OWNER: DR.

MOHAMEED MATAR SALEM AL KAABI

CONSULTANT: WHITE LINE ENGINEERING CONSULTANCY
CONTRACTOR: AL HASHEM BUILDING CONTRACTING
PROJECT: PROPOSED BUILDING (3B+G+11)
METHOD OF STATEMENT

1. DEFINITIONS
Anti-burst Reinforcement
Small mild-steel reinforcing cage located at all tendon anchorages, live and dead. Each anti-burst
cage usually consists of a combination of ligatures, spirals and straight bars.

Barricade
Structure designed to restrain the strands or jack should they unexpectedly release under pressure as a
result of the strands breaking or failure of the system in some other way. It is generally made from
timber and ply and is placed directly behind the live end anchorages during final stressing and de-
tensioning.

.Bripac
The name commonly used in the industry to describe the steel frame, which holds and supports
the coil of un strapped strand during transport and during the process of dispensing or „paying
out‟.

Competent Person
Person who an employer ensures has acquired through training, qualification, experience or a
combination of these, the knowledge and skill enabling that person to correctly perform a
nominated task.

Construction Work
As defined in S.3 of the Construction Safety UPC, 2007.

Dead End
The end of a tendon that is anchored in the concrete beam or slab whilst stressing takes place from
the opposite end. There are two types of dead ends; onion and swaged. No stressing takes place from
the dead end.

Duct (a.k.a. Sheathing)

A thin galvanized metal tube, usually oval or round, which contains the strand(s) to position and
separate them from the concrete so they are free to elongate during stressing.

Employee Representative
Includes an employee member of a health and safety committee or a person elected by the
employees at a place of work to represent them on health and safety matters
Final Stress

The design stress at which stressing is complete. This stressing must not be exceeded.

Grouting

The pumping of cement grout into the duct from one end to the other.

Initial Stress

A relatively low stress load that is applied to the tendons soon after the concrete has set.
This initial stressed is designed to prevent or minimize shrinkage or cracking in the concrete.

Jack

The jack is a hydraulically operated piece of equipment designed to grip the strands and stretch them
while bearing on the anchorage.

Live End

The end of a tendon held by wedge grips in an anchorage block, Where the tendon has two live ends,
even if stressing is only carried out from one end, it is referred to as a double live end tendon

Mono-Strand Stressing

The system of stressing concrete members by means of applying hydraulic force to each, strand
individually and progressively transferring the load to the concrete. It is often referred to as a „slab-
system‟ because it is ideally suited to the floor slabs of buildings.

Multi-Strand Stressing

The system of stressing concrete members by means of applying the load simultaneously to all
strands. Multi-strand post-tensioning is mainly used in large civil structures such as dams and
bridges.
Post-Tensioning

The installation, stressing and grouting of high strength steel tendons in concrete slabs and beams.
The tendons are stressed only after the concrete has reached a specified minimum strength. Except in
special cases, after stressing is complete the tendon is injected with cement grout which bonds the
strands to the surrounding concrete over the full length of the tendon so that even if the tendon is later
cut or damaged it cannot move in the concrete.
Pre-Tensioning

The process of placing concrete around pre-tensioned steel strands with subsequent transfer of the
load to the concrete once it reaches a specified strength. This process is usually used in the
factory production of pre-cast members such as beams, panels and columns.

Reeving

The process of manually or mechanically feeding individual strands into the duct.

Strand

A strand consists of seven high strength wires wound together into a compact group. The two sizes
of strand commonly used in mono-strand stressing have diameters of 12.7mm .

Stressing

The process of applying load to the strands. Pre-stressing of concrete includes pre-
tensioning & post-tensioning.

Stressing Operator

Person suitably trained and nominated by the employer to operate the stressing equipment.

Tendon (a.k.a. Cable)

A group of one or more strands contained in one duct.

Transfer Strength

The minimum compressive strength that the concrete must achieve before applying the final stress.

2. TENDON FABRICATION & INSTALLATION

The most economical and preferred method of installation is the pushing or pulling of strand directly
into the empty duct. Where strands are to be pushed, they shall be threaded and reeved into the duct
one by one. The strand shall be fed into the Strand Pushing Machine from a coil of strand contained
within a Bripac and then reeved into the duct. All strand reeving shall be completed prior to concrete
placement. Reeving operations shall be carried out with care to avoid any damage to the
strand or to the steel duct. Any damaged strands shall be rejected and replaced.

