Guide to good practice

Quality assurance
and quality control
for post-tensioned
concrete structures

1
iTT Thomas Telford
L London
 FIP COMMISSION ON PRACTICAL CONSTRUCTION
Chairman: P. Matt, Switzerland Technical Secretary: W. E. Murphy
Members
M. Adam, France S. Inomata, Japan W. Podolny, USA
M. Banic, Yugoslavia R.W. Irwin, New Zealand J.J. Sarrang, Hungary
W. Bilger, West Germany P.J. Jagus, India H.D. Starke, East Germany
P. Boitel, France D. Jungwirth, West Germany T.N. Subba Rao, India
Cheng Qinggua, China J.L. Koch, Australia J. Torvinen, Finland
D.B. Cox, South Africa A. Lindblad, Sweden K.L.J. Trinh, France
M. Ducommun, Canada J. Lindgren, Norway G. Via, Italy
S.P. Fadon, Spain G.S. Littlejohn, UK B. Voves, Czechoslovakia
I. Fogarasi, Hungary P. Mohr, Denmark E. Woelfel, West Germany
J. v. Geest, The Netherlands L. Muehe, West Germany
J. Groenveld, The Netherlands N. Petersons, Sweden

Working Group on Quality Assurance and Quality Control for Post-tensioned Concrete Structures

Chairman: J. Lindgren, Norway

Members
P. Boitel, France
I. Fogarasi, Hungary
M. Kersken-Bradley, West Germany
T. Lindstrand, Norway
C.R. Lord, UK
P. Mohr, Denmark
J. Moksnes, Norway

Published by Thomas Telford Ltd, Telford House, P O Box 101, 26-34 Old Street, London EC1P 1JH, England

First published 1986

ISBN 0 7277 0259 9

© Federation Internationale de la Precontrainte, 1986

All rights, including translation, reserved. Except for fair copying, no part of this publication may be reproduced, stored in a retrieval system
or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written
permission of the Publisher, Thomas Telford Publications, PO Box 101, 26-34 Old Street, London EC1P 1JH.

Although the Federation Internationale de la Precontrainte does its best to ensure that any information it may give is accurate, no liability or
responsibility of any kind (including liability for negligence) is accepted in this respect by the Federation, its members, its servants or agents.

Set by Bell and Bain Ltd, Glasgow

Printed and bound by Echo Press (1983) Ltd, Loughborough and London
 FOREWORD

At the meeting of the F I P Commission on Practical Construction, held during

the 1982 F I P Congress in Stockholm, it was decided to form a Working G r o u p
dealing with Quality Assurance and Quality Control for Post-tensioned Concrete
Structures. Subsequently, M r J. Lindgren agreed to chair this Working G r o u p .
Quality assurance has been successfully implemented in other industries, such as
nuclear and aeronautical engineering and, more recently, in offshore projects. It is
my belief that the concept also offers benefits to more conventional industries
such as construction. It is, however, necessary to adapt the system to suit the
conditions prevailing in our industry and to 'sell' the idea to all parties involved.
I would also like to emphasize the importance of the basic ideas behind the
proposed QA system: forward thinking by 'engineering for quality' rather than
'inspection for quality'; and recognition that the people performing the work are
those best qualified to supervise and verify its compliance with specified quality
criteria. Clients and authorities should direct their efforts mainly to the audit
function.
A QA system based upon these concepts will undoubtedly improve the quality
of our structures, and its direct costs will be offset by savings in areas such as
accident avoidance. ^ ~
It is hoped that this Guide to G o o d Practice will be well received not only by
those directly responsible for the construction process but also by their partners in
the construction process: the authorities, clients and consultants. I congratulate
the Chairman and the Members of the Working G r o u p for having succeeded in
presenting this complex topic in a clear and concise manner.

