adjacent spans, produce tensile stresses in the top slab that need to be counteracted with top
continuity tendons. Subsequent application of the barrier railing and possible wearing surface
should produce top compression at this location, minimizing the need for the top continuity
tendons. In time, internal redistribution of forces and moments due to the creep of the concrete
will induce compression in the top at midspan, further reducing the need for top continuity
tendons. Figure 1.14 shows details of typical top continuity tendons.

Figure 1.14 - Top Continuity Tendons for Balanced Cantilever Construction

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1.2.3.4 Continuity Tendons in End Spans

Several segments constructed on falsework are typically needed to complete an end span of a
balanced cantilever bridge at abutments or expansion spans between continuous units. A cast-
in-place closure joint connects the cantilever to the segments on falsework and continuity post-
tensioning tendons are installed, as shown in Figure 1.15. Usually, more continuity tendons are
needed in the bottom than the top. Although continuity tendons may not always be needed in
the top, it is good practice to provide at least two, one over each web. Continuity tendons may
be stressed from the expansion joint if access is available or they may be stressed at anchor
blisters within the superstructure.

Figure 1.15 - Bottom Continuity Tendons near Expansion Joint at a Support

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1.2.3.5 In-Span Hinges in Balanced Cantilever Construction

Long viaducts of balanced cantilever construction have been built with dapped-hinges
approximately at quarter points of expansion spans (Figure 1.16). This location was chosen
over hinges at midspan which demonstrated excessive midspan creep deflection in some early
generation bridges in Europe and the United States.

Subsequent improvements in long-term creep prediction models for concrete have reduced
uncertainties in deflection calculations. Midspan hinges have again been used satisfactorily.
Deflection may be controlled by using steel beams on sliding bearings placed inside a box
girder, between cantilever tips, to allow for expansion and contraction, but restrain rotation.
Care should be exercised in the design and detailing of any type of in-span hinge because local
details may be subject to complex force and stress distribution.

Figure 1.16 - In-Span Hinges in Balanced Cantilever Construction

1.2.4 Cast-in-Place Segmental Balanced Cantilever Bridges

An often used alternate to balanced cantilever construction using precast segments is cast-in-
place balanced cantilever construction using form travelers. Form travelers support the
concrete of the newly cast segment until it has reached a satisfactory strength for post-
tensioning. The types of longitudinal post-tensioning tendons used in cast-in-place balanced
cantilever construction are the same as for precast segment balanced cantilever.

Figure 1.17 shows the cast-in-place balanced cantilever construction of the Acosta Bridge in
Jacksonville, Florida. Figure 1.18 shows typical construction phasing for a three span bridge
built by the cast-in-place balanced cantilever method using form travelers.

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Figure 1.17 - Cast-In-Place Segmental Construction using Form Travelers

Figure 1.18 - Typical Construction Stages for Cast-In-Place Balanced Cantilever Construction

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1.2.5 Precast Segmental Span-by-Span Bridges

Span-by-span construction involves the erection of all segments of a span on a temporary
support system with small closure joints cast at one or both ends next to the segments over the
pier. Figure 1.19 shows typical phases for span-by-span construction.

Figure 1.19 - Span-By-Span Construction

The erection schematic shown in Figure 1.19 shows temporary erection trusses used to support
the precast segments during construction. Overhead erection gantries are also commonly used
to support the segments during erection.

1.2.5.1 External Tendons

For span-by-span construction, the use of external tendons provides for greater efficiency in the
cross section of the box for both longitudinal and transverse efficiency, by facilitating a web
thicker at the top than bottom. This raises the centroid of the whole cross section, and
maximizes the eccentricity and efficiency of the post-tensioning in the mid-span region needed
for the dominant effect of longitudinal flexure of this method. Figure 1.20 shows a typical layout
of span-by-span tendons for an interior span where all tendons deviate at a common deviation
saddle.

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The tendons from one span overlap with the tendons of the next in the top of the pier segment
to achieve continuity between the spans. At the very ends of each continuous unit, the ends of
the tendons anchor in the diaphragm of the expansion joint segment with anchors dispersed
vertically and approximately parallel to the web of the box.

Figure 1.20 - Typical Span Post-Tension for Span-By-Span Construction

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Figure 1.21 shows a similar layout for a typical expansion joint span. Current designs may
require an additional (straight) tendon per web to control the effects of thermal gradient and/or
provide added redundancy.

Figure 1.21 - Expansion Joint Span Post-Tensioning for Span-By-Span Construction

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1.2.5.2 Tendons that are Partially External and Partially Internal

In some cases, a post-tensioning tendon in a span-by-span bridge may be both external and
internal to the concrete. The profile of such a post-tensioning tendon is similar to that of an
external tendon except that between the deviators, it enters the bottom slab. The tendon is
external in the inclined regions (Figure 1.22). This provides additional tendon eccentricity at
midspan, but does not facilitate visual maintenance inspection or possible future replacement.
However, this type of layout has been used successfully for the Evans Crary Bridge, Florida,
and the Central Artery North Area ramps approaches to the Charles River Bridge in Boston.
The former was to provide a longer span than normal and the latter, to help address seismic
concerns of the time.

With this type of external-internal tendon, Service Limit State conditions are usually readily
satisfied. However, at the Strength Limit State, it is necessary to take into account the fact that
portions of such tendons are both external (i.e. unbonded) and internal (bonded or partially
bonded). An appropriate, non-linear, strain compatibility approach is usually necessary.

Figure 1.22 - External/Internal Span-By-Span Tendons

1.2.6 Precast Segmental Progressive Cantilever Bridges

When access to a bridge site is restricted so that precast components can only be delivered to
one of the end abutments, the superstructure may be erected in progressive cantilever.
Beginning by placing the first span of segments on falsework between the abutment and first
pier, subsequent segments are delivered along the completed portion and added in cantilever,

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progressively to the advancing end. When the cantilever reaches midspan, a temporary support
is introduced. More segments are added in cantilever over the temporary support until the
advancing end reaches the next permanent pier. This process repeats until the superstructure
is completed all the way to the last abutment.

This technique was used to construct the Linn Cove Viaduct carrying the Blue Ridge Parkway
around Grandfather Mountain in North Carolina (Figure 1.23). Environmental restrictions
permitted the use of only walkways and light equipment on the terrain beneath the viaduct.
Consequently, equipment and materials for the installation of drilled micro-shaft piles and
foundation construction was lowered into each pier location from the advancing end of the
cantilever. After completing a footing, precast concrete pier shaft segments were transported
along the completed portion of the bridge and lowered into position, building the pier to receive
and support the next cantilever.

Figure 1.23 - Progressive Construction of the Linn Cove Viaduct

The progressive cantilever erection method with changing support conditions requires a
complex post-tensioning layout that includes internal cantilever and continuity tendons with
draped tendons in the webs. Most tendons were permanent, but a few were temporary and
were released as necessary for the changing support conditions.

1.2.7 Transverse Post-Tensioning of Superstructures

Transverse post-tensioning is often used to precompress superstructure systems to offset
unwanted transverse tensile stresses. The most fundamental use of these tendons is in cast-in-
place concrete slabs. Spans comprised of precast planks or box beams are often joined by
transverse tendons used in conjunction with longitudinal cast-in-place closure joints.
Transverse post-tensioning is widely used in deck slabs of cast-in-place or precast segmental
bridges.

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Transverse post-tensioning has many uses in concrete bridge construction. Some examples
are offered in the following.

1.2.7.1 Transverse Top Slab Post-Tensioning

Top slabs of precast and cast-in-place segmental, and similar boxes cast-in-place on falsework
are often transversely post-tensioned. Transverse post-tensioning typically comprises internal,
multi-strand tendons grouted after stressing. Tendons are spaced at regular, frequent intervals,
approximately 2 to 3 feet along the length of the structure. Tendons anchor in the block-outs in
the edges of the top slab cantilever wings. Blockouts are subsequently filled with concrete and
are usually covered with a traffic barrier. Figure 1.24 shows a perspective view of typical
transverse post-tensioning tendons in a box girder. In precast segments, top slab transverse
tendons are usually tensioned and grouted while the segment is in storage in the casting yard.

Figure 1.24 - Transverse Post-Tensioning in the Top Slab of Box Girder

Wide bridges are often made of twin parallel boxes joined by a longitudinal cast-in-place
concrete strip. This closure strip may be conventionally reinforced or transversely post-
tensioned. When connected by transverse post-tensioning, only about half of the transverse
tendons within a segment are stressed for shipping and erection. The remainder are placed
through ducts in adjacent segments and the closure strip and stressed across the full width of
the bridge. The latter requires that tolerance be built into the details to accommodate mismatch
of the transverse (plan view) alignment due to casting, construction tolerances, differences in
elastic shortening, creep and shrinkage between one box and the other. Mismatch of vertical
alignment may also occur for similar reasons.

1.2.7.2 Transverse Post-Tensioning of Multiple Precast Element Superstructures

Short span bridges are often made of multiple precast, prestressed components placed
adjacent to one another to form the bridge deck. The precast components include planks for flat
slabs, double-tees, and box beams. These bridges may be built with or without toppings.
Precast components are often connected transversely with longitudinal closure pours and
transverse post-tensioning. High strength bars, mono-strands or multi-strand tendons may be
used. The amount of post-tensioning is a function of the specific bridge design requirements.

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Suitable allowance should be made for mismatch of tendon alignments due to casting and
erection construction tolerances, elastic shortening, creep shrinkage and vertical deflection, in
the details for transverse tendons.

1.2.7.3 Transverse Post-Tensioning in Diaphragms

Superstructure pier segments are occasionally transversely post-tensioned with multi-strand
tendons. These tendons may cross each other as they drape from the wing on one side to the
opposite face of the web on the other. Often, these transverse tendons extend from web-face to
web-face (Figure 1.25). These tendons are internal and are usually stressed and grouted in the
casting yard.

Proper attention should be given to the details in order to ensure that the tendons are effective
at the critical locations. For example, in Figure 1.25, the anchors are recessed into the web
face and the tendons do not contribute to the resistance of the interface-shear between the web
and diaphragm. They contribute only to the transverse tensile force capacity needed across
that portion of the diaphragm mostly inboard of the bearings.

Figure 1.25 - Transverse Post-Tensioning in Diaphragms

1.2.7.4 Vertical Post-Tensioning in Diaphragms

Vertical post-tensioning bars (Figure 1.26) are often provided to confine the anchor zones and
local splitting effects induced by the concentrated anchorage forces from post-tensioning
tendons anchored in groups in the diaphragms of segments. These vertical bars are internal
and are stressed and grouted in the casting yard.

