Table of Contents
DC45.1-18: Recommendations for Stay Cable Design, Testing and Installation (Digital Format)
1.0 — SCOPE
1.1 — Referenced standards and specifications
1.1.1 — American Association of State Highway and Transportation Officials (AASHTO)
1.1.2 — American Welding Society (AWS)
1.1.3 — ASTM International
1.1.4 — British Standards Institute
1.1.5 — California Department of Transportation (CALTRANS)
1.1.6 — European Committee for Standardization
1.1.7 — Federal Highway Administration (FHWA)
1.1.8 — French Association for Standardization
1.1.9 — German Institute for Standardization
1.1.10 — International Federation for Structural Concrete (fib)
1.1.11 — Post-Tensioning Institute (PTI)
1.1.12 — SSPC: Society for Protective Coatings
1.1.13 — Swiss Society of Engineers and Architects
2.0 — NOTATION, DEFINITIONS, AND ABBREVIATIONS
2.1 — Notation
2.2 — Definitions
2.3 — Abbreviations
3.0 — MATERIALS
3.1 — General
3.2 — Main tension elements
3.2.1 — Wire
3.2.1.1 — Quality control
3.2.2 — Strand
3.2.2.1 — Quality control
3.2.3 — Epoxy-coated strand
3.2.3.1 — Quality control
3.2.3.2 — Surface preparation
3.2.3.3 — Application of epoxy coating
3.2.3.4 — Inspection of materials
3.2.3.5 — Replacement of rejected epoxy strand
3.2.4 — Bar
3.2.4.1 — Quality control
3.2.5 — Wire or strand not specifically itemized in ASTM A421/A421M or A416/A416M
3.2.6 — Bars not specifically itemized in ASTM A722/A722M
3.3 — Individually sheathed strands with corrosion-inhibiting coating
3.3.1 — Surface preparation
3.3.2 — Application of corrosion-inhibiting coating
3.3.2.1 — Quality control
3.3.3 — Application of sheathing
3.3.4 — Inspection
3.3.5 — Replacement of rejected sheathed strand
3.3.6 — High-density polyethylene material for sheathed strand
3.3.7 — Polypropylene material for sheathed strand
3.3.8 — Corrosion-inhibiting coating material
3.3.9 — Performance tests for individually sheathed polyethylene or polypropylene strand
3.4 — Anchorage components
3.5 — Stay pipe
3.5.1 — Cross-sectional area
3.5.2 — Steel pipe
3.5.2.1 — Coating
3.5.3 — High-density polyethylene pipe
3.5.3.1 — Pipe specifications
3.5.3.2 — Material specifications
3.5.3.3 — Wall thickness
4.0 — SYSTEMS QUALIFICATION AND TESTING
4.1 — Corrosion protection
4.1.1 — General
4.1.2 — Barriers
4.1.2.1 — Anchorage/free length interface
4.1.3 — Materials
4.1.4 — Qualification of barriers
4.1.4.1 — Internal barriers
4.1.4.2 — External barriers
4.1.5 — Qualification of temporary corrosion protec¬tion system
4.1.6 — Qualification of anchorage assembly
4.1.6.1 — Leak test
4.1.6.2 — Preparation
4.1.6.3 — Testing
4.1.7 — Acceptance criteria
4.1.7.1 — Barriers
4.1.7.2 — Anchorage assembly
4.1.8 — Documentation
4.2 — Acceptance testing of stay cables
4.2.1 — Limitations of full-scale acceptance testing of stay cables—seismic loading
4.3 — Acceptance and performance testing of isolated MTE cable saddles
4.3.1 — Introduction
4.3.2 — Testing protocol for saddles
4.3.3 — Friction testing
4.3.3.1 — Testing procedure
4.3.3.2 — Interpretation
4.3.4 — Fatigue, strength, and corrosion protection
4.3.4.1 — Qualification of saddles
4.3.4.2 — Saddle fatigue test
4.3.4.3 — Additional testing