P. Matt
Chairman
FIP Commission on Practical Construction
 CONTENTS

1. Introduction

1.1. General philosophy

1.2. Aim

1.3. Quality assurance manuals . . . .

2. Organization

2.1. Definition of parties

2.2. Management policy

2.3. Organization charts

2.4. Personnel

2.5. Internal auditing

2.6. External auditing

3. Prestressing design

3.1. Objectives

3.2. Design calculations

3.3. Specifications

3.4. Procedures/stressing sequences .

3.5. Selection of materials

3.6. Tolerances

4. Procurement

4.1. Objective

4.2. Procurement documentation

4.3. Evaluation of suppliers . . . .

4.4. Form of contract

4.5. Expediting, warehousing and receival control

4.6. Planning

5. Construction planning

5.1. Objective

5.2. Facilities

5.3. Environmental conditions . . . .

5.4. Equipment

5.5. Schedules

Quality control and documentation

6.1. General

6.2. Quality control

6.3. Documentation

6.4. Guidelines for the different activities .

Ducting; Anchorage assemblies; Threading;
Stressing; Grouting; Sealing

Bibliography
 1. INTRODUCTION

1.1. General philosophy 1.2. Aim

Structures constructed by man are dependent upon This Guide to Good Practice aims to provide
human skill. With the complexity of modern structures, guidelines for contractors or suppliers performing post-
strategies to prevent human errors are necessary. tensioning work whereby their own internal systems
Quality assurance (QA) is well known in the mass- and procedures can ensure that quality is obtained and
production industries, but is in the introductory phase documented. Technical specifications and work
in the construction industry. The objective of this procedures will not be given, as these are to be found
Guide to Good Practice is to present an introduction in national codes, other FIP publications or in the
to QA for all parties involved in construction projects technical literature and proprietary publications.
where post-tensioning is involved. The Guide refers A client should normally define and specify all
primarily to post-tensioning work, but may also serve contractual relationships in contract co-ordination
as a guideline for the establishment and implemen­ procedures. It should be recognized that modern QA
tation of a QA system more related to a project than does not include continuous client acceptance/rejection
to mass production. conditions but to a large extent delegates approval
QA is essentially the process of planning or forward authority to the contractor. If, however, a client wishes
thinking which is necessary to ensure that the specified to maintain full authority for acceptance, this should
quality is obtained. 'Engineering for quality' rather be clearly stated in the contract.
than 'inspection for quality' should be the objective. This Guide may serve to bridge the development
Quality in this context means compliance with from the traditional client/contractor relationship to
specified requirements and quality control is the one based on modern QA principles.
element of QA which is employed to verify such
compliance. 1.3. Quality assurance manuals
Part of the concept of QA is the assumption that the It should be emphasized that the complete integrity
producer or supplier is best qualified to perform, of any QA system can only be secured through a
supervise and verify the work assigned to him. Clients formal approach based on a fully committed QA
and authorities should direct their efforts mainly to the manual. An effective quality assurance system requires
audit function, whereby they make certain that the a reference base for policies, procedures and
intended quality in all respects, including delivery and modifications. The QA manual should provide such a
cost, is obtained and documented. The client may, base and have the following essential contents:
however, choose to be more directly involved in the
day to day control and acceptance procedures. The (a) clear statements on policy and procedures for all
stages of design, procurement, manufacture and
degree of involvement should be clearly formalized
construction
through established and agreed co-ordination
(b) clearly defined sections covering organization
procedures.
and administration, job descriptions, quality
QA is not an activity to be performed by special
planning and documentation, purchasing,
teams or individuals, but is an integrated part of
vendor/supplier relations, storage, manufacture,
every work function. Key elements are management
calibration, inspection measurement and testing,
commitment, organization, administrative systems,
and service and site information
post-tensioning work procedures, documentation and
(c) a sound basis for auditing to ensure
audits.
maintenance of quality procedures with regular
The fundamental basis for this document is that
updating
through a properly developed and executed QA
(d) a status which while maintaining confidentiality
system, activities can be performed more efficiently,
has a distribution accessible to all personnel
safely, and hence economically.
involved and which generates quality awareness.

