Durable post-tensioned

concrete bridges
Cover photograph: Braidley Road Bridge, Bournemouth. Courtesy of Gifford and Partners

Durable post-tensioned concrete bridges

Concrete Society Technical Report No. 47
Second Edition

ISBN 0 94669 1 96 7

0 The Concrete Society 1996, 2002

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 Concrete Society Technical Report No. 47
Second Edition

Durable post-tensioned
concrete bridges

Report of a Concrete Society Working Party

in collaboration with the Concrete Bridge Development Group

The Concrete Society

MEMBERS OF THE WORKING PARTY

Since the inception of the Working Party in 1992 there have been many changes to the representation on the various Groups,
too numerous to list periods of service for individuals. The members of the Working Party for this revision were:

Mr G. M. Clark (Convenor from November 1999) Gifford and Partners

Professor G. Somerville (Convenor to November 1999) British Cement Association
Mr G. Bell VSL (UK) Limited
Professor J. Clarke The Concrete Society
Mr D. Collings Robert Benaim & Associates
Mr J. Darby Consultant
Mr R. Digman CARES
Mr M. Haynes Balvac Whitley Moran Ltd
Mr K. P. Houlden Balvac Whitley Moran Ltd
Mr N. Loudon Highways Agency
Mr A. Low h P
Ms L. J. Smith Hyder Consulting
Mr P. Stanley Mott MacDonald
Mr M. Walker The Concrete Society
Dr R. J. Woodward TRL

Valuable assistance has been given by the following:

Mr G. Bowring Balvac Whitley Moran Ltd

Mr B. Bowsher CARES
Professor J. Bungey University of Liverpool
Mrs A. Croft The Concrete Society
Dr D. W. Cullington TIU
Mr B. Hill Highways Agency
Mr D. Jones Freyssinet Ltd
Mr D. R. Moffett Balvac Whitley Moran Ltd
Dr M. Raiss Robert Benaim & Associates
Mr J. D. N. Shaw Weber SBD
Mr D. Storrar Highways Agency
Dr H. P. J. Taylor Tarmac Precast Concrete Ltd
Dr G. P. Tilly Gifford and Partners

vi
 --
CONTENTS

Members of the Working Party vi 4 GROUTED BONDED

Preface ix POST-TENSIONED CONSTRUCTION. . . . I 8
4.1 Introduction ' 18
PART ONE 4.2 Grouts and grouting 18
RECOMMENDATIONS FOR DURABLE 4.3 Vents and grout injection 18
POST-TENSIONED CONCRETE BRIDGES 4.4 Recommended protection systems I19
4.4.1 General 19
1 INTRODUCTION. . . . . . . . . . . . . . . 3 4.4.2 Prestressing system 19
1.I General background 3 4.4.3 The deck and its elements 20
1.2 Technical background 3 4.4.4 Possible additional measures for
1.3 Summary of progress 4 exceptional structures .,a 21
1.4 Summary of key provisions 5
1.4.1 Design and detailing 5 5 EXTERNAL UNBONDED
1.4.2 Duct and grouting systems 5 POST-TENSIONED CONSTRUCTION . . . . 2 2
1.4.3 Grout materials 5.1 Introduction 22
I .4.4 Certification of post-tensioning 5.2 Background 22
operations and training 6 5.3 Structural design and basic performance
1.4.5 Testing 6 requirements 22
5.4 Available protective measures . 23
2 FACTORS AFFECTING DURABILITY. . . . 8 5.5 Detailing 23
2.1 Genera1 8 5.6 Tendon systems 23
2.2 Materials and components 8 5.7 Detensioning and replacement of external
2.3 Construction quality 8 tendons 25
2.4 Expansion joints 8
2.5 Construction joints 9 6 SEGMENTAL CONSTRUCTION . . . . . . . 2 7
2.6 Cracking 6.1 General 27
2.7 Duct and anchorage layout 6.2 Anchorage location and detailing 28
2.8 Precast segmental construction and joint type 9
2.9 Proximity to seawater 9 7 VOID GROUTING 29
2.10 Road salts, waterproofing and drainage
7.1 Overview 29
2.11 Access for inspection and maintenance
I0 7.2 Aims of void grouting 29
7.3 Condition of bridge stock and potential
3 AVAILABLE PROTECTIVE MEASURES. . . I I
demand 30
3.1 Design strategy - multi-layer protection 7.4 Inspection records 30
3.2 The bridge as a whole 7.5 Grouting materials 30
3.2.1 General 7.6 Grouting equipment and methods 31
3.2.2 Bridge deck waterproofing systems l2 7.7 Determining the void characteristics 31
3.2.3 Coatings l2 7.8 Flushing with water 31
3.2.4 Drainage l2 7.9 Effect of existing defects 32
3.3 Individual structural elements l2 7.10 Specification for grouting 32
3.3.1 General l2 7.11 Trials 32
3.3.2 Concrete quality and cover l2 7.12 Quality control 33
3.4 Prestressing components 13
3.4.1 Introduction 13 8 TEST METHODS FOR GROUTED
3.4.2 Prestressing tendons 13 POST-TENSIONED CONCRETE. . . . . . . 3 4
3.4.3 Ducts 13 8.1 Introduction 34
3.4.4 Anchorage location 15 8.2 Range of tests considered 34
3.4.5 Anchorage details 17 8.3 The need for testing 34
Durable post-tensioned concrete bridges

