Post Tensioning

Quality control & Measures for
Prestressing works
Tommy Lee, VSL Singapore
IES Post-Tensioning Evening Talk Quality Control & Measures for Prestressing Works,
Tommy Lee
Contents
1.
2.
3.
4.
5.
Introduction
Workmanship Control
PT System Testing
PT Components Production Control
Good Practice on Site for Slab PT workmanship
a. 1 case of accident (at time of stressing)
6.
7.
Conclusion
Q&A
Tommy Lee
Introduction
This presentation emphasizes the need for Quality control in PT
and the importance in systematic approach in achieving quality
assured PT systems and operations.
Tommy Lee
Workmanship
- stressed by un-qualified contractor & personnel,

- using rented equipment and working to local specifications
Tommy Lee
Workmanship
Post-Tensioning ducts & strands installed and

stressed by un-qualified contractor in Russia.
Tommy Lee
Workmanship
Tommy Lee
Workmanship
Post-Tensioning tendon grouted by un-qualified contractor in United Kingdom using

simple cement slurry: Picture show situation after 7 years
Tommy Lee
What can be done to stop such poor

workmanship?
Tommy Lee
Installation and qualification of personnel and PT

companies
Execution of the works and the qualification of installers
is an area regulated by the national provisions of the EU
Member States
Interest of some EU Member States to have European
Standard on installation and qualification of personnel
and PT companies
First step was to create a voluntary document :
CEN (European Committee for Standardization)
Workshop Agreement, CWA 14646 (no official standard)
CWA 14646 may be transformed into prENV etc and thus
become European Standard in future
Tommy Lee
Installation and qualification of personnel and

PT companies
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10
Installation and qualification of personnel and

PT companies
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11

companies
PT Specialist Contractor :
Contractor or construction enterprise which carries out
installation, stressing, and filling of duct of the PT system
Having qualified, well trained, and experienced personnel
thoroughly familiar with the PT system
Trains and qualifies skilled specialists
Any work on site executed only under supervision of qualified
and experienced PT supervisor or PT site manager (certified
personnel)
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12

companies
PT Specialist
company
Technical
Logistics
Quality
Assurance
Site Operation
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13
PT System Testing
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14
PT System Failure
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15
PT System Failure
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16
PT System Failure
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17
How can we ensure the safety of the workers when

using PT Systems? Safety cannot be
compromise.
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18
Introduction and legal background of ETAs

CPD
CPD =
= Construction
Construction Products
Products Directive
Directive ::
Bring
Bring to
to single
single European
European market
market construction
construction products
products
which
which are
are fit
fit for
for use
use
i.e.
i.e. when
when installed
installed in
in the
the construction
construction works.
works. They
They
satisfy
satisfy the
the 6ERs
6ERs (Essential
(Essential Requirements)
Requirements)
Such
Such products
products obtain
obtain CE
CE marking
marking for
for identification
identification
Works
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19
EUs regulations
Construction Products
Directive 89/106/EEC
European Committee for

Standardization (CEN)
European Standards
European Organization
for Technical Approval
(EOTA)
European Tech. Approval
Guidelines (ETAG)
(i.e. ETAG013- for PT

Interpretative
Document)
IES Post-Tensioning Evening Talk Quality Control & Measures for Prestressing
Works,
Tommy Lee
20
Construction Products Directive
ETAG013 covers all relevant essential

requirements of CPD for Post-tensioning kits
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21
ETAG 013
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22
Scope and content of ETAG013

Use categories are :
Internal bonded tendons (concrete and composite
structures)
Internal unbonded tendons (concrete and composite
structures)
External tendons (concrete and composite structures)
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23