2. ORGANIZATION

2.1. Definition of parties Material Responsible for supply of materials

Authorities Have overall responsibility for supplier and equipment for execution of
approval with respect to building post-tensioning work by main
codes and national regulations contractor or prestressing contractor.
Client Owner, or agency on behalf of
owner
Consultants Responsible for design, and nor­
mally employed by client 2.2. Management policy
Main contractor Responsible for total construction The basic principle of effective QA is that each of
in accordance with contract with the parties listed in Section 2.1 is responsible for the
client quality of its respective work and activities. For this
Prestressing Responsible to main contractor for purpose, each party must have a management policy
contractor supply and installation of post- to establish and implement an adequate QA system. In
tensioning systems the absence of such a policy and system, the
 Client Main contractor
Authorities Main contractor QA audit
\—\ Client QA audit (external) management (internal)

Design .Audit
Project manager
consultant Audit

. Audit
Main contractor
Construction manager

Material
suppliers (QC only)
5
Prestressing
subcontractor
, Audit
Engineering
Planning
Procurement
Cost control
Safety
Audit

Fig. 1. Project organization chart. Note that there is an

external client audit
Construction QC Inspection
Subcontractors
supervision and testing Audit
conventional method of external monitoring and step-
by-step approval will normally apply. Fig. 2. Main contractor organization chart. All work functions
The cost of QA must be seen in relationship to total should have integrated QA systems subject to internal QA audits
economy. On large contracts, adequate resources are
more readily deployed and the economic benefits are
more obvious. On smaller contracts less ambitious QA schematic main contractor organization chart is shown
programmes and procedures may be justified, and in Fig. 2. For subcontracted post-tensioning works
should be reflected in the design and the management corresponding charts should be provided by the
routines. subcontractor. A schematic subcontractor organization
QA will often be seen as an expensive item; the chart is shown in Fig. 3. On all of these charts the
benefits are not equally apparent in the project names of all key personnel should be stated.
accounts. The cost benefit of QA must therefore be Internal charts identifying instruction/decision lines
appreciated in a wider context. It is imperative that the within each organizational unit (site, office, laboratory,
QA philosophy be defined from the onset and through etc.) and any cross-line functions of individuals should
all stages of the project. Failure to establish a common be prepared and made available to the personnel
basis will lead to confusion or duplication of control. involved.
The cost of properly executed QA must be borne by
the project, and proper allowance included in the 2.4. Personnel
relevant budgets. Failure to recognize this expenditure Post-tensioning work should be performed by
in the budgets or tenders may lead to problems, qualified personnel only. The required skill and
disputed claims and non-compliance. experience for different categories of personnel should
The question of guarantees should be seen in be related to the scope of work and the contractual
relation to the QA system adopted for the project. As obligations. An organization chart should always be
a general principle, external review and acceptance will prepared reflecting lines of communication and areas
not alter the fact that each party carries the overall of responsibility. Job descriptions should be prepared
responsibility for the quality of its own work or to ensure that the required skills and experience are
products. provided. For key personnel, updated resumes should
always be made available.
2.3. Organization charts The quality of post-tensioning operations should be
It is essential that the relationships between all subject to internal verification by competent personnel,
parties involved and between the individuals working and to internal supervision and inspection. The
within these parties are straightforward from a manner in which these functions are organized may
functional point of view and that they are clearly depend on the particular circumstances of a project
specified. This refers to the appropriate allocation of and of the company.
responsibilities in relation to the tasks, rights and On-line supervision should be supplemented by off­
duties and comprehensive coverage by contract line inspection if
specifications and job descriptions. Organization (a) specific technical knowledge or experience are
charts, focusing on the interface between parties, are required
considered to be an important supplement to written (b) on-line budget responsibilities may interfere with
specifications. the quality of the work.
An overall project organization chart should be
prepared which identifies the lines of authority and These off-line functions may be performed by engineers
lines of communication. A schematic project working in other units of the contractor's organization
organization chart is shown in Fig. 1. The main (provided they are sufficiently knowledgeable about the
contractor should provide a similar organization chart object of control), or working in the same unit
covering the major organizational units of the project. (provided they are not directly involved in the object
The chart, together with suitable job descriptions, of control). However, any off-line appointment for
should define the functions of informing, reporting, verification, inspection or checking should only be
consulting, supervising, inspecting and approving. A made by the management.
 ORGANIZATION

Main contractor Main contractor! adherence to a prescribed identification system,