Figure 1.26 - Vertical Post-Tensioning in Diaphragms

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1.2.7.5 Transverse Post-Tensioning in Deviator Ribs of Precast Segments

Transverse deviator ribs of span-by-span bridges may contain tendons (usually straight bars) in
the top of the ribs across the bottom slab anchored in the web face (Figure 1.27). These are
internal and are stressed and grouted in the casting yard.

Figure 1.27 - Transverse Post-Tensioning in Deviation Ribs

1.2.7.6 Vertical Post-Tensioning in Webs

Vertical post-tensioning bars are occasionally added to webs (Figure 1.28), usually in the high
shear zone near the piers, to control principal tension stresses and mitigate or avoid associated
cracking. Care should be given to details of the corners to ensure a proper connection and
transfer of forces with the top and bottom slab reinforcing.

Figure 1.28 - Vertical Post-Tensioning in Webs

Occasionally, in large segments of major segmental or cable-stayed bridges, strand tendons

may be used for transverse post-tensioning of webs and diagonal transverse struts or ties that
connect and transfer loads to cable-stay anchor points.

1.2.8 Post-Tensioning of Substructures

Substructures for standard AASHTO I-girders, Bulb-T’s, spliced girders, cast-in-place post-
tensioned and many segmental structures are typically built using reinforced concrete
construction. However, for large bridges or to accommodate other special construction needs,
post-tensioned substructures may be appropriate. Post-tensioned substructures may be used
for bridges of all types of superstructures. Some of the more typical applications are shown in
the following sections.

1.2.8.1 Hammerhead Piers

Transverse post-tensioned tendons using strand or bar tensile elements provide an effective
reinforcing scheme for Hammerhead Piers (Figure 1.29). This is especially true for large
hammerheads with significant cantilevers or where vertical clearances restrict the available

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depth. The tendons are internal to the concrete and are stressed and grouted after the pier
concrete has reached sufficient strength.

Figure 1.29 - Post-Tensioning in Hammerhead Piers

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1.2.8.2 Straddle Bents

Straddle bents are often required to support upper level roadways in complex multi-level
interchanges (Figure 1.30). Limited vertical clearances often restrict the depths of the straddle
bent caps, resulting in a post-tensioned rather than conventionally reinforced concrete member.

In a typical straddle bent, tendons drape to a prescribed profile that may be similar to the drape
in a beam on simple supports, or it may rise over the columns where a monolithic connection is
made to transfer moments into the columns and provide frame action. The columns may be
reinforced or post-tensioned, depending upon the magnitude of the forces and moments
induced in the frame.

Tendons in straddle bents are internal and grouted during construction. However, it is possible
to apply external tendons of a similar type to repair, or rehabilitate a damaged structure.

Figure 1.30 - Post-Tensioning in Straddle Bents

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1.2.8.3 Cantilever Piers

Cantilever piers (C-piers) are also used in multi-level interchanges or in flyover bridges where a
concentric column would intrude into a horizontal clearance associated with an underlying
roadway. For structural efficiency and economy, a typical cantilever pier usually contains
transverse and vertical post-tensioning (Figure 1.31).

Detailing of cantilever piers should provide for proper development of prestressing forces in the
cantilever, column and footing. Anchors at corners must cross in an effective manner to oppose
tension and develop pre-compression all around the exterior of the pier. An alternative would
be to use a continuous tendon rather than two separate tendons.

Tendons are internal, stressed and grouted during construction. Similar external tendons may
be used for repair or rehabilitation. Special attention would be needed, however, to anchor
them and develop forces around the top corner and into the footing.

Figure 1.31 - Post-Tensioning in Cantilever Piers

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1.2.8.4 Precast Piers

Precast concrete segmental piers with vertical post-tensioning have been used on several
projects. Vertical post-tensioning usually consists of PT bars for short to moderate heights.
Strand tendons are typically required for taller piers. Bars are typically anchored in footings and
extend to the pier caps. Strand tendons are usually continuous and extend from an anchor in
the cap on one side of the pier, down the pier, loop through the footing and up the opposite side
to another anchor in the cap. Post-tensioning bars are also used to temporarily secure precast
segments and compress epoxy in the joints as they are erected prior to installing permanent
strand tendons. Hollow precast, oval section segments were used for the Foothills Bridge No. 2
on the Foothills Parkway in Tennessee (Figure 1.32).

Figure 1.32 - Precast Hollow Segmental Piers, Foothills Bridge No. 2

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Precast segmental piers with an I-section were used for the Mid-Bay Bridge in Florida. The
taller piers were post-tensioned with strand tendons, looping through the foundations, (Figure
1.33).

Figure 1.33 - Precast I-Piers

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1.2.8.5 Precast Segmental Box Section Arches

Precast concrete hollow box section segments were used for the main arch ribs of the Natchez
Trace Parkway Bridge in Tennessee (Figure 1.34). These were erected using temporary cable
stays to the central pier column, which in turn were balanced by tie-backs anchoring in the
adjacent hillsides. Temporary post-tensioning bars were used to secure each new segment to
that previously erected to compress the epoxy joint. Strand tendons were used to make
continuity of the two arch halves, and to prestress against flexure in the crown-loaded arch.

Figure 1.34 - Natchez Trace Parkway Arches, Tennessee

1.2.8.6 Transverse, Confinement Tendons at Tops of Piers

Large concentrated bearing loads on the top of piers induce local transverse tensile stresses.
These stresses may be resisted by mild steel reinforcement or by transverse post-tensioning.
Because tendon lengths are typically short, bar tendons are typically used in this application.
Special conditions may call for the use of strand tendons. An example of this is the transverse
post-tensioning tendons in the tops of the large elliptical piers of the main span unit of Sunshine
Skyway Bridge in Florida. Internal multi-strand transverse tendons were used in a hoop layout
to provide the required transverse prestressing.

1.3 Temporary Longitudinal Post-Tensioning (Bars) – Typical Applications

1.3.1 Erection of Precast Cantilever Segments
Temporary post-tensioning bars are a key feature of precast segmental balanced cantilever
construction. Each new precast segment added to the cantilever is first secured to the previous
segment using temporary post-tensioning bars to squeeze the epoxy joint and hold the segment
until the main longitudinal tendons can be installed. Construction operations are arranged to
make it possible to lift a segment, apply epoxy, install temporary bars and squeeze the joint
before the epoxy begins to set.

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Depending on the size of the segment, there may be three to eight temporary bars distributed
around the cross section. In most precast cantilever bridges, there is at least one temporary PT
bar in a duct in the concrete wing of the segment. In some bridges, temporary external PT bars
anchor in blocks on the underside of the top slab and on the top of the bottom slab.
Alternatively, bars may be installed in ducts within the top and bottom slabs and anchored in
blockouts at the segment joints. Figure 1.35 shows the application of epoxy on the Foothills
Bridge No. 2. Figure 1.36 shows the stressing of temporary post-tensioning bars for the same
project.

Figure 1.35 - Applying Epoxy between Precast Segments

at the Foothills Parkway Bridge No. 2

Figure 1.36 - Stressing Temporary Bar in Bottom Slab

of the Foothills Parkway Bridge No. 2

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1.3.2 Closure of Epoxy Joints in Span-by-Span Erection

Temporary PT bars are usually needed for span-by-span erection in order to squeeze the
epoxy. In such cases, the bars may be anchored at temporary blocks (blisters) on the interior of
the section or at diaphragms and deviators, passing through them in ducts. Using slow-set
epoxy, it is possible to erect and epoxy several segments of a span at one time.

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Chapter 2 – Post-Tensioning System Materials and Components

Satisfactory performance of post-tensioned bridges depends upon the appropriate selection,
design, specification and fabrication of various materials and components that make up the
post-tensioning system. This chapter offers general guidance and information for materials and
components. Some of the information in this chapter is taken from various industry
specifications and information from manufacturers and suppliers. Two important resources are
“Specifications for Grouting of Post-Tensioned Structures” (PTI M55.1-12) and “Guide
Specification for Grouted Post-Tensioning” (PTI/ASBI M50.3-12).

2.1 Prestressing Steel

2.1.1 Strands and Bars

2.1.1.1 Strands
Strand for post-tensioning is made of high tensile strength steel wire. A strand is comprised of 7
individual wires, with six wires helically wound to a long pitch around a center “king” wire. All
strand should be Grade 1860 MPa (270 ksi) low relaxation, seven-wire strand conforming to the
requirements of ASTM A416 “Standard Specification for Steel Strand, Uncoated Seven Wire
Strand for Prestressed Concrete.” ASTM A416 provides minimum requirements for mechanical
properties (yield, breaking strength, elongation) and maximum allowable dimensional
tolerances. Strand from different sources may meet ASTM A416 but not necessarily be
identical in all respects.

Strand is most commonly available in two nominal sizes, 12.7mm (0.5in) and 15.2mm (0.6in)
diameter, with nominal cross sectional areas of 99mm 2 and 140mm 2 (0.153 and 0.217 square
inches), respectively. Though the majority of post-tensioning hardware and stressing equipment
is based on these sizes, the use of 15.7mm (0.62in) diameter strand has been increasing.

Strand size tolerances may result in strands being manufactured consistently smaller than, or
larger than nominal values. Recognizing this, “Acceptance Standards for Post-Tensioning
Systems” (Post-Tensioning Institute, 1998) refers to the “Minimum Ultimate Tensile Strength”
(MUTS), which is the minimum specified breaking force for a strand. Strand size tolerance may
also affect strand-wedge action leading to possible wedge slip if the wedges and strands are at
opposite ends of the size tolerance range.

Strand conforming to ASTM A416 is relatively resistant to stress corrosion and hydrogen
embrittlement due to the cold drawing process. However, since susceptibility to corrosion
increases with increasing tensile strength, caution is necessary if strand is exposed to corrosive
conditions such as marine environments and solutions containing chloride or sulfate, phosphate,
nitrate ions or similar. Consequently, ASTM A416 requires proper protection of strand
throughout manufacture, shipping and handling. Protection during the project, before and after
installation, should be specified in project drawings and specifications.

Various methods have been developed to provide improved corrosion protection to individual
prestressing strands. Some of these methods include:

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• Greased and plastic sheathed mono-strand for unbonded tendons has been widely used
in buildings, but not generally in bridges in the United States. Plastic sheathed mono-
strands are, however, available for cable-stays or external tendon applications for new
structures and the repair of old ones.

• Epoxy coated strand meeting the same requirements as ASTM A416 is available and
should also conform to ASTM A882 “Standard Specification for Epoxy-Coated Seven
Wire Strand.” Epoxy coated strand is available as an outer coating only, or as a coating
that also fully fills the interstices between wires. The latter is preferred for post-
tensioning or cable stay applications. Special wedges are required that bite through the
thickness of the coating and engage the strand; power seating of the wedges is usually
required.