Optional use categories are :
(a) Restressable tendon (internal and external)
(b) Exchangeable tendon (internal and external)
(c) Tendon for cryogenic applications
(d) Internal bonded tendon with plastic duct
(e) Encapsulated tendon
(f) Electrically isolated tendon
(g) Tendon for use in structural steel and composite
construction as external tendon
(h) Tendon for use in structural masonry construction as
internal and/or external tendon
(i) Tendon for use in structural timber construction as
internal and/or external tendon
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24

Post-Tensioning Kits comprise:
Tensile elements (strand, wire, bar) made of prestressing
steel, monostrands
Anchorages (stressing and fixed)
Couplings (movable and fixed)
Ducts made of steel strip
Steel pipe
Plastic pipe
Corrugated plastic ducts
Special Filling materials
Bursting reinforcement
Special accessories (vents, supports, caps,...)
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25

ETA can be obtained for :
Kit containing tensile elements,
anchorages, couplings, ducts,
filling material, deviators,
bursting steel, and special
accessories
Special filling materials as
specified in (Grease, wax,
special grout)
N.B.: PT kits can be used for any
type of structure. However,
ground anchors and stay cables
are not covered
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26
Requirements, assessment, acceptance criteria
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27

Required tests :
Resistance to Static load
Resistance to Fatigue
Load transfer to the structure
Friction coefficient along tendon path and in
anchorages
Deviation/ deflection limits
Practicability/ reliability of installation
Other Optional tests are also listed for
considerations
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28

Resistance to static load :
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29

Resistance to static load - Acceptance criteria :
Maximum load 95% of actual tensile strength of

prestressing steel
Total elongation of prestressing steel 2%
Failure by fracture of prestressing steel
Acceptable residual deformations of anchorage

components after testing
Deformations in anchorage components shall stabilise at

load held at 80% GUTS
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30

Resistance to fatigue :
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Resistance to fatigue - Acceptance criteria :
No fatigue failure in anchorage components

No more than 5% of tensile element cross
section lost during fatigue test at 2x106 cycles
with 80 MPa stress range at maximum load of
65% characteristic strength of prestressing steel
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32

Load transfer to structure :
Test to be performed at minimum concrete strength specified for

transfer of prestressing
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33
Load transfer to the structure (mechanical and

bond anchorages)
Load transfer to structure - Acceptance criteria :
Crack width at 1st time to 80% GUTS 0.15mm

Crack width at 10th time to 12% GUTS 0.15mm
Crack width at 10th time to 80% GUTS 0.25mm
Strain and crack readings shall stabilise
Ultimate force in test Fu 1.1 Fpk (f cm,e / f cm,0)
Slip of bond anchorages shall stabilise
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34
ETA Submission summary
Actual material characteristics of components used for testing

shall be determined and documented
Test results shall be submitted for compulsory requirements

(static load, fatigue, load transfer)
Analysis and comparison with experience is acceptable for

other requirements and optional use categories
Acceptance of test data in accordance with `The provision of

data for assessments leading to ETA
List of requirements applies for initial request for ETA. Renewal

of ETA requires no testing but submittal of past experience.
Extension of ETA may require testing for modifications
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35
PT Components Production Control

(under ETAG013)
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36
Approval and certification procedures

Attestation and evaluation of conformity
Tasks of kit manufacturer :
Keep updated list of all component manufacturers (copy to
CB)
Audit of each component manufacturer each year (copy of
audit report to CB)
Take specimens each year from at least one job site and
perform a series of single strand tensile element tests as
per Annex E.3 (copy of report to CB)
Keep all results available for at least 10 years
Factory production control (may comply with ISO 9001)
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37

Factory production control (may comply with ISO 9001),

including :
- Incoming materials
- Inspection and testing during production
- Control of non-conforming products
- Complaints
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38

-Incoming, Inspection and testing plan
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39

- Tasks of kit manufacturer : Inspection and testing plan
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40

Tasks for the Cerfication body
- : Continuous surveillance
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41
ETAG 013
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42
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43
ETA Content :
ETA text (general document for external use)
Additional information (held available for distribution to
users unless it is confidential)
Confidential information (manufacturing drawings,
material specifications) needs to be deposited with AB and
CB. These are confidential and proprietary and shall not be
given to other parties
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44