Construction manager QA audit their comprehensiveness and unambiguity
Subcontractor (c) performing sample checks on testing methods,
Management
equipment, calibrations, check-lists, and work
procedure descriptions
Audit Subcontractor J3A audit (d) monitoring tendering, subcontracting and
Site manager procurement policies
(e) identifying organizational deficiencies
(/) assessing the effectiveness of method statements,
procedures and documentary controls
Audit Construction QC
Procurement, (g) analysing cases and causes of inconsistent or
warehousing, supervision and inspection and
etc. planning testing inadequate quality
Fig. 3. Subcontractor organization chart. Note that there (h) reviewing deviation and non-conformance
should be an external main contractor audit and a subcontractor routines.
internal audit
The internal QA auditor should report directly to the
company management.

2.5. Internal auditing 2.6. External auditing

Internal auditing is an independent company External auditing may be performed by the client,
function and should be performed by a QA unit or the authority, or both. Ideally, external auditing
representative within the contractor's organization on corresponds to a control of compliance with the
appointment by the management only. Internal audit­ descriptions of the QA manual, and thus may be
ing should ensure compliance with the descriptions confined to an assessment of the efficiency of the
of the QA manual, e.g. by internal audit. If the external audit reveals deficiencies
(a) monitoring the adequate execution of informing, in the internal audit system, the external audit may be
consulting, supervising and inspecting functions, expanded to include all the activities listed in Section
and checking the validity of organization charts 2.5.
and job descriptions The findings of all audits, whether internal or
(b) performing sample checks of documents (briefs, external, should be reported in a systematic manner
design specifications, drawings, site records, which enables corrective action to be taken by the
material control records, etc.) as to their proper parties.

3. PRESTRESSING DESIGN

3.1. Objectives design assumptions made, e.g. sequence and stages,

The objectives of design are to define the required tolerances, minimum strength and elongations.
post-tensioning force and its location, and to ensure Responsibilities for the production, review, and
that this force is obtained and maintained for the implementation of procedures rest with the relevant
design life-time of the structure. This force is estimated discipline managers.
on the basis of numerous assumptions related to the
quality of materials, equipment, and workmanship Table 1. Factors to be considered in prestressing design
which require verification during construction by an
Category Main factors
adequate quality control (QC) system. The main
factors to be considered are given in Table 1. Concrete Strength
Concrete mix design
3.2. Design calculations Modulus of elasticity, E
Shrinkage and creep
Design calculations should be performed in
accordance with relevant national codes and Ducts and prestressing Alignment
specifications, and checked by competent personnel. steel Friction coefficient
Wobble factor
E modulus
3.3. Specifications Relaxation of steel
The design requirements should be clearly stated in Tensile strength
specification documents and drawings. Numerous post-
tensioning systems are available and selection of any Anchors Locking system and losses
system should be based on defined technical merits. Calibration of manometers
Jacks
However, the specifications should recognize any
limitation imposed by site conditions. Corrosion protection Grouting
Anchor caps
3.4. Procedures/stressing sequences Workmanship Skill and experience
All post-tensioning work should be performed to Procedures
defined procedures which are commensurate with the
Table 2. Quantities to which tolerances may be applied 3.5. Selection of materials
Material requirements related to design should be
Category Quantities to which tolerances can
be applied given in the contract specifications. Additional
requirements may be appropriate, depending on the
Installation of ducts, Distance between duct supports chosen system and the site conditions. Such
tendons and Alignment and spacing of ducts requirements may include
anchorages Placing of anchorages
Minimum straight part of tendons (a) rigidity of ducts
behind anchorages (b) additional reinforcement, particularly in the
Minimum bending radius
Minimum cover
anchorage zone
Location of vents (c) other items as deemed appropriate by the
designer.
Stressing Stressing forces
Elongations
3.6. Tolerances
Grouting Water/cement ratio of grout Tolerances should be specified and should reflect
Fluidity of grout
Expansion and bleeding of grout
local conditions and the design requirements. Toler­
Grouting pressure ances may be applied in the installation of ducts,
tendons and anchorages, stressing, and grouting. The
quantities to which they may be applied are given in
Table 2.