• Strand made from fiber material (such as carbon or aramid fibers) has limited application
as post-tensioning to date. These composite materials offer advantages for enhanced
corrosion resistance, but lack the benefit of a high modulus of elasticity that is routinely
provided by steel and which is crucial to good load-deflection behavior of a prestressed
structure without excessive cracking under service loads.

• Few U.S. manufacturers supply galvanized strand. The galvanizing process leads to
some reduction in tensile strength of prestressing steel. This reduction is typically
compensated by starting the wire drawing process with rod of higher strength (or utilizing
larger rod for drawing) so that at conclusion of the process dimensions and minimum
strength specified for equivalent non-galvanized prestressing wire is achieved. This
strand is not typically used in U.S. bridges.

Tendons in prestressed concrete structures do not experience stress cycling significant enough
to induce fatigue problems. Fatigue is a concern only in certain applications such as cable-
stays in cable-stayed bridges where traffic loads significantly affect stress variations.

2.1.1.2 Bars
Bars should be Grade 1035 MPa (150 ksi), high strength, thread bar meeting the requirements
of ASTM A722, “Standard Specification for Uncoated High-Strength Steel Bar for Prestressing
Concrete,” Type II bar. Bars are available in both a coarse and fine thread depending on the
manufacturer. Each may have advantages in different situations. It is good practice to limit the
stress level and number of re-uses for temporary applications, according to recommendations of
the Manufacturer. In the absence of such information, it is suggested that for new bars, the
stress should not exceed 50% fpu and the number of re-uses be conservatively selected based
on the critical nature of usage. Re-use of bars should only be after inspection for damage from
previous uses.

Post-tensioning bars are available in various sizes from 16mm (5/8in) to over 50mm (2in)
diameter. However, for convenience in handling, installation, and removal and re-use in normal
applications for post-tensioned bridges, 32mm (1-1/4in) or 35mm (1-3/8in) diameter bars are
typically used.

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Bars are not as easily damaged by corrosion as strands because of their lower strength, large
diameter and smaller ratio of exposed surface to cross section area. Hot rolled bars also
acquire a natural surface oxidation from the rolling process that enhances their protection.
Nevertheless, bars need to be protected during extended periods of exposure especially in
aggressive environments.

2.1.2 Shipping, Handling and Storage

All prestressing steel should be protected against physical damage and corrosion at all times
from manufacture to final installation and grouting. It should be packed in containers for
shipping handling and storage. A rust-preventing corrosion inhibitor should be placed in the
package or be incorporated in the carrier type packaging material. The corrosion inhibitor
should have no deleterious effect on the steel or grout or on the bond strength of steel to grout.
The inhibitor carrier type packaging should conform to Federal Specification MIL-P-3420.
Damaged packaging should be replaced or restored to its original condition.

All bars of each size from each mill heat of steel and all strand from each manufactured reel to
be shipped to the site should be assigned an individual LOT number and be tagged in a manner
that each such LOT can be accurately identified at the site. All unidentified prestressing steel
(strand or bar) or loss of positive proof of identification is sufficient reason for rejection.

Shipping containers should be clearly marked with a statement that it contains high-strength
prestressing steel, the type of care needed for handling, the type and amount of corrosion
inhibitor used and the date it was placed, and any other safety precautions and instructions.
Strand should be clearly identified that it is low-relaxation (stabilized) strand per the
requirements of ASTM A416 and the corresponding LOT number for which quality control test
samples have been taken. Strands not so designated should be rejected.

Reels of strand should be examined by the Contractor and inspected by the Construction
Inspector when first received on site and periodically while in storage. During use, any reel that
is found to contain broken wires or corrosion should be carefully examined. Lengths of strand
containing broken wires or corrosion should be removed and discarded. Prestressing steel
should also be protected during installation in the structure.

Post-tensioning bars for both temporary and permanent applications should be identified in a
similar manner and inspected for damage or excessive corrosion. At any time during
construction, the Construction Inspector should have the authority to reject any prestressing
steel that has sustained physical or corrosion damage.

2.1.3 Acceptance
To ensure that correct materials are supplied and used, specific quality control procedures for
material acceptance should be in place. Procedures may differ from State to State or from
Owner to Owner. An Owner may require that post-tensioning systems be pre-qualified prior to
use in construction by the Owner’s pre-qualification program. Pre-qualification in this manner
involves prior submission and approval of test reports and certifications.

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Samples for testing should be furnished at the job site for each manufacturer of prestressing
steel and bar. Each sample furnished for testing should be accompanied by certification
showing:

• Coil/reel number (strand only);

• Heat number;
• Chemical composition;
• Yield strength;
• Breaking strength; and
• Elongation properties

An example of typical frequencies of sampling and LOT designations are, as follows:

• For strand: three randomly selected samples, 1.5m (5ft) long, per manufacturer, per size
of strand, per shipment, with a minimum of one sample per ten delivered reels and
minimum of one per LOT/HEAT.

• For bar: three randomly selected samples, 1.5m (5ft) long, per size of bar, per heat of
steel with a minimum of one sample per shipment.

One of each of the samples furnished to represent a LOT should be tested in accordance with
appropriate ASTM standard. The remaining samples should be properly identified, tagged, and
stored. In the event of a loss or failure, the stored samples should be used for evaluation. For
acceptance of the LOT represented, test results must demonstrate 100% of fpu.

Following initial acceptance, the Contractor should maintain good control over the storage,
identification, and record keeping regarding the prestressing steel. The Contractor should
supply copies of certifications and test results to the Construction Inspector. The latter should
regularly and periodically check stored components, records and results.

Prior to use, strand should be inspected with respect to corrosion. Refer to Section 11.5 of
“Guide Specification for Grouted Post-Tensioning” (PTI/ASBI M50.3-12) for strand
condition/acceptance with regard to corrosion.

Approval of any prestressing materials by the Construction Inspector should not preclude
subsequent rejection if material is damaged in transit or later found to be defective for any
reason. Costs of acceptance and quality control tests are typically included in the project bid
items for post-tensioning work and no separate payment is made. Testing should conform to
the applicable ASTM Specifications. The location where the post-tensioning is to be installed is
considered the “site” and may be the project site or a casting yard.

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2.2 Anchorages and Associated Hardware

2.2.1 Anchorages

2.2.1.1 Basic Bearing Plates

A basic bearing plate is a flat plate bearing directly against concrete. This includes square,
rectangular, or round plates, sheared or torch cut from readily available steel plate, normally
ASTM A36. Basic bearing plates are used in conjunction with galvanized sheet metal or plastic
trumpets to transition from the strand spacing in the wedge plate to the duct (Figure 2.1).

Basic bearing plate anchorages should comply with the requirements of Section 10.3.2 of the
AASHTO LRFD Bridge Construction Specifications.

Figure 2.1 - Basic Bearing Plate Anchorage System

2.2.1.2 Special Bearing Plates or Anchorage Devices

A special bearing plate or anchorage device is any anchorage hardware that transfers tendon
force into the concrete but does not meet normal analytical design requirements for basic
bearing plates. Covered by this definition are devices having single or multiple plane bearing
surfaces, and devices combining bearing and wedge plate in once piece. These anchorages
typically require increased confinement reinforcement and should be accepted on the basis of
physical tests. Figure 2.2 shows a cut-away view of a multi-plane anchorage system. Figure
2.3 shows the components of the anchorage system for a four strand tendon in flat duct,
commonly used in slabs.

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Figure 2.2 - Multi-Plane Anchorage System (Courtesy of VSL)

Figure 2.3 - Anchorage System for Flat Duct Tendon (Courtesy of DSI)

Use of a special bearing plate or anchorage device is acceptable if it complies with the testing
requirements of Section 10.3.2.3 of the AASHTO LRFD Bridge Construction Specifications.

2.2.1.3 Wedge Plates

Wedge plates, in conjunction with wedges, transfer the prestressing force in the strands to the
anchorage. Wedge plates should comply with PTI’s “Guide Specifications for Grouted Post-
Tensioning,” Section 4.3.2.

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2.2.1.4 Wedges and Strand-Wedge Connection

Wedge performance is critical to the proper anchoring of strands. Different wedges have been
developed for particular systems and applications such that there is no single standard wedge.
However, wedges for post-tensioning systems should have the following characteristics:
• Wedge length at least 2.5 times the strand diameter.
• Wedge angle of 5 to 7 degrees.
• Internal serrated teeth for gripping the strand.
• Case-hardened low carbon or alloy steel.
• Two or three parts with a spring wire retainer clip or o-ring in a groove around the thick
end.
Wedges are case hardened with a ductile core, in order to bite into the strand and conform to
the irregularity between the strand and wedge hole. In so doing, the surface may crack. This is
normally acceptable and does not affect performance so long as wedge sections do not break
completely into separate pieces. Often, it is only the portion outside the retainer ring that
cracks.

Wedges should comply with PTI’s “Guide Specifications for Grouted Post-Tensioning,” Section
4.3.2.

2.2.2 Post-Tensioning Bars Anchor Systems

Anchorage systems for post-tensioning bars are comprised of bearing plates and anchor nuts
similar to the components shown in Figure 2.4. The anchorage system should comply with
PTI’s “Guide Specifications for Grouted Post-Tensioning,” Section 4.3.2.

Figure 2.4 - Post-Tensioning Bar Anchorage System (Courtesy of DSI)

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2.2.3 Permanent Grout Caps

Permanent grout caps similar to those shown in Figure 2.5 should be provided in accordance
with Protection Levels specified in Section 3.0 of “Guide Specification for Grouted Post-
Tensioning PTI/ASBI,” M50.3-12. Project specific documents should specify when and where
caps are required.

Permanent grout caps should be made of a non-corrosive material such as fiber reinforced
plastic, stainless steel, or galvanized ferrous metal with a minimum thickness of zinc of 120 μm.
To ensure an enduring, maintenance-free, life of 75 years fiber reinforced plastic caps should
contain an anti-oxidant additive with an environmental stress cracking endurance of 192 hours
per ASTM D1693; stainless steel caps should meet the requirements of ASTM A240 Type 316.

Grout caps shall meet the requirements of PTI/ASBI M50.3-12 Section 4.3.3.

Figure 2.5 - Permanent Plastic Grout Caps (Courtesy of VSL)

2.3 Ducts
Ducts are used to form a continuous void through the concrete for later placement of the post-
tensioning tendon steel. Originally, little attention was paid to the possible role of the duct as a
barrier to corrosive agents. Today, strong emphasis is placed on the quality, integrity and
continuity of the duct as a corrosion barrier in itself. This has resulted in a move toward the use
of plastic ducts in some states. Nevertheless, previous duct materials are still available and
their use continues in other regions. Consequently, the following recommendations should be
adapted as appropriate to meet local needs and conditions in accordance with Protection Levels
specified in Section 3.0 of “Guide Specification for Grouted Post-Tensioning PTI/ASBI,” M50.3-
12.