4.3.5 — Acceptance of prior tests of cable saddles
4.4 — Acceptance of prior tests of stay cables
4.5 — Quality control of other stay cable components
4.6 — Fire resistance qualification testing
4.6.1 — Furnace and test temperatures
4.6.2 — Test specimen and monitoring temperature of MTE
4.7 — Summary of testing requirements
5.0 — LRFD DESIGN
5.1 — Loads
5.1.1 — Dead loads
5.1.2 — Live loads
5.1.3 — Fatigue load
5.1.4 — Dynamic load allowance
5.1.5 — Wind loads on stay cables
5.1.6 — Thermal loads
5.2 — Wind-induced vibrations
5.2.1 — Mechanisms of dynamic excitation
5.2.2 — Monitoring of cable vibrations
5.2.3 — Design provisions
5.2.3.1 — Contingency measures
5.2.3.2 — Rain-wind-induced vibrations
5.2.3.4 — Aerodynamic contour of cable
5.2.3.5 — Damping
5.2.3.6 — Stabilizing cables
5.2.3.7 — Connections
5.2.3.8 — Rattling
5.3 — Design
5.3.1 — Design limit states
5.3.2 — Load factors and combinations
5.3.2.1 — Construction limit state
5.3.3 — Resistance factors
5.3.3.1 — Special seismic resistance factors
5.3.4 — Bending effects—free length
5.3.4.1 — Strength of stay cable anchorages for lateral loads
5.3.5 — Fatigue limit state
5.4 — Cable replacement
5.5 — Loss of cable
5.5.1 — Cable loss due to fire
5.6 — Construction
5.7 — Design of cable saddles
5.7.1 — General
5.7.1.1 — Design requirements
5.7.2 — Design criteria
5.7.2.1 — Cable radius
5.7.2.2 — Slip and force transfer
5.7.2.3 — Cable bending stresses
5.7.2.4 — Cable loss with saddles
5.7.2.5 — Analytical requirements for seismic loading
5.7.3 — Detailing
5.7.3.1 — Corrosion protection system
5.7.3.2 — Qualification of saddle corrosion protection system details
5.7.4 — Testing
5.7.4.1 — Saddle design testing
5.7.4.2 — Fatigue testing
5.7.4.3 — Friction testing
5.8 — Alternative stay cable systems
5.9 — Guide pipe minimum design forces
5.10 — Extrados/low-fatigue stay systems
6.0 — INSTALLATION OF STAY CABLES
6.1 — Quality control program
6.2 — Fabrication
6.2.1 — General
6.2.2 — Prefabrication
6.2.3 — Site fabrication
6.3 — Handling of stay cable components
6.3.1 — Procedures
6.3.2 — Cable protection and coiling
6.3.3 — Equipment and lifting devices
6.3.4 — Damage and repair
6.4 — Packing and shipping
6.4.1 — Stay cable metallic components
6.4.2 — Strands, wires, and bars
6.4.2.1 — Bare strands and wires
6.4.2.2 — Bare bars
6.4.2.3 — Epoxy-coated, galvanized, or sheathed strand
6.4.3 — Anchor and socket assemblies
6.4.4 — Pipe
6.4.4.1 — High-density polyethylene pipe without tension element
6.4.4.2 — Steel pipe
6.4.5 — Preassembled cables with HDPE pipe
6.5 — Material site inspection
6.6 — Storage
6.6.1 — Requirements and limitations
6.6.2 — Facility
6.6.3 — Environmental control
6.7 — Pre-installation inspection
6.7.1 — Bare, epoxy-coated, galvanized, or sheathed strands and wire
6.7.2 — Bare strands and wires
6.7.3 — Epoxy-coated or sheathed strands
6.7.4 — Bar
6.7.5 — High-density polyethylene pipe
6.7.6 — Steel pipe
6.7.7 — Pre-assembled cable
6.7.8 — Anchors and socket assemblies
6.8 — Stay pipe assembly preparation
6.8.1 — High-density polyethylene pipe
6.8.1.1 — Pipe length
6.8.1.2 — Fusion welds
6.8.2 — Steel pipe
6.8.2.1 — Welding requirements
6.8.2.2 — Inspection for steel pipe welding