4. PROCUREMENT
4.1. Objective merits, and emphasis should also be placed on the
The objective of the procurement function is to supplier's QA system. The requirements for suppliers
ensure the timely delivery of material, equipment, and are equivalent to those for the other parties. If this is
external services according to the production schedule. not the case, the contractor should extend his own
system to include the supplier or subcontractor.
4.2. Procurement documentation Subcontractors should accept and be fully committed
Procurement documentation must define precisely to the main contractor's quality objectives.
the specifications, which should be within the potential
of the supplier, and give a clear understanding of the 4.4. Form of contract
requirements. The facility to make certain that It is essential that the required QA system is clearly
specifications and drawings issued to suppliers are up- defined in the tender documents, and is reflected in the
to-date and that modifications are issued and general project organization and the price format.
implemented in a controlled manner should be Otherwise the contractor should clearly specify his
incorporated into the purchasing documentation and intentions in the tender document and make
issuing procedures. reservations with regard to the supplier's and
Materials supply certification, commensurate with subcontractor's QA systems.
the specification, should be obtained at the appropriate
stage. The purchasing department should be held 4.5. Expediting, warehousing and receival control
accountable for the quality of the material it procures. The QA system should embrace all activities from
Purchase orders should contain precise references, ordering of materials, through expediting, warehousing,
and where practical enclose copies of the particular and receival control, to installation. Timely delivery of
specification to which the materials or items are to be the right components is an important quality factor.
supplied or manufactured.
Instructions for identification marking, as simple as 4.6. Planning
possible in design, should be included together with an Procurement schedules should be prepared to ensure
agreed programme and plan for the manufacture, (a) that post-tensioning work is in phase with the
consignment and delivery. progress of the general construction work
Certification of quality at an appropriate stage and (b) proper sequencing of the different activities in
in an acceptable form, together with agreed storing manufacture and installation of the various
and inspection facilities and arrangements, should form components
part of the supply contract. (c) that the QA activities are properly considered.
4.3. Evaluation of suppliers
Suppliers are evaluated on commercial and technical
 CONSTRUCTION PLANNING

5. CONSTRUCTION PLANNING

5.1. Objective materials, before, during and after installation.

All construction activities should be performed in a Environmental conditions should in principle be
planned and systematic manner. Work procedures clearly specified in the tender documents and reflected
should be prepared and implemented by the construc­ in the contract price.
tion manager, and adequate resources (i.e. personnel,
equipment, and time) should be made available. 5.4. Equipment
All equipment used for stressing and grouting should
5.2. Facilities have adequate capacity and be calibrated to the
Facilities should be available which ensure that the specified tolerances. The calibration status should be
work can be performed as specified in the contract. documented and maintained throughout the
The extent and quality of the facilities required should construction period. All calibrations should be
be defined and provided in advance of construction, performed in accordance with relevant procedures.
and should in each case reflect the scope of work and Back-up or spare equipment should be readily
local conditions. available so that undue delays are prevented.
Typical facilities to be considered are storage for
prestressing components, storage for grout com­ 5.5. Schedules
ponents, water and power supplies, fabrication facilities Separate schedules for the prestressing work should
(tendons, sheaths, etc.), facilities for transport, handling, be prepared, based on the general contract schedule.
and working platforms, plant for mixing and pumping These schedules should cover all activities, including
of grout, and safety appliances. delivery of materials, manufacturing of tendons,
placing of ducts and anchorages, threading, stressing,
5.3. Environmental conditions grouting, and sealing. Detailed schedules may be
Environmental conditions may significantly affect required for different construction units and
the quality and the progress of prestressing work. The production periods, and should include manpower and
work procedures and the facilities should therefore plant requirements. Particular requirements for the
make proper allowance for likely environmental stressing sequence should be clearly identified.
conditions, e.g. extreme weather conditions such as Attention should be paid to the maximum
high and low temperatures, precipitation, wind, and permissible time intervals between threading, stressing
dust. Particular attention should be paid to corrosive and grouting, consideration being given to detrimental
agents and their effect on the properties of all corrosion effects.