CE Marking
Name of kit manufacturer
Year when marking was affixed
Number of Certificate of Conformity
ETA-number
The use category(ies)
The number of the CB
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45
Good Practice for Slab PostTensioning -Workmanship
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46
Workmanship
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47
Standards for Post- tensioning kits

Elements
Standards
High tensile steel and strand for prestressing of

concrete
BS 5896-1980, pr EN 10138, ASTM A416,

JISG3536, ISO 156303
Prestressing steel, including individually

prEN 10138 part 1-4 (part 3 covering strands)
greased and sheathed monostrands (excl. filling
material)
Post tensioning systems
EN 13391-2004 (replace BS 4447)
Steel ducts (steel strip sheaths)
EN 523-2003
Steel pipe
prEN 10255
Corrugated Plastic ducts (for internal tendons)
Fib technical report, bulletin 7 (some parts do

not apply to ETAG 013)
Smooth Plastic ducts (for external tendons)
prEN 12201 part 1 and part 2
Bursting reinforcement
prEN 10080, EN 10025
Grout for prestressing tendons
EN 445-2007, EN 446-2007, EN 4472007(replace 1996 versions)
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48
Strand- Quality Control

Strand Compliance to Standard
ASTM A416 / ISO 156303 / BS 5896/PrEN10138/JISG3536
- Quality Check Test Certificates ( Tensile strength, Yield
strength, Relaxation test ( max 2.5% after 1000h at 70%UTS)
- Visual Check Mechanical Damage
- Tolerance on Strand diameter
- Corrosion protection ( water soluble oil) at supply stage or
Installed cable with VpCl powder if the tendons are grouted
after 2 -6 weeks.
- Storage of Strands
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49
Content
1.0 - Before Concreting
2.0 After Concreting
3.0 Before Stressing
4.0 Jack Installation
5.0 After Stressing
6.0 After Stressing 1 hour
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50

Leading hand & worker should check no damages in tendon ducting.
Correct tendon profile? Duct Secured? Any

damage? Any Kink? Continuity of duct?
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51

Engineer should check the installation of anti-bursting
reinforcement.
Correct Spacing? Bar Type?

Spiral or Stirrup? Steel Grade?
Number of links?
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52
2.0 After Concreting

Worker should check the anchorage component condition
during installation
Any concrete slurry on

surface? (If need clean
off, dont hammer
casting violently )
If any major cracks / voids noted inform supervisor

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53

- Foreman should explain the stressing sequence to workers
- Foreman should ensure all persons aware of planned stressing
sequences and possible interfaces between teams etc. and
confirm communication systems.
- Necessary Signage shall be clearly displayed.
Understand?
How to communicate?
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54

Engineer and foreman should check stressing sequence
(e.g. To ensure no persons Avoid standing
behind the stressed strand within the specified
of times)
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55
3.0 Before stressing

Stressing worker should carry out pre-work visual inspection of
equipment and a trial run of jack without loading are carried out to
check the condition of the cable, jack, pump, hose and gauge.
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56

Foreman and leading hand should check
Engineer and Foreman should check strength of concrete and gain
approval from main contractor / consultant
Any honeycomb, crack, void ?
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57

Foreman & Leading Hand should check correct warning sign.
Correct Sign? Enough Sign? Placed in a correct position?

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58

Before jack installation, stressing worker should re-check
installed wedges in anchorage.
Wedge in pair? Wedge inside anchor block & even?