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2.3.1 Duct Size

2.3.1.1 Strand Tendons

Section 5.4.6.2 of the AASHTO LRFD Bridge Design Specifications calls for the inside cross-
sectional area of the duct to be at least 2.0 times the net area of the strand tendon. The one
exception cited by AASHTO is in the case where the tendons are to be placed by the pull-
through method. In this case, the inside duct area should be 2.5 times the net area of the
strand tendon. Section 4.3.5 of “Guide Specification for Grouted Post-Tensioning” (PTI/ASBI
M50.3-12) standardizes the inside cross-sectional area of the duct to be at least 2.5 times the
net area of the strand tendon cross sectional area.

Oval “flat” ducts are commonly used for transverse tendons in deck slabs of concrete box
girders. These transverse tendons have typically been made of up to 4 strands of 0.6in
diameter, though there are systems that will accept up to 5 strands. The internal clear
dimensions of oval duct should be a minimum of 25mm (1 in) vertically and 75mm (3 in)
horizontally.

2.3.1.2 Bar Tendons

Tendons containing a single post-tensioning bar should have an internal duct diameter at least
12mm (½ in) greater than the maximum outside dimension of the bar or bar coupler. A greater
clearance may be preferred or be necessary for some applications. Examples of this use would
be to provide greater tolerance for temporary bars or to accommodate bridges with slightly
curved alignments.

2.3.2 Ducts for Tendons

2.3.2.1 Corrugated Steel

Corrugated steel ducts are spirally wound to the necessary diameter from strip steel with a
minimum wall thickness of 0.45mm (26-gauge) for ducts less than 66mm (2-5/8 in) diameter or
0.6mm (24-gauge) for ducts of greater diameter. The strip steel should be galvanized to ASTM
A653/A653M with a coating weight of G90. Corrugated steel ducts should be manufactured
with welded or interlocking seams with sufficient rigidity to maintain the correct profile between
supports during concrete placement (Figure 2.6). Corrugated steel ducts should also be able to
flex without crimping or flattening. Joints between sections of duct and between ducts and
anchor components should be made with positive, metallic connections that provide a smooth
interior alignment with no lips or abrupt angle changes.

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Figure 2.6 - Corrugated Metal Duct

2.3.2.2 Smooth, Rigid, Steel Pipe

Rigid steel ducts are typically used in those portions of external tendons deviating though
segmental bridge pier segment diaphragms or deviators. In these areas of curved tendon
alignments, the steel pipe should be pre-fabricated to the required radius. Smooth steel pipes
should conform to ASTM A53/A53M “Standard Specification for Pipe, Steel, Black and Hot-
Dipped, Zinc Coated, Welded and Seamless,” Grade B Schedule 40.

2.3.2.3 Corrugated Plastic

Corrugated plastic ducts, as shown in Figure 2.7, are also used for tendons internal to the
concrete. These ducts should be seamless and fabricated from polyethylene or polypropylene
meeting the requirements of Section 4.3.5.2 of “Guide Specification for Grouted Post-
Tensioning” (PTI/ASBI M50.3-12).

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Figure 2.7 - Corrugated Plastic Duct

2.3.2.4 Corrugated Plastic, Tight-Radius Duct

Corrugated plastic duct, specifically formulated for tight-radii applications, is an option to curved
steel rigid ducts presented in Section 2.3.2.2. Locations for application of this type of duct
include anchorage blisters, external tendon deviation points, and looped vertical tendons in
precast, post-tensioned piers. When used in internal applications, the duct can be connected
with the same duct splices as straight portions of corrugated plastic duct to provide a continuous
duct from anchorage to anchorage. The duct can be pre-bent and delivered to the site similar to
rigid steel duct.

The wear resistance of the tight-radius corrugated plastic duct should be confirmed for the
minimum bend radius as a function of tendon size (number of strands). For further information,
refer to “Improved Performance Using Corrugated Plastic Duct in Tight-Radius Post-Tensioning
Applications” (Krauser).

2.3.2.5 Smooth, High Density Polyethylene Pipe (HDPE) for External Tendons
HDPE smooth pipe is available in different diameters, wall thickness, physical and chemical
properties. Though there can be some variability in commonly available materials, all HDPE for
ducts should conform to Section 4.3.5.3 of “Guide Specification for Grouted Post-Tensioning”
(PTI/ASBI M50.3-12). In addition, it is very important that the duct has satisfactory properties
for handling, storage, installation and durability for the application.

The color of HDPE smooth pipe for duct is normally black from a small amount of carbon in the
material, to protect against degradation from ultraviolet light. The wall thickness, diameter and
physical strength (Hydrostatic Design Basis) should be sufficient to initially withstand grouting
pressures, and in the long term, not deteriorate or split. Wall thickness requirements are
specified in Section 10.8.3 of the AASHTO LRFD Bridge Construction Specifications.

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2.3.2.6 Plastic Fittings and Connections for Internal Tendons

All duct splices, joints and connections to anchorages should be made with couplings and
connectors that produce a smooth interior duct alignment with no lips or kinks. All fittings and
connections between lengths of plastic duct and between ducts and steel components (e.g.
anchors or steel pipe) should be made of materials compatible with corrugated plastic ducts.
Plastic materials should contain antioxidant stabilizers and have an environmental stress
cracking of not less than 192 hours as determined by ASTM D1693 “Standard Test Method for
Environmental Stress-Cracking of Ethylene Plastics,” Condition C. Duct tape should not be
used to join or repair ducts or make connections.

2.3.2.7 Grout Inlets, Outlets, Valves and Plugs

Grout inlets, outlets, valves and plugs should be made of polypropylene or polyethylene meeting
the requirements for plastic, corrugated ducts. Grout inlets, outlets, valves and plugs shall meet
the requirements of PTI/ASBI M50.3-12 Sections 4.3.12 and 4.4.4. Figure 2.8 shows grout
vents installed in cantilever ducts of a precast segmental bridge pier segment.

Tubes for inlets and outlets for strand tendons should have a minimum inside diameter of 20mm
(3/4 in). For bar tendons and for tendons comprising up to 4 strands, tubes should be at least
10mm (3/8 in) internal diameter. Inlets and outlets should be closeable with suitable valves or
plugs. For grouting of long vertical tendons, dual mechanical shut-off valves are usually
necessary to facilitate intermediate stages of grouting and venting.

Inlets and outlets should be arranged and attached to ducts, anchorages and grout caps in a
manner that allows all air and water to escape in order to ensure that the system is completely
filled with grout. (See Chapter 4 for examples of locations of inlets and outlets).

Figure 2.8 - Grout Vents at Center of a Precast Segmental Pier Segment

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2.3.2.8 Duct Couplers for Precast Segmental Bridges

Duct couplers should be used at match-cast joints between precast segments and similar
situations if necessary to create a continuous, air and water-tight seal. The duct couplers shall
be mounted to the bulkhead of the casting machine to assure alignment between match cast
segments, while having flexibility to accept some misalignment and angular deviation. During
segment erection, the sealing gaskets and other details of the coupler should not prevent the
match-cast joint from closing under the application of temporary post-tensioning. Figure 2.9
shows components of a typical duct coupler. Figure 2.10 shows duct couplers connected to the
ducts and mounted to the bulkhead prior to casting a precast segment.

Figure 2.9 - Duct Coupler for Precast Segmental Internal Tendons

Figure 2.10 - Duct Couplers in Precast Segmental Construction

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2.3.2.9 External Tendon Duct Connections

Connections between sections of plastic pipe should be made using heat welding techniques or
with mechanical couplers. Connections between external HDPE pipe and steel pipe embedded
in the concrete should be made using circular sleeve (boot) made of Ethylene Propylene Diene
Monomer (EPDM). The sleeves should be secured with 10mm (3/8 in) wide power seated, 316
stainless steel band clamps, using one on each end of the sleeve (boot) to seal against leaking
grout. Welded and Boot connections should be in accordance with Sections 4.3.9 and 4.3.11 of
“Guide Specification for Grouted Post-Tensioning” (PTI/ASBI M50.3-12).

2.3.2.10 Shrink Sleeves

Tendon connections may be enhanced by the use of shrink sleeve wrap overlaying the
connection and portions of adjacent ducts. This may be used in aggressive environments
where connections may be directly exposed to de-icing salts or other contaminants entering
through expansion joints or other similar openings. Common applications include enhancing the
connection of polyethylene to steel ducts in external tendons, and between steel ducts cast into
pier segments of precast segments. Shrink sleeves should be in accordance with Section 4.3.7
of “Guide Specification for Grouted Post-Tensioning” (PTI/ASBI M50.3-12).

2.3.2.11 Diabolos
Diabolos are curved pathways cast into precast segmental deviators and/or pier segment
diaphragms that allow external tendons to pass through without the need for connecting to an
embedded rigid steel duct. The curved pathways flare at each end to accept a range of angle
changes in tendon geometry. Diabolos are created either by casting a permanently embedded
diabolo pipe into the segment, or through the use of reusable diabolo form inserts.

Where diabolos offer an alternative solution to calculating and detailing individual tendon pipe
bends, they are structurally different from individual pre-bent pipes that bear evenly over a
uniform radius. The actual contact length in diabolos varies, and may be quite short, depending
upon the minimum radius of the deviator flare.

Figure 2.11 illustrates the difference in bearing and contact between pre-bent pipes and diabolo
deviators. Figure 2.12 shows reusable diabolo form inserts used for the Phase 1 Dulles
Corridor Metrorail Project in Tysons Corner, VA.

Figure 2.11 - Pressure Distribution: Diabolos vs. Steel Pipe

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Figure 2.12 - Reusable Diabolo Inserts at Deviation Segment

2.3.3 Shipping, Handling and Storage of Ducts

Spiral-wound duct made from galvanized strip steel may be prefabricated or fabricated on site
as necessary. Plastic duct may be shipped in coils or in bundles of straight lengths.

In order to avoid inadvertent introduction of contaminants or debris, it is recommended that the

ends of duct coils or bundles be protected and covered during shipping and storage. Special
temporary end caps may be used to seal the ends of individual ducts. Plastic ducts should be
protected from sunlight, and ultraviolet degradation, and all ducts protected against crushing
and excessive bending until installed in the bridge. All ducts and pipes should be stored in a dry
location, on a raised platform, protected from weather and contamination.

2.3.4 Acceptance of Duct Materials

All duct materials (metal or plastic) ducts should comply with the requirements of AASHTO
LRFD Bridge Construction Specifications and meet the requirements of Sections 4.4.3 and 4.4.4
of “Guide Specification for Grouted Post-Tensioning” (PTI/ASBI M50.3-12).