Associated Quality Assurance Documentation

Coil Identification Tag.

Strand Manufacturer Material Test Certificate.

Tendon Manufacturing Record.

Pre-stressing Installation Inspection Record.

Equipment

Angle Grinder, Bripac, Onion Jack, Staple Gun, Strand Pusher, Swage Frame.

Materials

Low Relaxation - Stress Relieved Strand (12.7mm ).

Galvanized Sheathing (40x20, 70x20 & 90x20).

Anchorage Castings & Couplers (2s, 3s,4s & 5s).

Method of Execution

Confirm site shop-drawings are latest revision and approved for construction.
Complete Formwork / Falsework and stop-ends for relevant pour area (By others).

Determine Occupational Health Safety and Rehabilitation requirements with regard to installation
of the pre-stressing system.

Accept material & equipment deliveries.

Set out location of stressing anchorages and pockets in accordance with shop-drawings.
Slot and drill edge forms (By others).
Install cast-in anchorages as per shop-drawings.
Mark out tendon spacings and lay sheathing as per shop-drawings.
Carefully place strand coil in Bripak prior to cutting retaining straps with tin snips.
Remove and discard strapping and packaging.
Retain the coil identification tag, noting coil Id number, and refix to Bripac.

Position coil of strand adjacent to work area and away from thoroughfares.
Ensure area is of sufficient strength to support weight of coil (3 Tonne).

Position the strand-pushing machine in front of the anchorage and the duct, into which the strand
is to be threaded.

Thread the strand into the wheels of the strand-pushing machine.

Reeve the strand using the pushing machine and utilising two men, one at each end of the duct.
 Stand clear of strand being drawn from coil into sheathing. Do not stand between pusher and coil.

The final (over-length or stressing-length) projection of the strand is to be checked ensuring that
the jaws of the pre-stressing jack will grip the strand.
The strand shall be saw cut at the entry end of the sheathing a minimum of 550mm from the
bearing face of the cast-in anchorage.

Use goggles whenever strand is being cut.

Heat type cutting devices are not to be used to cut strand.

Reeve strand for all tendons as per shop-drawings.

At completion of all reeving operations recoil unused strand within Bripac placing cap over
leading end and cover with plastic to prevent corrosion.
Check sheathing, repair any minor damage, remove and replace if major.
Ensure that sheathing is positioned as designed and not damaged during installation.
• Profile the sheathing in accordance with the shop-drawings & secure to anchorages and formwork
so it doesn‟t move during normal construction activities.
Tape and seal the sheathing to anchorages, place intermediate grout vents to top of sheathing at
high and low points as required.
Ensure that anti-burst reinforcement is present at all anchorage locations.
Complete final inspection of pre-stressing system and advise builder / contractor when installation
is complete.
Submit expected tendon extensions and material test certificates to builder / contractor for
approval in principal (As required by specification).
Oversee placement of concrete in and around duct and anchorages ensuring adequate compaction
& vibration takes place.
Immediately following concrete placement in a member any tendons therein shall be pulled back
and forth for approximately 500mm to ensure that they are perfectly free inside the duct.
Where the tendon has a dead-end anchorage or is coupled to a previously stressed anchorage, (the
duct shall be flushed with water to remove all foreign matter immediately after the whole of the
concrete has been placed in the section of the member where the tendon is located.)

3. STRESSING

Description

Stressing is identified as a special process and as such all operations shall be performed by
competent personnel with training and experience in this type of work and shall be carried out under
the direction of a skilled Supervisor. Stressing shall not occur until directed by the relevant Engineer
after determination of the concrete strength necessary for transfer.
Associated Quality Assurance Documentation

Calibration certificate for hydraulic stressing equipment. .( Hydraulic Jack, Pressure Gauge with
calibration certificate 6 month )
Calculations relating to tensioning force to be applied and predicted extensions of the strand
elongation after release of force onto the anchorage. Pre-stressing Record.

Equipment

Electric/Hydraulic Pump, Hydraulic Jack, Pressure Gauge

Materials

Anchorage components; anchor head, coupling block, spacer block, barrels & wedges.

Method of Execution

Determine Occupational Health Safety and Rehabilitation requirements with regard to stressing of
the pre-stressing system.
After form worker has removed edge forms, inspect anchorage zones and advise of any

Perceived defects in cast concrete which may affect stressing works.

