PT VSL Jaya Indonesia

Grout Quality in
Prestressing Tendon
From Suitability Test to
Inspection and Repair

BIMTEK PUPR-AP3I-IAPPI-AMBI-HPJI : 11 Nov 2020

Content

1. Corrosion in Prestressing Tendon.

2. Grout Specifications.
3. Suitability tests.
4. Tendon Inspections.
5. Tendon Replacement.
Corrosion in Prestressing Tendon

Morandi Bridge, Genoa, Italy (One pylon with adjacent spans collapsed, 2018)
Corrosion in Prestressing Tendon

Corrosion of Internal Prestressing Tendon Failure of External Prestressing Tendon

4
Corrosion in Prestressing Tendon

5
Corrosion in Prestressing Tendon

1996 2001

2002 2002 2010 2013

Corrosion in Prestressing Tendon
 Grout Specifications : SNI and EN
ACCEPTANCE CRITERIA
NO TEST METHOD REMARKS
SNI 6880 : 2016 EN 445,446,447 : 2007
1 Bleeding &
Expansion Bleeding : 0% (at 3 hours) Bleeding : ≤ 0.3% (at 3 hours) SNI ˃ EN
Expansion : 0% ≤ x ≤ 4% (at 24 hours) Expansion : -1% ≤ x ≤ +5% (at 24 hours) SNI ˃ EN
2 Compressive
Strength 7 days must be 21 Mpa 7 days ≤ 27 N/mm2 SNI ˂ EN
28 days must be 35 Mpa 28 days ≤ 30 N/mm2 SNI ˃ EN
3 Flow Time
11s ≤ x ≤ 30s (for 1725 mL fresh grout) ≤ 25s (for 1000 mL fresh grout)
4 Grout Spread
N/A ≥ 140 mm
5 Setting Time
Initial Setting : ˃ 3 hours Initial Setting : ≥ 3 hours SNI = EN

Final Setting : ˂ 12 hours Final Setting : ≤ 24 hours SNI ˃ EN

6 Sieve
No lumps remain (sieve 2.36 mm) No lumps remain (sieve ≤ 2.00 mm) SNI ˂ EN
7 Density Method of sampling, measuring weight and volume, Method of sampling, measuring weight and volume, equipment
equipment used and density determined shall be reported used and density determined shall be reported

Wick induced Test (SNI)

8
Grout Specifications : SNI and EN

Inclined Tube Test (EN)

Using transparent pipe

9
Suitability Tests – Requirement in SNI

10
Suitability Tests – Prior to Start the Works

11
Suitability Tests – With Inclined Tube Test
Passed all tests Passed wick Failed the first Failed Flow
induced test, but Flow cone test cone test and
failed inclined (W/C adapted density test.
tube test (high to pass) Will affect
bleeding), will flowability
cause void in during
the tendon pumping the
grout, faster
setting time,
risk of void

12
Suitability Tests – Risk due to high bleed
Grout mix with high bleed
poses a risk at high points
especially for External Tendon
at location behind the
Anchorage within diaphragm.

13
 Suitability Tests – Risk due to high bleed
A
B
C
D

Longitudinal section and cross section of failed tendon after 8 years of construction (FHWA, 2013)

14
Suitability Tests – Case of Ringling Causeway Bridge

15
Suitability Tests – Case of Ringling Causeway Bridge

16
Suitability Tests – Case of Ringling Causeway Bridge

17
Tendon Inspection – Financial Argument

18
Tendon Inspection – After Injection (SNI)

Checking grout condition and filling level at end cap

behind the anchor and any other grout outlets.

19
Tendon Inspection – Internal Tendons

20
Tendon Inspection – External Tendons
Visual Inspection

21
Tendon Inspection – External Tendons

22
Tendon Inspection – External Tendons
Tapping Hammer

Strand bundle on the upper side of

tendon in contact with HDPE duct

23
Tendon Inspection – External Tendons
Electrical Capacitance Tomography (ECT)

24
Tendon Inspection – External Tendons
Magnetic Flux Leakage

25
Tendon Inspection – External Tendons
Endoscope

26
Tendon Replacement – Internal Tendon

27
Tendon Replacement – External Tendon

28
 Conclusion

1. Grout mix design has to be verified by Suitability Test considering

various cement brands available for the respective project.
Inclined tube test should be performed in addition to wick
induced test.

2. Grouting operations should be done by trained/certified

personnel managed by the Prestressing specialists.

3. Inspection and maintenance needs to be done regularly and

continuously, as no structure can achieve its design life without
proper maintenance.

4. It is important to know the current status of the grouted tendons

as they are critical for the structural safety and serviceability.

29