2.3.5 Acceptance of Post-Tensioning System

Post-tensioning systems should be approved in accordance with Section 4.4.4 “Guide
Specification for Grouted Post-Tensioning” (PTI/ASBI M50.3-12).

For acceptance and approval of a post-tensioning system, all components’ tests and results of
post-tensioning system approval tests should be carried out by an independent approved body
or testing laboratory. This testing should be completed prior to submission of Shop Drawings
and other related documents to the Engineer for approval.

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It is recommended that a system supplier provide full documentation including:

• Technical documents and drawings of general assembly of the system and details of
components.
• Instructions and method statements for installation, stressing and grouting.
• A quality assurance plan covering production, shipping, handling, storage and
installation of the system.
• Instructions for surveillance and maintenance of the system in service.

On site, the Contractor should maintain a complete record of all documentation, test reports,
shipping dockets and approvals. Copies should be provided to the Inspector (CEI) to ensure
compliance.

2.4 Grout
2.4.1 Purpose
Cement grout is chemically basic and provides a passive environment around the post-
tensioning bars or strands. The grout also serves to bond internal tendons to the structure.
Appropriate protection of post-tensioning tendons begins with complete filling of the ducts with
high quality grout.

Post-Tensioning Institute document “Specification for Grouting of Post-Tensioned Structures,”

PTI M55.1-12, is an excellent resource for the grouting of tendons. This specification delineates
four classes of grout that can be used for most post-tensioning applications. These four classes
of grout and their recommend exposure conditions are:

Class A – Nonaggressive: indoor or nonaggressive outdoor.

Class B – Aggressive: subject to wet/dry cycles, marine environment, deicing salts.
Class C – Nonaggressive or aggressive (pre-packages)
Class D – Determined by Engineer

Refer to Section 3.3 of “Specification for Grouting of Post-Tensioned Structures,” PTI M55.1-12,
for further information concerning grout classifications.

2.4.2 Cement and other Pozzolans for Grout

The primary constituent of grout is ordinary Portland cement (Type I or II) that meets the
requirements of ASTM C150/C150M. Other cementitious material may be added to enhance
certain qualities of the final product. Fly ash and slag cements can improve corrosion
resistance in aggressive environments. The addition of dry silica fume (micro-silica) can
improve resistance to chloride penetration because the particles help fill the interstices between
hydrated cementitious grains thus reducing the permeability. When used, these pozzolan
admixtures should meet the following requirements:

• Fly Ash - Class C and Class F conforming to ASTM C618.

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• Slag Cement - Conforming to ASTM C989/C989M. Only Grade 120 slag shall be
specified for use in post-tensioning grouts.
• Silica Fume - Conforming to ASTM C1240. Densified silica fume shall not be used.

The water-cementitious material ratio should be limited to a maximum of 0.45 to avoid

excessive water retention and bleed and to optimize the hydration process. Any temptation to
add water to improve fluidity on-site must be resisted at all times. Fluidity may be enhanced by
adding a high range water-reducer, HRWR, (Type F or G).

2.4.3 Admixtures
Grouts made of only cement and water often exhibit segregation and voids due to excessive
bleed water. Like concrete, admixtures may be used to improve workability and reduce the
water required, reduce bleed, improve pumping properties or entrain air. Care must be
exercised to use the correct quantities in the proper way according to the manufacturer’s
instructions and to remain within the mix properties established by qualifying laboratory tests.

Calcium nitrite may help improve corrosion resistance in some situations by bonding to the steel
to form a passive layer and prevent attack by chloride ions. The use of calcium nitrite may
influence other properties such as setting time and strength.

High range water reducer (HRWR) improves short term fluidity. However, a grout with HRWR
may lose fluidity later when being injected through hoses and ducts. Unlike a concrete mix, it is
not possible to re-dose a grout especially when it is in the pump, hoses and ducts. Also, HRWR
tends to cause bleed in grouts. On-site grout mixing with HRWR is not recommended.

Other admixtures include: Set Controlling, Air Entraining, Anti-Bleed, Expansion Creating, and
Corrosion Inhibiting.

The addition of these should be strictly in accordance with manufacturer’s recommendations.

Furthermore, the mix should be qualified by appropriate laboratory testing. On site, daily grout
production must be monitored by various field tests in order to maintain quality control and
performance.

2.4.4 Pre-bagged Grouts

Grouts where the constituent materials are measured and batched on site do not always have
uniform properties. This arises from variations in materials, day to day mixing differences, crew
changes, weather conditions, and so forth. In an endeavor to eliminate problems related to
grout variations, several State DOT’s have obtained greater quality control by requiring “pre-
bagged” grouts. In a pre-bagged grout, all the constituent materials have been thoroughly
mixed and blended at the factory in the dry condition. This ensures that nothing other than
water needs to be added while mixing on site.

A manufacturer of a pre-bagged grout may already have had the material pre-qualified by a
State DOT or other agency. In this case, it is appropriate to accept it on the basis of a written
certification; providing that the manufacturer has on-going quality control tests that can be
confirmed by submitting test reports to the Engineer. The certification should show the mixed

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grout will meet the pre-qualified standard. On site, daily grout production must be monitored by
various field tests in order to maintain quality control and performance.

2.4.5 Thixotropic vs. Non-Thixotropic Grout

A thixotropic grout is one that begins to gel and stiffen in a relatively short time while at rest after
mixing, yet when mechanically agitated, returns to a fluid state with much lower viscosity. Most
grouts made with cementitious materials, admixtures and water are non-thixotropic. Thixotropy
may be exhibited by some, but not necessarily all, pre-bagged grouts.

A critical feature of a grout is that it should remain pump-able for the anticipated time to fully
inject the tendon. This may be significant for long tendons or where a group of several tendons
is to be injected in one continuous operation. Some thixotropic grouts can have very low
viscosity after agitation, becoming easy to pump.

2.4.6 Laboratory Tests

Acceptance of a grout is usually based upon the results of laboratory tests. Laboratory tests on
trial batches of the proposed grout using the same materials and equipment to be used on site
are used to qualify a grout. Trial grout should be prepared by personnel experienced in
preparing and testing grout mixes. This should be done at an approved material testing
laboratory. All tests should be performed at temperature and humidity conditions expected on
site. Trials should precede construction by at least eight weeks in order to allow time for testing
and resolution of any concerns.

Laboratory tests typically performed on grouts are presented in the following sections. Refer to
the “Specification for Grouting of Post-Tensioned Structures,” PTI M55.1-12 for additional
information. Testing of grouts previously prequalified through testing may be waived by the
Design Engineer. Testing of prepackaged grouts shall be performed at the minimum and
maximum water/bagged material ratios.

2.4.6.1 Setting Time

Grout set time is tested in accordance with ASTM C953 “Standard Test Method for Setting Time
of Grouts.” The setting time should be more than 3 but less than 12 hours. The tested setting
time does not relate to the placement or working life of the mix.

2.4.6.2 Grout Strength

Grout cube specimens, 50mm (2 in), are prepared and tested according to ASTM C942
“Standard Test Method for Compressive Strength of Grouts.” The strength should be 21MPa
(3000 psi) at seven days and 35MPa (5,000 psi) at 28 days.

2.4.6.3 Permeability
Grout permeability should be tested in accordance with ASTM C1202 “Test Method for
Electrical Indication of Concrete’s Ability to Resist Chloride Ion Penetration.” A value less than
2500 Coulombs after 6 hours is generally acceptable when subjected to a potential of 30 volts.

2.4.6.4 Volume Change

Volume change should be tested in accordance with ASTM C1090 “Standard Test Method for
Measuring Changes in Height of Cylindrical Specimen from Hydraulic Cement Grout.” A value
of 0.0% to less than +0.1% at 24 hours and no more than +0.2% at 28 days is acceptable.

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2.4.6.5 Pumpability and Fluidity (Flow Cone)

Grouts should be tested according to ASTM C939 “Standard Test Method for Flow of Grout,
modified by filling the flow cone above the standard level, and measuring the time to fill a one-
liter container. The efflux time should be between 5 and 30 seconds immediately after mixing.
After allowing the grout to stand for 30 minutes without agitation and then remixing for 30
seconds, the efflux time should be less than 30 seconds. It is recommended that some of the
laboratory qualification tests be run at the ends of this spectrum.

Figure 2.13 - Standard and Modified ASTM C939 Flow Cone Testing

2.4.6.6 Simulated Field High Temperature Fluidity Test

This non-standard test was developed by the Florida Department of Transportation to ensure
that a mix remains sufficiently workable for pumping under simulated high temperature site
conditions after re-circulating for a one hour period. The following procedure, taken from FDOT
Standard Specification, Section 938, may be used for guidance:

(a) Perform the test in a temperature conditioned laboratory. Condition the room, grout,
water, duct, pump, mixer and all other equipment to be used to a temperature of 32.5°C
(90°F) for a minimum of 12 hours prior to the test.
(b) Use 122m (400 ft, ± 3m (10 ft)) of duct (tube) for the test. Use a duct with an inside
diameter of 25mm (1 inch).
(c) Mix the grout to the specified water content. Pump the grout through the duct until
the grout discharges from the outlet end of the duct and is returned to the pump.

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(d) Start the one hour test period after the duct is completely filled with grout. Record the
time to circulate the grout through the duct. Constantly pump and re-circulate the grout
into the commercial grout mixer storage tank.
(e) Pump and re-circulate the grout for a minimum of one hour.
(f) Record at 15 minute intervals throughout the test period, the pumping pressure at the
inlet, grout temperature, and fluidity at the discharge outlet.

The result is satisfactory if the flow-cone efflux time (standard or modified ASTM C 939) after
one hour of recirculation is not greater than 30 seconds.

2.4.6.7 Bleed
The “Wick Induced Bleed Test” involves immersing a 1000 mm (40 in) length of conditioned,
clean, seven wire strand (either 0.5” or 0.6” in diameter) in a cylinder with a height of 1000 mm
(40 in) and diameter of 80 mm (3 mm), filled with 900 mm (35 in) of carefully prepared grout and
following a modified version of ASTM C940 to record the bleed water above the grout as
detailed in the Section 4.4.1 of “Specification for Grouting of Post-Tensioned Structures,” PTI
M55.1-12. A bleed of 0.0% after 3 hours at normal ambient room temperature of approximately
20ºC (68ºF) is acceptable (Figure 2.14).

Figure 2.14 - Wick-Induced Bleed Test

The “Schupack Pressure Bleed Test” uses a Gelman Filter to retain grout particles and records
the bleed water expelled under air pressure applied up to 0.34MPa (50 psi) (Figure 2.15). The
test should be performed per ASTM C1741. Refer to Section 4.4.6.2 of “Specification for
Grouting of Post-Tensioned Structures,” PTI M55.1-12 for additional test information and test
limits.