Place anchorage components, anchor head / coupling block / spacer block / barrels &

Wedges, over protruding strands.

• Clearly mark the stands with paint creating a reference point for measuring tendon

extensions.

• Check that concrete has gained the required strength (to be determined by others).
• Ensure stressing jack is accompanied by valid calibration.
• Refer to shop-drawings for stressing sequence and requirements.
• Hoist stressing jack into position over protruding strands.
• Connect hydraulic pump to jack, and pressure gauge to pump.

Initial Stress

• The application of an initial stressing load shall be carried out in accordance with the project
specification and consulting engineers requirements.
• Generally, an initial stress usually only 25% of the final stress is applied approximately 24hrs
 • after completion of concrete placement. This stressing load is applied to each and every
individual strand.

Initial stress to less than 30% of final stress does not require flagging or barricades.

Final Stress

• Clear area in which stressing is to take place.

Place appropriate signage and barriers around area.

• Signs stating “Caution Stressing in Progress” must be used when stressing is taking

place. Clear all areas immediately behind the stressing jack. Barricades will be

constructed from two layers of plywood.

Stress tendons to requirements of structural drawings and in accordance with

calibration report and check seating of wedges at live anchorages after lock-off.

• Final jacking force is not to exceed 85% of the minimum-breaking load.

• Ensure that stressing load is applied gradually and evenly.
• Measure & record tendon extensions, completing standard stressing record and

forward to Project Engineer for review.

• After reviewing results, forward stressing reports to Client for approval by Consulting
Engineer.
 5. GROUTING

Description

The pumping of cement grout into the duct from one end to the other, bonding strands to
sheathing, creating a composite section and providing corrosion protection. Grouting is identified
as a special process and as such all operations shall be performed by personnel with training and
experience in this type of work and shall be carried out under the direction of a skilled Supervisor.

Associated Quality Assurance Documentation

• Tendon Manufacturing Record.

• Grout Sample Record.

Materials

• Type „A‟ Portland cement.

Equipment

• Colloidal Cement Mixer

Method of Execution

• Grout / Cement Type

• Before commencement of grouting, the total amount of required cement plus 5% for waste
shall be available at the site.
• The quantity of cement required shall be established according to the type of tendon.
• All grout used for the grouting of pre-stressing ducts shall consist of Portland cement - Type
A, water.
• Portland cement should comply with AS1315.
• Cement should be fresh and its temperature at time of use should not exceed 35°C.
• Any cement showing signs of deterioration, e.g. Formation of lumps should not be used.

Mixing

• Only clean water shall be used when mixing grout.

• The water/cement ratio (w/c) for grout shall be in the range 0.40 to 0.45 by weight.
• The water cement ratio should be kept as low as possible.
• Add water to the mixer first, at the rate of 8.5 litres per 20kg bag of cement.
• Any admixture being used should be mixed in with the water prior to adding the cement by
uniformly dispersing it in the mixer.
• The quantity of any other additives required shall be calculated as a percentage of the weight
of cement, in accordance with the recommendations of the additive manufacturer.
• Minimum mixing time should be 2 minutes.
 Grouting of tendons

• Before commencing grouting, all vents/drains should be opened. These should then be closed
in order, moving away from the point of injection. Close vents as grout of same consistency
as that at point of injection issues.
• Grout injection should be continuous, to avoid blockages or the formation of voids in the
grout column.
• Commence grouting tendon from the lowest end through standard hose connected to
anchorage grout tube.
• Continue batching and pumping until good quality grout issues from vents moving away from
the pump point and progressively close vents. Grout shall be bled through the high bleed
point until all remnant water and diluted grout is expelled.
• At this point the operator shall discontinue pumping and wait for one minute for the grout to
settle.
• Bleed tubes shall remain open and unobstructed during this period.
• Pumping shall recommence and then repeat the bleeding process.
• The injection point shall then be locked off.
• Repeat procedure for all tendons.
• The injection and bleed tubes of grouted tendons shall be checked a minimum of 12 hours
after grouting. If the grout has shrunk down the tubes shall be topped up with a neat cement
and water mix.
• Remove grout tubes not less than 24 hours after tendon grouting is completed.

Yours sincerely,

ULTRA FORCE PRESTRESS CONCRETE

Eng. AHMED FARRAG
Operation Manager
00971 50 35 75 844