8.4 Test methods appropriate in particular Clause 3 Duct systems 50

circumstances 35 Clause 4 Grouting equipment 51
8.4.1 Type-approval at pre-contract stage (duct Clause 5 Batching and mixing of grout 51
systems, grout materials and procedures) 35 Clause 6 Injecting grout 52
8.4.2 Trial grouting within a contract Clause 7 Grouting during cold weather 53
(geometry, materials and procedures) 35 Clause 8 Properties of grout 53
8.4.3 Duct assembly verification before main Clause 8.1 Fluidity 53
grouting 36 Clause 8.2 Bleeding 53
8.4.4 Duct integrity after concreting or Clause 8.3 Volume change 54
assembly of precast units, but before Clause 8.4 Strength ,: .: 54
main grouting 36 Clause 8.5 Sieve test 54
8.4.5 Grout stiffness test of main grouting 36 Clause 8.6 Sedimentation test 54
8.4.6 Automated quality control testing of Clause 9 Testing of grout 54
main grouting 36 Clause 9.1 General conditions 54
8.4.7 Survey of existing grout conditions Clause 9.2 Fluidity test 54
before re-grouting 37 Clause 9.3 Bleeding test 55
Clause 9.4 Volume change test ' 56
9 REFERENCES.. . . . . . . . . . 38 Clause 9.5 Sedimentation'test 56
Clause 10 Admixtures 57
PART TWO Clause 10.1 General 57
REQUIREMENTS FOR DURABLE Clause 10.2 Types 57
POST-TENSIONED CONCRETE BRIDGES Clause 10.3 Chemical composition 58
Clause 10.4 Material requirements 58
10 NOTES FOR GUIDANCE ON Clause 10.5 Dosage 58
SPECIFICATION FOR DUCT Annex 1 (Appendix 1 7 K to the Specification for
AND GROUTING SYSTEMS FOR Highway Works) - Concrete - Duct and
POST-TENSIONED TENDONS . . . . . . . . 4 3 Grouting Systems for Post-Tensioned
Tendons 59
10.1 Introduction 43
Annex 2 Suggested Amendments to the Method
10.2 Notes for guidance on the specification 43
of Measurement for Highway Works 60
10.2.1 Trials 43
10.2.2 Grout materials 44 APPENDIX A
10.2.3 Ducting 44 TEST METHODS. . . . . . . . . . . . . . . . , . .61
10.2.4 Testing 45
A1 Leak tightness tests for duct systems 61
10.2.5 Grouting 45
A2 Grout stiffness tests 61
A3 Void sensors 62
11 CONTRACTORS QUALITY SYSTEM
A4 Duct pressure sensors 62
REQUIREMENTS. . . . . . . . . . . . . . . 4 6 A5 Automated quality control systems ' 62
11.1 Introduction 46 A6 Volume of voids before re-grouting 63
11.2 Basic quality system elements 46 A7 Stability bleeding test (inclined tube test) 64
11.3 Product requirements 47 A8 Alternative bleeding test 65
11.4 Certification 48
APPENDIX B
12 SPECIFICATION FOR DUCT UNITS . . . . . . . . . . . . . . . . . . . . . . . . . 6 6
ANDGROUTING SYSTEMS FOR
APPENDIX C
POST-TENSIONED TENDONS . . . . . . . . 4 9
SOURCES OF FURTHER INFORMATION . . 67
Clause 1 Planning, trials and basic requirements 49
Clause 2 Grout materials 50 SUBJECT INDEX. . . . . . . . . . . . . . . . . . . 6 8

...
Vlll
This Report is a revision of the first edition of Technical At a time when the International Federation for Structural
Report 47, which was published by The Concrete Society in Concrete (fib) is preparing revised guidelines for grouting,
1996. The recommendations in the first edition have been and several other countries are improving their specifi-
extended and improved, based on experience of use and on cations, it is appropriate that the UK should be fully up-to-
much of the similar work that has been carried out interna- date with state-of-the-art recommendations for grouting
tionally. practices. However, it should be remembered that practices
continually develop and evolve and while these new
The measures described are aimed at improving design,
standards will improve performance significantly, there will
detailing, specifications, materials, construction methods and
always be scope for further development.
testing for grouted post-tensioned concrete bridges with
either internal or external tendons. My particular thanks go to all of the current Working Party
members and to the Highways Agency for their support and
Producing this extensively revised and updated second edition
cooperation. 1 am also indebted to Mark Raiss and George
of the Report has been a success thanks to the cooperation
Somerville who masterminded the production of the first
from all parts of the industry - clients, designers, contractors
edition which formed the basis for this new edition.
and specialist post-tensioning f i s - and I am grateful to all
who have contributed, entirely on a voluntary basis.
G. M. Clark

ix
 __
PART ONE ll^lll

RECOMMENDATIONS FOR DURABLE

POST-TENSIONED CONCRETE BRIDGES

0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3

Factors affecting durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8

R Available protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11

Grouted bonded post-tensioned construction . . . . . . . . . . . . . . . . . . . . . . . page 18

H External unbonded post-tensioned construction . . . . . . . . . . . . . . . . . . . . . page 22

Segmental construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27

Void grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29

Test methods for grouted post-tensioned concrete . . . . . . . . . . . . . . . . . . . page 34

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page38