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Figure 2.15 - Bleed Under Pressure Test (Gelman Filtration Funnel)

2.4.6.8 Corrosion
An Accelerated Corrosion Test (ACT) may be used to quantify the expected level of corrosion
for a specific grout. The test is based on research made under FHWA-RD-91-092 which
indicates that a mean time to corrosion of 1,000 hours when tested at 0.2V is suitable. This test
is not yet standardized. However, it is particularly useful in determining combinations of
admixtures that may adversely affect the corrosion protection performance of a grout. The
maximum chloride content for grout is 0.08%.

2.4.6.9 Wet Density

A wet density value for grout should be established in the laboratory using an American
Petroleum Institute Mud Balance (API Recommended Practice 13B-1: “Standard Procedures for
Field Testing Water-Based Drilling Fluids”) for the maximum and minimum recommended water
dosage. The values determined from this testing should be compared to those provided by the
Manufacturer.

Once this range has been established, wet density can be monitored in the field to ensure that
grout water content is appropriate, using an American Petroleum Institute Mud Balance (API
Recommended Practice 13B-1: “Standard Procedures for Field Testing Water-Based Drilling
Fluids”).

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2.4.6.10 Inclined Tube Test

The inclined tube test shall be performed in accordance with EN 445 “Grout for Prestressing
Tendons – Test Methods,” produced by the American National Standards Institute. Grout bleed
should not exceed 0.3% of the initial volume of the grout after being kept at rest for 3 hours.

2.4.7 Shipping, Handling, Storage and Shelf-Life

Cement and other materials may be delivered in bags but should be stored in a weatherproof
building. Storage in the open may be allowed providing that materials are on a raised, dry
platform with adequate weatherproof covering. Additives should be stored in a warm
environment. Dissolvable packaging materials should not be allowed for any components as
they can break down to pulp and cause equipment or duct blockage.

It is essential that the Contractor maintain a record of all delivered materials. A copy of the
manufacturer’s quality control data sheet should accompany each LOT of grout components
shipped to the site. A LOT is that parcel of material from the same production run shipped to
the site. Each shipment should be clearly identified with the corresponding LOT number so that
it can be tracked to the manufacturer’s quality control records. Copies of shipment records and
quality control test reports should be maintained by the Contractor and copies provided to the
Construction Inspector.

Prior to use, all materials in storage should be checked to make sure they have not exceeded
the manufacturer’s shelf life or have not absorbed moisture and begun to clump or hydrate. It is
recommended that cementitious materials and pre-bagged grouts not be stored on site for more
than one month before they are used.

Dry silica fume is available in bags. Special care is essential when mixing dry silica fume with
cement and additives in order to produce a job-site grout mix, as it can lead to clumping and a
poor result. Pre-bagged grouts containing silica fume have been dry blended and do not exhibit
this problem.

Any material with a total time from manufacture to use in excess of six months should be
retested, or recertified by the supplier before use or else be rejected and replaced. Approval of
any grout or grout materials by the Construction Inspector should not preclude subsequent
rejection if material is damaged in transit or later found to be defective for any reason.

2.4.8 Acceptance
A proposed grout is normally accepted on the basis of the laboratory tests listed in Section 2.4.6
performed before construction, or on the basis of certification from the manufacturer that the
(pre-bagged) grout materials meet the pre-qualification requirements of the Owner or project
specifications. The manufacturer should have a continuing quality control program to ensure
that production continues to meet the specified requirements. Copies of certificates should be
checked and a record kept by the Contractor and the Construction Inspector. Use of a
particular grout on site may continue providing that certification and documentation is kept up to
date, that materials in storage remain usable and that daily grout mix production tests meet
specified limits. Approval to use a grout should be withdrawn if these quality control standards
are not maintained.

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2.4.9 Field Mock-Up Tests

When specified in the Contract Documents, field mock-up tests may be used to demonstrate
that materials, components such as inlets and outlets, mixer, pumping and grout injection
methods will result in complete filling of a duct. Mock-ups are appropriate for new means and
methods, new types of components or grout materials. Production tendons should not be used
for the mock-up test.

Mock-up Tests should be in accordance with Section 4.7.2 of “Specification for Grouting of Post-
Tensioned Structures,” PTI M55.1-12. As far as possible, a mock-up should simulate the type
and size of tendon, duct, anchorages and proposed attachments and be arranged to a similar,
representative, geometric duct profile. The following field mock-up tests are suggested for
guidance:

(A) For continuously draped tendons in spliced girders or cast-in-place construction: one
tendon mock-up of the longest tendon from anchor to anchor, including all proposed
intermediate duct couplings and grout inlets and vents. The profile should simulate the tendon
with the maximum accumulated curvature from anchor to anchor.

(B) For cantilever or continuity internal and external tendons in precast or cast-in-place
segmental construction: one tendon mock-up of the longest tendon from anchor to anchor,
including all proposed intermediate duct couplings and grout inlets and vents. The profile
should simulate the tendon with the maximum accumulated curvature from anchor to anchor.

(C) For vertical tendons: one tendon mock-up of the longest tendon from anchor to anchor,
including all proposed intermediate duct couplings and grout inlets and vents. The profile
should simulate the tendon with the maximum accumulated curvature from anchor to anchor.

The following tests should be conducted and satisfied during the field mock-up trials:

• Pumpability and Fluidity (Flow Cone) (2.4.6.5)

• Simulated Field High Temperature Fluidity Test (2.4.6.6 - Optional)
• Wick Induced Bleed Test (2.4.6.7)
• Wet Density (2.4.6.9)
• The Schupack Pressure Bleed Test (2.4.6.7) should be satisfied for projects where
longitudinal tendons have a maximum difference in height at any point over 6 feet or
vertical tendons are over 20 feet high.

2.5 Other PT System Qualification Tests

Project specific documents should state when a dynamic system qualification test for unbonded
(external) tendons is necessary. This should comply with the most recent AASHTO LRFD
Bridge Construction Specifications. In the absence of any other information, for guidance,
reference may be made to “Acceptance Standards for Post-Tensioning Systems,” PTI, 1998.

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Chapter 3 – Post-Tensioning Duct and Tendon Installation

This Chapter addresses construction procedures and operations from Shop Drawings, through
tendon installation and stressing. Grouting is addressed in the next chapter. Information and
details in these two Chapters may be used for guidance.

3.1 Shop Drawings

3.1.1 Drawings and Details

3.1.1.1 Purpose
To permit competition and to encourage further development in the field of post-tensioned
bridge construction, in general, normal contract plans and specifications do not specify a
particular manufacturer’s post-tensioning system. The Engineer of Record usually selects the
type, size, location and number of tendons, but the Contractor selects the anchorage system.
All post-tensioning systems should have prior approval before being used.

All systems now in general use have been developed by independent companies and represent
different methods by which the prestressing force is applied. Each offers certain advantages as
compared to the others, but each will, when properly installed and stressed, accomplish the
intended result.

A post-tensioning system proposed by a Contractor should be shown on shop drawings. These

drawings should include details for the methods and materials used, including all plan
reinforcement and any rearrangement of or addition to reinforcing steel that differs from that
shown on the Contract Plans. Shop drawings represent an important supplement to Contract
Plans.

Shop drawings are normally reviewed by the Bridge Designer or Construction Inspector (CEI).
The Designer normally checks them for completeness, contract compliance, clearances or
interference of ducts and reinforcing steel. Despite the approval process, the Contractor
remains responsible for the correctness of the shop drawings and ensuing construction.

Shop drawings are needed for integration of approved post-tensioning systems (i.e. post-
tensioning supplier’s information and details), reinforcement, post-tensioning, and other
embedded items (including those for the Contractor’s chosen “means and methods” of
construction) for precast and cast-in-place components. Shop drawings should also include
corrosion protection details and designate the level of protection achieved, as defined in “Guide
Specification for Grouted Post-Tensioning,” PTI/ASBI M50.3-12.

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3.1.1.2 Typical Contents

Shop drawings from a Manufacturer of a Post-tensioning system typically address various
details such as:

• Dimensions, details and materials for all manufactured components.

• For strand systems, dimensions and details of anchors, wedge-plates, wedges, for each
size and tendon.
• For bar systems, dimensions and details of anchor plates, anchor nuts, bars and
couplers for each bar size.
• Details of grout inlets and outlets at anchorages.
• Size, type connection and sealing details of grout caps.
• For each type of duct, dimensions, details, type of material, duct connectors and
methods of connecting ducts to anchor cones (trumpets).
• Segmental Duct Couplers (if used).
• Details of means and methods of attaching intermediate grout inlets and outlets to the
ducts, including sizes of grout pipes, materials, and shut-off valves.
• Dimensions, clearances, force and stroke of stressing jacks for post-tensioning bars and
strands, including single, mono-strand and multi-strand jacks as necessary.
• Typical details of ancillary equipment such as power source, hydraulic lines, pressure
gages for use with the stressing jacks.
• Jack calibration charts to show relationship between dial gage pressure and force
delivered.

Often, much of the above information is available from a catalogue data, particularly for
anchors, couplers, wedges, nuts, bars, ducts, jacks and equipment. Other information shown
on additional shop drawings prepared by a Contractor or his (Specialty) Engineer or in a post-
tensioning or construction manual for a specific project usually includes procedures, such as:

• Duct profile and minimum clearances.

• Details, types and locations of duct supports, connections to temporary bulkheads, and
means of maintaining alignment and profile.
• Segmental Duct Couplers (if used).
• The method for installing strands, individually or in a complete bundle for each tendon.
• The sequence in which tendons are stressed.
• The end(s) from which tendons are stressed.
• Assumed coefficient of friction (µ) and wobble coefficient (k).
• The estimated elongation and maximum jacking force for each tendon.
• The estimated anchor set or seating loss.
• Similar information for post-tensioning bar tendons.
• When temporary post-tensioning bars are used to secure a precast match cast segment,
the sequence and force to which each should be coupled and stressed around the
cross-section.
• The sequence and means by which temporary post-tensioning bar or strand tendons are
de-tensioned and removed.
• For all permanent installations, locations of grout inlets and outlets, details, direction of
grouting and sequence in which tendons are grouted (See also Chapter 4).

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3.1.1.3 Typical Approval Process

A typical shop drawing submittal, review and approval process for a Design-Bid-Build project is
illustrated in Figure 3.1. Typical responsibilities associated with this approach to shop drawings
include:

• Contractor: Arrange for the preparation of the necessary shop drawings and other
relevant information required by the Contract. Receive and review shop drawings from
Suppliers, Manufacturers, and the Contractor’s Engineer. Submit shop drawings to the
Owner in accordance with the project plans and specifications. Coordinate distribution
of approved shop drawings or return shop drawings for changes and resubmittal.