Cavity is clean? Correct wedge type?
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59

Worker must stand on the two sides, in other words clear of
the jack. (i.e.. not hit by falling jack)
Pump operator and jack operator shall establish good
communication link
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60
4.0 During Stressing
No holding of jacks allowed during stressing
Workers by the side of jack, never walk pass the tendon

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61

Look out man required for two end stressing anchorage
Inform supervisor if there are

circumstances which may lead to
slippage or
failure of the stressed tendon
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62

Stressing of two adjacent tendons by two stressing teams
not allowed
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63

Follow the stressing sequence and report the
stressing status at the required times to the in charge.
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64
5.0 After Stressing
- Stressed tendon not accessible after 1 hour

- Protective barriers shall be placed at end of tendon used
with stressing anchorage
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65

Foreman / leading hand should check
concrete surface near anchorage zone (any crack?)
check the condition of anchorage and stressed tendon
Only perform checks from the side of stressed tendon
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66

- Re-check the time record of tendon.
If all OK, remove protective barriers and resume
operations.
- If not, protective barriers remain and other operations
cannot proceed
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67
What could go Wrong?
Tendon
32
Tendon 31
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68
What Could go Wrong?
Tendon 31.
Tendon 32
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69
What could go wrong?
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70
Conclusion
Practicing good Quality Control in PT enhances

safety
It is a complex but manageable task
Poorly installed PT systems/ components will
compromise safety of human lives
Quality control requirements shall be measurable
and verifiable.
BCA is moving towards adopting Eurocodes for
Design and the study of similar nature to ETA for
PT system
Tommy Lee
71
Q&A
Tommy Lee
72

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Quality control & Measures for

- stressed by un-qualified contractor & personnel,

Post-Tensioning ducts & strands installed and

Post-Tensioning tendon grouted by un-qualified contractor in United Kingdom using

What can be done to stop such poor

Installation and qualification of personnel and PT

Installation and qualification of personnel and

Installation and qualification of personnel and

Installation and qualification of personnel and PT

Installation and qualification of personnel and PT

How can we ensure the safety of the workers when

Introduction and legal background of ETAs

European Committee for

(i.e. ETAG013- for PT

Construction Products Directive

ETAG013 covers all relevant essential

Scope and content of ETAG013

Scope and content of ETAG013

Scope and content of ETAG013

Scope and content of ETAG013

Requirements, assessment, acceptance criteria

Requirements, assessment, acceptance criteria

Requirements, assessment, acceptance criteria

Requirements, assessment, acceptance criteria

Maximum load 95% of actual tensile strength of

Total elongation of prestressing steel 2%

Failure by fracture of prestressing steel

Acceptable residual deformations of anchorage

Deformations in anchorage components shall stabilise at

Requirements, assessment, acceptance criteria

Requirements, assessment, acceptance criteria

No fatigue failure in anchorage components

Requirements, assessment, acceptance criteria

Test to be performed at minimum concrete strength specified for

Requirements, assessment, acceptance criteria

Load transfer to the structure (mechanical and

Crack width at 1st time to 80% GUTS 0.15mm

ETA Submission summary

Actual material characteristics of components used for testing

Test results shall be submitted for compulsory requirements

Analysis and comparison with experience is acceptable for

Acceptance of test data in accordance with `The provision of

List of requirements applies for initial request for ETA. Renewal

PT Components Production Control

Approval and certification procedures

Attestation and evaluation of conformity

Factory production control (may comply with ISO 9001),

Attestation and evaluation of conformity

Attestation and evaluation of conformity

Approval and certification procedures

Approval and certification procedures

Attestation and evaluation of conformity

Good Practice for Slab PostTensioning -Workmanship

Standards for Post- tensioning kits

High tensile steel and strand for prestressing of

BS 5896-1980, pr EN 10138, ASTM A416,

Prestressing steel, including individually

EN 13391-2004 (replace BS 4447)

Steel ducts (steel strip sheaths)

Corrugated Plastic ducts (for internal tendons)

Fib technical report, bulletin 7 (some parts do

Smooth Plastic ducts (for external tendons)

prEN 12201 part 1 and part 2

prEN 10080, EN 10025