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M55.1-19: Specification for Grouting of PT Structures

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Description

This is a fourth edition of a comprehensive Specification providing minimum requirements for the selection, design, testing, and installation of cementitious grouts. Based on proven knowledge and developed with the ANSI consensus process, it addresses grout materials, QA/QC testing, and detailed grouting procedures. It provides requirements and guidance for the different Classes of post-tensioning grout materials related to the tendon protection levels and the qualification testing for PT grout materials. It also covers mixing and pumping procedures, production testing, and post grouting inspection.

This Specification should be used in its entirety to avoid unnecessary differences in requirements and provisions out of context. It is primarily intended for use in bridges but is also applicable to a wide variety of structure types, including buildings. The companion document PTI/ASBI M50.3, Specification for Multistrand and Grouted Post-Tensioning, should be used in conjunction with this document.

This edition of the Specification includes many far-reaching modifications that directly address grouting issues encountered in the past; some of them are:

• Wet density testing at last outlet of each tendon to ensure grout quality and documentation

• Robustness test; grout testing with 110% of maximum recommended water

• Field testing for acid-soluble chloride ion (Cl-) based on either cement weight or weight of mixed grout

• Grout material bag weight and sulfate ion level certification

• New addition of shelf life requirements

• Explicit prohibition of tendon flushing

53 pages; 8½ x 11 in. (soft cover)

Published August 2019

 

Table of Contents

1.0 — INTRODUCTION

1.1 — Scope

1.2 — Uses

1.3 — Key factors

1.4 — Definitions

1.5 – Referenced standards and specifications

1.5.1 – American National Standards Institute (ANSI)/American Petroleum Institute (API)

1.5.2 — ASTM International

1.5.3 – Federal Highway Administration (FHWA)

1.6 — Post-Tensioning System (PTS) Tendon Protection Levels (PL)

2.0 — MATERIALS

2.1 — General

2.2 — Portland cement

2.3 — Supplemental cementitious materials

2.4 — Chemical admixtures

2.4.1 — Set-controlling admixtures

2.4.2 — Air-entraining admixtures

2.4.3 — Anti-bleeding admixtures

2.4.4 — Expansion-causing admixtures

2.4.5 — Corrosion inhibitors

2.5 — Aggregates

2.6 — Water

2.7 — Ducts

2.8 — Inlets and outlets

2.9 — Grout caps

2.10 — Traceability of materials

3.0 — DESIGN

3.1 — General

3.2 — Scope

3.3 — Class A, B, C, and D grouts

3.3.1 — Positive pressure grouting

3.3.3 — Proportions of grout

3.3.4 — Chloride ion content

3.4 — Testing requirements for Class A, B, C, and D grouts

3.4.1 — Class A

3.4.2 — Classes B and C

3.4.3 — Class D

4.0 — TESTING, QUALITY CONTROL, AND QUALITY ASSURANCE

4.1 — General

4.2 — Scope

4.3 — Materials certifications

4.4 — Laboratory testing

4.4.1 — Non-prepackaged grouts

4.4.2 — Prepackaged grouts

4.4.3 — Setting time test

4.4.4 — Grout strength test

4.4.5 — Permeability test

4.4.6 — Volume change test

4.4.7 — Pumpability and fluidity tests

4.4.8 — Bleed tests

4.4.9 — Corrosion test

4.4.10 — Wet density test

4.4.11 — Inclined tube test

4.4.12 — Shelf life test

4.5 — Personnel qualifications

4.6 — Grouting procedures

4.6.1 — Written grouting procedures

4.6.2 — Mixing and placing grout

4.7 — Field testing

4.7.1 — Field trial tests

4.7.2 — Field mockup tests

4.7.3 – Production tests

5.0 — CONSTRUCTION

5.1 — General

5.2 — Time to grouting and temporary corrosion protection

5.3 — Preparation for grouting operations

5.3.1 — Materials and equipment

5.3.2 — Ducts

5.3.3 — Inlets and outlets

5.3.4 — Operators

5.3.5 — Safety

5.3.6 — Supplies

5.3.7 — Testing equipment

5.4 — Storage of materials

5.5 — Equipment

5.5.1 — General

5.5.2 — Mixer, storage hopper, and screen

5.5.3 — Grout injection equipment

5.5.4 — Duct air test

5.5.5 — Backup equipment

5.6 — Mixing and injecting of non-thixotropic grouts

5.6.1 — Batching and mixing of grout

5.6.2 — Preparation for grouting

5.6.3 — Grouting operations

5.6.4 — Vertical grouting

5.6.5 — Post-grouting operations

5.6.6 — Measures to be taken after grouting

5.6.7 — Checklist and record of grouting operation

5.7 — Temperature considerations

5.7.1 — Hot climates

5.7.2 — Cold climates

6.0 — REFERENCES

APPENDIX A — TROUBLESHOOTING GROUTING PROBLEMS

A.1 — Problems and solutions

A.1.1 — Duct line plugs

A.1.2 — Downtime, equipment failures, and outages

A.1.3 — Cross grouting (unintended grout flow between ducts)

APPENDIX B — STANDARD TEST METHOD FOR EVALUATION OF CORROSION PROTECTION CAPABILITY OF PT GROUTS (ACCELERATED CORROSION TEST FOR GROUTS)

Scope

Referenced documents

ASTM Standards

Significance and use

Apparatus

Test specimens

Instrumentation

Experimental procedure

Precision and bias

Keywords

APPENDIX C – GROUTING CHECKLIST – SAMPLE

APPENDIX D – GROUTING RECORD FORM – SAMPLE

ADDENDA AND ERRATA INFO

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