6. QUALITY CONTROL AND DOCUMENTATION

6.1. General Acceptance of the work should be recorded on

In post-tensioning works, all successive activities purpose-made checklists, carrying signatures of the
determine the overall and final quality of the work. authorized personnel.
Skilled workmanship at each stage is therefore It is essential that each discipline recognizes its
essential to ensure that the quality requirements are obligation with regard to quality. By means of
met. Inspection of the finished product is virtually signatures, this responsibility is made more obvious
impossible to perform, and inferior work is not easily and promotes an awareness of QA in the individuals
rectified. This highlights the need for efficient QA involved. By insisting on separate signatures from the
systems. Meticulous adherence to sound practices and production personnel and then from the inspector, the
procedures are of vital importance to the successful integrity of the system is obtained.
execution of post-tensioning work. The inspector, in this context, is a member of the
prestressing contractor's organization with qualifica­
6.2. Quality Control tions equal to or better than those of the responsible
Verification of the obtained quality requires production personnel. His purpose is that of reviewing
continuous monitoring of the materials used and the the quality of the work to the satisfaction of all parties.
workmanship employed. Quality control, i.e. inspection
and documentation, should be performed in a planned 6.3. Documentation
and systematic manner and laid down in agreed The quality of the work should be documented
procedures. through certificates, records, checklists and log books.
Properties of materials should be verified through Such records should be compiled from day one in the
suppliers' certificates and testing by approved project and be continuously up-dated and
laboratories. The type and frequency of each test complemented. Standard forms and records are
should be specified and agreed. The work should be strongly recommended to ensure that all relevant data
performed and inspected by qualified personnel only. are recorded.
The qualifications of supervisors, operators and Effective documentation is that which records
inspectors should be documented. The work should be concisely the minimum amount of information
inspected and approved on a step-by-step basis. necessary to ensure its validity.
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F/g. 4. ^4 typical cable stressing report form Fig. 5. A typical cable grouting report form
 QUALITY CONTROL AND DOCUMENTATION

STRESSING RECORD
QUALITY CONTROL Page

Elong. Cutting
Date Cable Location check permission Remarks
stressed no. (mm) date/sign

Fig. 6. A typical stressing record form

6.4. Guidelines for the different activities 6.4.3. Anchorage assemblies

Most national and international codes such as the The anchorages should transfer the prestressing force
FIP Guides listed in Section 7 contain detailed to the adjoining concrete. Attention should be paid to
requirements and specifications for post-tensioning such factors as protection of anchor blocks and wedges
systems. Guidance on construction, quality control, against damage and corrosion, anchorage locations,
and documentation requirements for the main post- anchorage reinforcement, grouting tubes and vents,
tensioning activities are given below. placing and compaction of concrete at the anchorages,
and corrosion protection.
6.4.1. Prestressing steel The inspection and documentation requirements are
All prestressing steel should carry a mill certificate similar to those stipulated for ducting.
from the manufacturer or a nominated testing
authority. The steel and the certificates should be
marked for proper identification. In addition, random 6.4.4. Threading
samples should normally be taken and tested by an Threading of cables is performed either prior to or
independent authority if this is clearly stated and after concreting. The main concern is protection of the
specified in the contract documents. Particular cables during and after threading, so that the
attention should be paid to the physical and chemical mechanical properties of the steel are preserved. All
properties of the steel, protective coatings, physical cables must be properly marked to ensure subsequent
damage, corrosion, and handling and storage. correct identification.
The documentation should consist of mill and test The threading records should include the length and
certificates which should carry a stamp of approval. type of each cable and any anomalies experienced
Rejects should be clearly marked and removed from during threading which may affect subsequent
site or put on hold pending further investigation. operations.