6.9 — Installation
6.9.1 — Installation program
6.9.1.1 — Cable alignment and centering devices
6.9.1.2 — Minimum cable forces
6.9.1.3 — Final acceptance of stay forces
6.9.2 — Vibration control
6.9.3 — Jacks and gauges
6.9.4 — Stressing
6.9.5 — Detensioning
6.9.6 — Installation records
6.9.6.1 — Monitoring
6.9.6.2 — Permanent records
7.0 — STAY CABLE INSPECTION AND MONITORING
7.1 — General
7.1.1 — Design considerations
7.1.2 — Inspection and maintenance
7.1.3 — Inspections
7.2 — Visual inspection of stays
7.3 — Condition evaluation
7.4 — Non-destructive evaluation and monitoring
7.5 — Frequency of inspection
7.6 — Monitoring of cable vibrations
7.7 — Cable inspection and maintenance manual
7.7.1 — Items for inspection and maintenance manual
8.0 — VIBRATION CONTROL SYSTEM PERFOR¬MANCE
8.1 — Requirements
8.2 — Working amplitudes
8.3 — Extreme amplitudes
8.4 — Operational conditions
8.5 — Amplitude effect on anchors
8.6 — Inherent structural damping
8.7 — Performance verification
9.0 — CITED REFERENCES
APPENDIX A—DETAILS OF “ONE PIN TEST”
APPENDIX B — SAMPLE OF GALVANIZED STRAND SPECIFICATIONS
APPENDIX C — CORROSION PROTECTION SYSTEM DETAIL
App.C.1 — Temporary corrosion protection
App.C.2 — Wrapping with protective tape
App.C.3 — Coating for steel pipe
App.C.3.1 — Shop-applied prime coat
App.C.3.1.1 — Surface preparation
App.C.3.1.2 — Prime coat preparation
App.C.3.1.3 — Prime coat application
App.C.3.1.4 — Quality inspection for prime coat
App.C.3.2 — Field-applied intermediate and finish coats
App.C.4 — Portland cement grout
App.C.4.1 — General
APPENDIX D — CONVERSION FACTORS SI TO US UNITS
APPENDIX E — ALTERNATE SADDLE FATIGUE TEST SETUP
M50.1-98: Acceptance Standards for PT Systems (Digital Format)
TABLE OF CONTENTS
SYSTEM APPROVAL TEST REQUIREMENT SUMMARY
1 SCOPE
1.1 References
1.2 Definitions
2 PRESTRESSING MATERIALS
2.1 Strands
2.2 Bars
2.3 Special Prestressing Materials
3 BEARING PLATES
3.1 Basic Bearing Plates Design Criteria
3.2 Special Bearing Plates Testing Requirements
4 CONNECTIONS
4.1 Strand-Wedge Connections
4.2 Bar-Anchor Nut and Bar-Coupler Connection Performance Requirements
5 SHEATHING
5.1 Duct for Bonded Tendons General Performance Requirements
5.2 Duct for External Tendons
5.3 Sheath for Ground Anchors
5.4 Transition
5.5 Grouting Attachments
6 QUALIFICATION TESTS
6.1 Number of Required Component Qualification Tests
6.2 System Qualification Tests
7 INSTALLATION EQUIPMENT
7.1 Stressing Equipment
7.2 Strand Installation Equipment
7.3 Grouting Equipment
INDEX
M50.3-19: Specification for Multistrand and Grouted Post-Tensioning (Digital Format)
1.0 — INTRODUCTION
1.1 — General description
1.2 — Alternative post-tensioning scheme
1.3 — Referenced standards and specifications
2.0 — DEFINITIONS AND ABBREVIATIONS
2.1 — Definitions
2.2 – Abbreviations
3.0 — POST-TENSIONING SYSTEM (PTS) TENDON PROTECTION LEVELS (PL)
3.1 — Protection Level 1A (PL-1A)
3.2 — Protection Level 1B (PL-1B)
3.3 — Protection Level 2 (PL-2)
3.4 — Protection Level 3 (PL-3)
4.0 — MATERIAL AND PERFORMANCE REQUIREMENTS
4.1 — General
4.2 — Material standards
4.2.1 — Strand
4.2.2 — Bar
4.2.3 – Special prestressing materials
4.3 — Component standards
4.3.1 — General