• Contractor’s Engineer: Prepares post-tensioning related calculations and shop drawings

on behalf of the Contractor.

• Engineer (Designer): Receives post-tensioning calculations and shop drawings from the
Owner (often the Contractor makes simultaneous submissions to the Owner and
Engineer in order to expedite approvals.) Reviews submittals for compliance with the
information shown on the plans. Approves (completely or “as noted”) or rejects the
submittal and returns the submittal to the Owner. Forwards a copy of the information
transmitted to the Owner to the Construction Inspector (CEI).

• CEI – Construction Engineering and Inspection: Receives notice of shop drawing

submittal from the Contractor. Receives and reviews the Engineers return of the shop
drawing. Represents the interest of the Owner on the job-site (Resident Engineer).

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Figure 3.1 - Typical Shop Drawing Approval Process for Post-Tensioning

3.1.2 Stressing Calculations

To ensure that the correct force is applied to each tendon, calculations are made to account for
losses (friction, wobble, anchor set and anchor friction) along the length of a tendon and to
estimate the elongation as a check against the gauge pressure on the jack. Calculations are
usually made by the Contractor’s Engineer or installer of the Post-Tensioning and should be
checked by the Engineer (Designer or CEI). Key information, such as jacking force or gauge
pressure and anticipated elongation, is developed for subsequent tendon stressing.

Friction losses along the length of the tendon, between anchorages, are attributed to two
sources. The first of these frictional losses is the result of the expected friction between tendon
and duct as the profile of the tendon changes. These losses are related to angular changes in
the tendon profile. The top sketch in Figure 3.2 shows the trajectory of a tendon within a
desired duct profile. The friction coefficient (µ) is defined to predict losses of this type. The
value of the friction coefficient is a function of the duct material.

Predicting frictional losses along the length of a tendon using the friction coefficient alone does
not typically correlate well with field results. Another coefficient of frictional loss, wobble (k), is
used to account for additional friction between strand and duct as a result of unintended duct
misalignments. The concept of duct wobble is shown in the bottom sketch of Figure 3.2.

The equation relating tendon force at a point along the length of a tendon, as a function of
friction and wobble determined from the formula:

− + kx
P( x) = Pjack ⋅ e
Equation (3.1)

Where: x = distance along length of tendon where tendon force is being evaluated
P(x) = Force in tendon at a distance x along tendon length
Pjack = Stressing force at anchorage
µ = friction coefficient
K = wobble coefficient
θ = total angular change from stressing end to point x

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Figure 3.2 - Frictional Losses Related to Friction and Wobble

Anchor set should be taken into account for both the stressing end and dead end of a tendon.
For long tendons, often the elongation may be greater than the travel on the jack. It is then
necessary to take more than one pull of the jack. Each time the jack is released, the anchor set
occurs again at the jacking end. Since the load is picked up again upon re-gripping, the anchor
set of individual pulls is not cumulative. Only the final anchor set affects the loss of tendon
force. However, keeping account of cumulative elongations and anchor set during repeated
pulls by a jack is always helpful for resolving unforeseen problems.

Stressing of a tendon may be performed from one or both ends. Stressing from both ends may
be sequential, first from one end then the other, or simultaneous using two jacks. In some types
of construction, it may only be necessary to stress from one end; for example, where tendons
are relatively short, say up to about 50m (150 feet) and have relatively small friction loss.
However, for long tendons, especially those within internal ducts set to a curved profile that
passes continuously through three or four spans, friction loss may be so significant that it is
essential to stress the tendon from both ends to ensure adequate force throughout.

Stressing calculations are illustrated with two examples: first for a long tendon draped to a
profile through four continuous spans and stressed sequentially from both ends; second for a
deviated external tendon in an end span stressed from the expansion joint.

Various parameters for calculation of tendon forces and elongations are defined as follows:

• Length of tendon (L)

• Assumed area of tendon (A)

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• Modulus of Elasticity assumed (E)

• Coefficient of friction between tendon and duct (μ)
• Wobble coefficient (k)
• Distance from jacking end to location of interest (x)
• Accumulated angle of curvature to point (θ(x))
• Length of portion of tendon between two points “i” and “j”, = x i j
• Anchor seating loss (W)
• Friction in anchor (%)
• Friction in jack (%)
• Pjack = force at the jack

Typical values for friction and wobble coefficients are provided in Table 5.1 of “Guide
Specification for Grouted Post-Tensioning”, PTI/ASBI M50.3-12. Section 5.4 of the same guide
specification provides typical values for the modulus of elasticity of the post-tensioning steel.

The total elongation is obtained by summing the increments of elongation for each portion of the
tendon, based on the average of the force at the beginning and end of that portion:

Pave ⋅ xij
∆L = ∑
As ⋅ Es
Equation (3.2)
Where: Pave = average force over xij

Stressing calculation information should be forwarded to the site engineer or inspector. This
information should include:

• Tendon identification
• Assumed area of strands (A)
• Assumed modulus of elasticity (E)
• Required jacking force, P jack
• Anchor set (W) assumed for each end of each tendon
• Calculated elongation at each end, before release of the jack and anchor set for each
end of the tendon, depending upon the ends to be jacked first and second
• The anticipated total elongation, ∆L, before anchor set

Calculations of tendon force and elongation are made using assumed values for the tendon
area (A) and modulus of elasticity (E). If elongations measured during stressing operations are
outside of tolerances, actual values of A and E for the particular reel of strand should be used to
resolve discrepancies.

3.1.2.1 Example 1: Four-Span Girder

Consider the four-span girder bridge with spans of 135’-180’-180’-135’ as shown in Figure 3.3.
Two spans of the bridge and the profile of a tendon which is made up of parabolic segments are
shown in Figure 3.4. Calculate the forces along the length of the tendon and the expected

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elongations accounting for friction, wobble, and anchor set. The tendon is made of 12-0.5”
diameter strands, giving it a cross sectional area of 6.24 in2. The tendon is stressed from both
ends, first at End A and then End B. The stressing force is 1264 kips (75% fpu). The modulus of
elasticity of the tendon is 28,000 ksi. The friction coefficient is 0.25 and the wobble coefficient is
0.0002ft/ft.

Figure 3.3 - Four-Span Girder

Figure 3.4 - Tendon Geometry

The calculation is made by considering each arc of the profile in turn and applying Equation 3.1
to determine the force at the beginning and end of each segment of tendon length. The
calculation begins at the stressing end and continues across the length of the tendon. Table 3.1
shows a table of the results of these calculations. The total elongation is found by summing the
last column of the table in Table 3.1. For this example, the total elongation is calculated to be
41.62 inches.

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Loss Segment
Loss Force
Section x h Segment Elongation
(%) (kips)
(%) (inches)

1 0.0 0.00 0 1.00 1.00 1264 0.00

2 54.0 4.00 0.1481 0.9533 0.9533 1205 4.58

3 67.5 4.50 0.1333 0.9542 0.9097 1149 5.46

4 13.5 0.90 0.1333 0.9646 0.8775 1109 1.05

5 18.0 1.08 0.1200 0.9670 0.8485 1072 1.35

6 72.0 4.32 0.1200 0.9566 0.8116 1026 5.19

7 72.0 4.32 0.1200 0.9566 0.7764 981 4.96

8 18.0 1.08 0.1200 0.9670 0.7507 949 1.19

9 18.0 1.08 0.1200 0.9670 0.7259 917 1.15

10 72.0 4.32 0.1200 0.9566 0.6944 877 4.44

11 72.0 4.32 0.1200 0.9566 0.6642 839 4.24

12 18.0 1.08 0.1200 0.9670 0.6423 812 1.02

13 13.5 0.90 0.1333 0.9646 0.6196 783 0.74

14 67.5 4.50 0.1333 0.9542 0.5912 747 3.55

15 54.0 4.00 0.1481 0.9533 0.5636 712 2.71

Table 3.1 - Example 1 Tendon Force and Elongation Calculation

Two observations are made with regard to the calculated total elongation. First, this elongation
is greater than the available stroke of normal stressing jacks. As a result, obtaining the full
elongation will require several separate pulls from End A. The calculations reflected in Table
3.1 do not consider the initial anchor set at End B. This anticipated anchor set occurs while end
B is a non-stressing “dead end”. In theory, it should be added to the total anticipated elongation
for stressing from End A. For instance, if all of the elongation could be measured at End A, the
apparent elongation at A would become 41.62 + 0.375 = 41.995 in. - if anchor set at End B is
assumed to be, say, 0.38 in. However, in the field not all the force will be applied in one step at
End A. Typically an initial load, typically 20%, is applied at A to remove slack and seat the
wedges at End B. Elongations are typically measured after this initial load. A correction is
added for the initial 20% based upon that measured from 20 to 100% load.

Table 3.1 shows a graph of the tendon force along the length of the tendon when the tendon
has been stressed to the full jacking force. Note that the area below the tendon force curve is
equal to the work to elongate the tendon. Dividing this area by the tendon area and modulus of
elasticity produces the elongation of the tendon when stressing at End A.

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Figure 3.5 - Tendon force Diagram for Stressing at End A

When the jacking force is reached at End A, the wedges are made snug and the tendon force
released. The tendon draws the wedges, or seats them, into the wedge plate. Values of wedge
can vary with post-tensioning system, but a typical value is 3/8 inch. As the wedge seating is
being seated the tendon is shortening, reducing the tendon force at the wedges. Only a portion
of the length of the tendon may, however, be affected by the anchor set. This is because the
work to seat the wedges is typically much less than the work done to elongate the tendon.

Figure 3.6 shows the effect of an anchor set of 0.375 inches on the forces along the length of
the tendon after stressing at End A. The shaded area in Figure 3.6 represents the work
performed during the anchor seating. This area is determined by finding a point along the
length of the tendon to a location where the anchor set does not impact the tendon stressing
force (point of zero movement). Working back from the tendon force at that point to the
anchorage, the loss in tendon force is related to the geometry of the tendon, friction and wobble,
just as when originally stressed. A typical simplification for this calculation is to mirror image the
force loss diagram about a horizontal line passing through the point of zero movement.

For this example, the point of zero movement was determined by trial and error to be 75.2’ from
the stressing end. The force at the point of zero movement is 1187.5 kips, and the force at the
anchorage with anchor set loss is 1111 kips. The convergence on these values was found by
equating the shaded area in Figure 3.6, divided by the tendon cross sectional area and modulus
of elasticity, to the anchor set of 3/8”:

Equation (3.3)
((94.0 k ⋅ 54 ') + (17.5k ⋅ 21.2 '))12
Set = = 0.374" ≈ 0.375"
6.24in 2 28, 000ksi

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Figure 3.6 - Tendon Force Diagram after Anchor Set at End A

The second stage of stressing is now performed from End B. After stressing from End A, the
force in the tendon at End B is calculated to be 712 kips. When jacking at End B, the jack will
not begin to move until the load exceeds this amount. The jack at End B will pick up load at 712
kips and continue to the final jacking force of 1264 kips, effecting the force in the tendon until it
reaches a point where the force is equal to that from jacking at End A. In this case, because the
bridge is symmetrical, this occurs at the middle of the tendon, over the middle pier.