6.4.2. Ducting
Ducts (sheaths) should allow the prestressing 6.4.5. Stressing
cables to obtain the prescribed trajectory, and enable All cables should be stressed in accordance with a
them to be stressed and grouted as specified. These procedure which clearly defines the stressing sequence,
functions should be adequately reflected in the work the force to be applied and the theoretical elongation.
procedures. Particular attention should be paid to duct These data should be provided by the designer. In
geometry, strength and support of ducts in relation to addition, attention should be paid to such items as
other adjoining construction activities, duct splices, calibration of the stressing equipment, the actual
connections, vents, drains, environmental conditions, strength of the concrete at the time of tensioning, load
and provision of spare ducts. and extension records (including tolerances), and
All quality-related activities and items should be safety.
inspected, approved and recorded prior to concreting. The load/elongation measurements provide vital
During concreting appropriate steps must be taken to information on the obtained prestressing force and on
maintain the intended serviceability of the ducts. The possible significant deviations from the design
documentation should normally consist of checklists assumptions. Meticulous stressing records are therefore
showing that the itemized quality requirements are met essential for a complete evaluation of the obtained
for each duct, within the given tolerances. Any agreed quality. Cables should not be cut or grouted until
deviations should be clearly identified and flagged. permission has been granted by the proper authority.
 GROUTING RECORD
QUALITY CONTROL Page

Date Refill Approved

Cable Location required
grouted no. date/ Remarks
yes/no sign

Fig. 7, A typical grouting record form

6.4.6. Grouting properties, pump pressures, volumes, rate of progress

Efficient grouting of cables ensures corrosion and environmental conditions. The approval of the
protection of the steel and the transfer of forces to the grouting for cables or groups of cables should be
surrounding concrete. Successful grouting depends on clearly marked by authorized signatures on record
the quality of the grout material, and on the adopted sheets.
grouting procedure. The required properties of the In the event that other corrosion coatings such as
grout (strength, pumpability, volume stability, etc.) grease are substituted for grouting, records should be
should be clearly specified and documented in advance. kept which permit proper quality assessments at
Specification of the procedure is essential to specified intervals.
successful grouting, and should address such items as
grout composition and properties, duct soundness (i.e.
there should be no obstacles, or communication 6.4.7. Sealing
between ducts), grouting sequence, grouting pressure All anchorage assemblies should be properly sealed
and rate, venting, volume checks, regrouting or to prevent corrosion of the steel. The type of seal
topping up, communication between operators at duct should be specified by the designer, and shown on
inlets and outlets, and safety. relevant drawings. The main points to observe are
The adequacy of a grouting procedure may be
verified on selected cables in the structure, or by large (a) the surface condition of the adjoining concrete
scale trials prior to construction. and of the anchorage, to secure the bond
Major irregularities during grouting should, if (b) tie-back reinforcement, if required
possible, be remedied by immediate flushing of the (c) type and properties of sealing material and
duct concerned. Failure to flush out the grout primer, if specified
constitutes non-conformance, which necessitates (d) geometrical shape and cover
remedial action in accordance with agreed non­ (e) curing conditions.
conformance procedures. Grout which appears to be of Seals may be required for intermediate vents and
inferior quality should as a rule be rejected, and the outlets, and if so should be specified by the designer.
cause investigated before grouting continues. The quality control and documentation procedures
Efficient quality control of grouting requires a for this item should be similar to those adopted for
sufficient number of operators to verify all quality- concreting in general.
related activities at the grout ports, inlets, vents and Samples of record sheets for the activities described
outlets. in this chapter are shown in Figs 4-7. The records
Grouting records should be kept for each cable, and required for any particular project should be prepared
should contain itemized information on grout and agreed at the start of the project.

7. BIBLIOGRAPHY
Acceptance and application of post-tensioning systems. FIP Practical construction. FIP Guide to G o o d Practice,
Recommendations, Publication 15.724, FIP, London, Publication 15.335, FIP, London, 1975.
1981. Principles of quality assurance with respect to prestressing
Approval, supply and acceptance of steels for prestressing steels. FIP Report, Publication 15.704, FIP, London,
tendons. FIP Recommendations, FIP, London, 1974. 1982.
Basic reinforced concrete and prestressed concrete Quality assurance within the building process. IABSE
construction. FIP Guide to G o o d Practice, Publication Workshop, RIGI, International Association for Bridge
15.387, FIP, London, 1978. and Structural Engineering, Zurich, Switzerland, 1983.
Grouting of vertical ducts. FIP Guide to Good Practice, Quality control and quality assurance for concrete structures.
Publication 15.388, FIP, London, 1978. CEB Bulletin dTnformation, N o . 157, Comite Europeen
du Beton, Lausanne, Switzerland, 1983.