4.3.2 — Post-tensioning anchorages
4.3.3 — Permanent grout caps
4.3.4 — Bar couplers
4.3.5 — Duct
4.3.5.1 — Corrugated metal duct
4.3.5.2 — Corrugated plastic duct
4.3.5.3 — Smooth HDPE duct
4.3.6 — Duct connections and fittings
4.3.7 — Heat-shrink sleeves
4.3.8 — Precast segmental duct couplers
4.3.9 — External smooth HDPE duct connections
4.3.10 — Rigid ducts and steel pipes
4.3.11 — Connection tolerance between pipe and duct
4.3.12 — Inlets, outlets, valves, and plugs
4.4 — System approval testing
4.4.1 — Post-tensioning anchorages
4.4.2 — Grouting component assembly pressure test (PL-1B, PL-2, and PL-3 only) and system safety proof test (PL-1A only)
4.4.3 — Duct testing
4.4.4 — Corrugated plastic duct
4.4.5 — System pressure tests
4.4.5.1 — Corrugated plastic duct connections
4.4.5.2 — Precast segmental duct couplers
4.4.5.3 — Internal duct systems
4.4.5.4 — External duct systems
5.0 — INSTALLATION DRAWINGS AND STRESSING CALCULATIONS
5.1 — General
5.2 — System drawings
5.3 — Tendon drawings
5.3.1 — Plans and elevations
5.3.2 — Sections
5.3.3 —Measurements
5.3.4 — Tolerances
5.3.5 — Stressing data
5.3.6 — Material take-off
5.3.7 — Temporary openings for PT work
5.3.8 — Installation requirements
5.4 — Stressing calculations
6.0 — QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC)
6.1 — QA program
6.2 — Procurement
6.3 — Project quality plan
6.4 — Receiving
6.4.1 — Wedges
6.4.2 — Prestressing steel
6.4.3 — Anchorages
6.5 — Identification and traceability of materials
6.6 — Sampling of prestressing material
6.7 — Defects during installation
7.0 — PERSONNEL QUALIFICATIONS
7.1 — Supervision
8.0 — SHIPPING AND STORAGE OF MATERIALS
8.1 — General
8.2 — Anchorages
8.3 — Wedges
8.4 — Metal duct
8.5 — Plastic duct
8.6 — Strand
8.7 — Bars
8.8 — Cement and grout
8.9 — Accessories
9.0 — BEARING PLATE AND DUCT INSTALLATION
9.1 — General
9.2 — Measurements
9.3 — Tolerances
9.4 — Anchorage components
9.5 — Deviation pipes
9.6 — Ducts
9.7 — Accessories
9.8 — Splices and joints
9.9 — Location of grout inlets and outlets
10.0 — PLACING CONCRETE
10.1 — Precautions
10.2 — Proving of post-tensioning ducts
10.3 — Problems and remedies
11.0 — PRESTRESSING STEEL INSTALLATION
11.1 — General
11.2 — Strand
11.3 — Bar
11.4 — Corrosion protection
11.5 — Acceptance criteria
12.0 — STRESSING OPERATIONS
12.1 — General
12.2 — Maximum stress at jacking
12.3 — Stressing sequence
12.4 — Stressing jacks and gauges
12.5 — Calibration of jacks and gauges
12.6 — Elongations and agreement with forces
12.7 — Friction testing
12.8 — Wire failures in strand tendons
12.9 — Cutting of post-tensioning steel
12.10 — Capping of tendons
12.11 — Record of stressing operations
13.0 — GROUTING OPERATIONS
13.1 — Duct air test
14.0 — PROTECTION OF POST-TENSIONING ANCHORAGES
14.1 — General
14.2 — Pourbacks
14.3 — Anchorage coating system
15.0 — REPAIRS OF HOLES AND ACCESS OPENINGS
15.1 — Openings
16.0 — REFERENCES
APPENDIX A – TYPICAL POURBACK DETAILS AND INLET AND OUTLET DETAILS
APPENDIX B – TYPICAL REPAIR DETAILS FOR ACCESS OPENINGS, BLOCKOUTS, AND HOLES
M55.1-19: Specification for Grouting of PT Structures (Digital Format)
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