The shaded area shown in Figure 3.7 between the two tendon force diagrams, divided by the
tendon area and modulus of elasticity is equal to the elongation due to stressing the tendon at
End B. For this example the tendon elongation due to second stage stressing is 5.93 inches.

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Figure 3.7 - Tendon Force Diagram after Stressing from End B

The final change in tendon force is a result of the anchor set at End B. By symmetry of the
tendon and jacking force, the resulting loss due to anchor set is the same that was computed at
End A. This loss and the final tendon force diagram after stressing is shown in Figure 3.8.

Figure 3.8 - Tendon Force Diagram after Anchor Set at End B

It should be noted that in this example, no account has been taken for the elastic shortening of
the structure under the axial compression force of the tendon. If this stressing is performed only
on the girder before any deck slab has been cast and if the above tendon is the first of several,
then the elastic shortening is estimated approximately as follows:

Consider an average force in the tendon of 960 kips while stressing from End A. Also consider
a girder cross sectional area of 80 ft2, a bridge length of 630 feet, and a modulus of elasticity of
concrete of 650,000 ksf. The elastic shortening of the bridge during the stressing of the tendon
from End A would be 0.14 inches.

This amount of elastic shortening is small. However, in the field, it would have the effect of
increasing the measured elongations; approximately in proportion to the calculated elongation at
each end. It follows that stressing of a subsequent tendon of the same profile would result in
the same elongations for that tendon. However, it also follows that elastic shortening caused by
stressing of a second tendon reduces the effective force in the first tendon. Such reduction also
occurs for the effect of all subsequent tendons stressed after earlier ones. The effect of such
staged post-tensioning is normally taken into account by the Designer during design of the
bridge. The Designer should consider the effects of elastic shortening in the design of post-
tensioning forces.

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3.1.2.2 Example 2 – External Deviated Tendon in End Span

Consider the external tendon in the end-span of a typical span-by-span bridge (Figure 3.9).
Calculate the forces along the length of the tendon and the expected elongations accounting for
friction, wobble, and anchor set. As with Example 1, the tendon is made of 12-0.5” diameter
strands, giving it a cross sectional area of 6.24 in2. The tendon is stressed from the right end
only. The stressing force is 1264 kips (75% fpu). The modulus of elasticity of the tendon is
28,000 ksi.

Friction between the tendon and duct can only occur at deviators and in those portions of duct in
the diaphragms of pier or expansion joint segments where the tendon path curves to an anchor.
In this example, there is a curve at the dead end only and none at the stressing end. Curvature
friction, μ, applies at the deviators and the dead end diaphragm, but there is no loss due to
wobble in external tendons, so k = 0.0.

Figure 3.9 - External Deviated Tendon in End Span

As with Example 1, the calculation for tendon force and elongation is made by considering each
angular change in turn and applying Equation 3.1 to determine the force at the beginning and
end of each segment of tendon length. The calculation begins at the stressing end and
continues across the length of the tendon. Table 3.2 shows a table of the results of these
calculations. The total elongation is found by summing the last column of the table in Table 3.2.
For this example, the total elongation is calculated to be 11.87 inches.

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Loss Segment
Loss Force
Section x h Segment Elongation
(%) (kips)
(%) (inches)

1 0.0 0.00 0.00 1.00 1.00 1264 0.00

2 48.6 0.00 0.00 1.0000 1.0000 1264 4.22

3 1.5 0.00 0.0759 0.9812 0.9812 1240 0.13

4 33.6 0.00 0.00 1.0000 0.9812 1240 2.86

5 2.2 0.00 0.1085 0.9732 0.9549 1207 0.18

6 48.4 0.00 0.00 1.0000 0.9549 1207 4.01

7 2.2 0.00 0.1085 0.9732 0.9294 1174 0.18

8 3.6 0.00 0.00 1.0000 0.9294 1174 0.29

Table 3.2 - Example 2 Tendon Force and Elongation Calculation

The final force diagram after friction and anchor set loss for Example 2 is shown in Figure 3.10.
Note the horizontal force lines between deviation points. The lack of change in force in these
regions is a result of there being no wobble for external tendons.

Figure 3.10 - Example 2: External Tendon Force after Friction and Anchor Set

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3.2 Tendon Testing On Site

On-site testing may be required to establish or confirm design parameters related to the post-
tensioning tendons. Procedures for two of these tests, friction evaluation and modulus of
elasticity evaluation, are provided in the following Sections.

3.2.1 Friction
The purpose of a friction test is to verify the assumptions for the coefficients of friction and
wobble. This test would be appropriate for all but small scale applications where it would suffice
to adopt friction and wobble values from other, previous, experience.

A friction test is normally performed on a typical tendon representative of the type or group of
tendons being installed – for example, on one tendon in one girder of several in the span or on
perhaps two similar cantilever tendons in the top of precast or cast-in-place segments.

For any tendon, there are two unknowns, the coefficients of friction (μ) and wobble (k).
However, for any given test set up where the force is measured at each end of the tendon, there
can only be one equation and result based upon the standard force loss equation.
Consequently, two unknowns (μ and k) have to be derived from one equation. This is not
possible unless one of the unknowns is already known.

For an external tendon in, say a span-by-span bridge, the points of curvature are relatively
discrete and the angles consumed are known. In the straight portions there is no wobble. So in
such a case, providing that the pre-curved steel pipe ducts in the pier diaphragms and deviator
saddles have been correctly installed, then it may be assumed that k = 0. Thus a test on this
type of tendon should provide a reasonable result for the effective coefficient of friction, μ,
between the tendon and the steel pipes.

For a tendon in the top of a segmental precast or cast-in-place cantilever, usually the alignment
is relatively, but not completely, straight between two curves at each end anchor. If the duct for
this type of tendon has been carefully and well installed so that there is no wobble, then it may
be assumed that k = 0 and a test should provide a reasonable result for μ.

On the other hand, if there is uncertainty as to how well a duct has been installed or if it is
known to have significant unintentional wobble, it is necessary to make a judgment as to a
suitable proportion of loss due to friction and loss due to wobble. It is suggested that the wobble
coefficient be taken as the assumed value for “k” – and use the test result to give “μ”.

An alternative approach to determine both coefficients μ and k would be to perform the friction
test on two similar, say cantilever tendons – a short one and a long one. Assuming the tendons
are installed with the same materials and standard of care, this would provide two independent
results (i.e. two equations) which could be solved simultaneously for μ and k.

In any event, it is recommended that each friction test be performed on at least two, very similar
or identical, tendons – of the same length and curvature layout - for example, in a segmental
cantilever, one tendon over the left web and its counterpart over the right web. The average of

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the pair represents one result (i.e. one equation). In an I-girder with a continuously draped
tendon profile, the two tests could be performed on two very similar tendons in the same girder
or the same profile of tendon in two parallel girders – where again, the average of the two
represents one result (equation).

In general, friction testing is likely to give reasonable results only on relatively long tendons
(over about 30m (100 ft)) since it is necessary to measure both forces and elongations under
incremental loading to a sufficient level of accuracy. For this reason, an in-place friction test is
not appropriate for some applications such as, straight longitudinal or transverse tendons in
“flat-oval” ducts or similar in voided precast slabs or transverse deck slab tendons in precast or
cast-in-place segments.

It is usual to test a minimum of one tendon in a group of tendons performing the same function –
e.g. one tendon in each web of a two-web box. Tendon function may be generally described as:

• Internal cantilever tendon or continuity tendon (e.g. in precast or CIP segments)

• External draped (deviated) tendon (e.g. in span-by-span construction)
• Profiled (draped) internal tendon (e.g. I-girders and CIP boxes)

Selected tendons should represent the general size (that is number of strands) and length. It is
recommended that friction test groups be identified on shop drawings for approval.

The test procedure is to tension the tendon at one anchor assembly and measure the force at
the dead end using a load cell or calibrated jack. The tendon should be tensioned to 80% of
ultimate in increments of not less than 20%. For each increment, the gauge pressure at the
jacking end, the load cell (or jack) force at the dead end and the elongation at the jacking end
should be recorded. Also, note the anchor set at both ends. Take into account the loss of force
due to friction in the anchorages and wedge plates as the strands deviate slightly through them
and any friction in the jack. The manufacturer of the post-tensioning system should be able to
provide percentage estimates for these losses. For very long tendons that require multiple jack
pulls, it is essential to keep an accurate account of elongation at the jacking end and each
corresponding intermediate anchor set (wedge pull-in).

If wedges are not installed, and if the available jacking equipment can facilitate it, forces and
elongations measured while gradually releasing the jacking load should reveal a lag or
hysteresis resulting from the reverse effect of friction (Fig. 3.11). The force and elongation may
not immediately return to zero due to residual friction effects.

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Figure 3.11 - On-Site Friction Test

When performing friction tests, it is recommended that forces and elongations be reconciled
within a tolerance of 5% for all tendons. The 5% to 7% tolerance in AASHTO LRFD
Construction Specifications is for production tendon elongations – no guidance is given for
friction tests.

If the total measured elongation is different to the anticipated (calculated) elongation by more
than 5% then the reasons for it should be investigated. It may be necessary to make more
detailed calculations or to run a similar test on another tendon. It is suggested that assumed
values for friction (μ) and wobble (k) not be varied by more than 10% when attempting to
reconcile measured and anticipated results.

A significant shortfall in elongation is indicative of poor duct alignments or obstructions. The

likely causes should be examined and appropriate corrective measures taken.

The strands must be removed after completion of the friction test in order to remove the load
cell, and the strands cannot be reused due to wedge “bite marks” on the strands.

3.2.2 Modulus of Elasticity

The modulus of elasticity, E, is provided per coil of strand, or bundle of bars for each of the
manufacturers lots. This is derived from proof tests performed by the manufacturer as part of
his quality control of the strand, or bar, production.

The modulus of elasticity for an individual strand is generally about 193 to 200GPa (28,000 to
29,000 ksi.) There is a school of thought that the effective modulus of elasticity of a bundle of
strands made up into a multi-strand tendon may be slightly less than that of an individual strand
because of the bundle effect or the “un-wrapping”, if any, as strands are stressed. This is not
necessarily so. In some bench-tests performed on an approximate gauge length of 9m (30 feet)
with no contact between tendon and duct, the modulus of the group of strands proved to be the

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