METHOD STATEMENT

FOR
PRESTRESSING I-GIRDER CASTING

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 TABLE OF CONTENTS

SECTION 1 : PURPOSE

SECTION 2 : SCOPE OF WORK

SECTION 3 : RESOURCES

SECTION 4 : METHODOLOGY

GENERAL

HT STRAND CUTTING & IDENTIFICATION

PROFILING

STRESSING

EQUIPMENTS

STRESSING OPERATION FOR STRANDS

DE-TENSIONING OF STRANDS

SECTION 5 : CONTROLS DURING CONCRETE POURING

SECTION 6 : SAFETY REQUIREMENTS AND HEALTH PROTECTION

SECTION 7 : QUALITY ASSURANCE AND QUALITY CONTROL

SECTION 8 : APPENDICES

SECTION-01: PURPOSE

The objective of this method statement is to describe in detail all the operations connected with the pre-
tensioning work for construction of pre –tensioned I Girder. However it takes also into account the general
requirements of the Local Authorities, the specifications by the Designer & Consultants.

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SECTION-02: SCOPE OF WORK

The scope of work corresponds to Pre-Tensioning of Pre-Cast I girders for construction of flyover project
consists of following operations at site in order of sequence.

1. Cutting of HT strands
2. Placing of HT strands
3. Cutting and placing of HDPE de-bonding tube
4. Initial adjustment, checking of profile
5. Stressing of strands by mono jacks / multi-pulling jacks
6. De-stressing the strands-transfer of pre-stress to cast units
7. Cutting the excess length of strands at either ends of girder and applying epoxy sealing inside of
HDPE de-bonding tube.

SECTION-03: RESOURCES

3.1. Strands
3.1. a. Specification of the strands

According to the project specification the strands shall meet the requirements of the ASTM A 416,
Grade 1860N/mm2, low relaxation, with following properties:
 Nominal diameter : 15.2 mm
 Nominal steel area : 140.0 mm2.

3.1. b. Barrels to suit 15.2 mm dia HT Strands

3.1. c. Grips/ Wedges – Re-usable

SECTION-04: CONSTRUCTION METHODOLOGY

4.1 General

In this section detailed methodology of carrying out Pre-Tensioning operations

4.1.1 HT Strands cutting and Identification

a. On receipt of coils from the manufacture, it is inspected for its proper packing and identification tags
against the delivery challan.
b. Each coil is unloaded near to the store and stored off the ground and under cover.
c. The test certificate for each coil furnished by the manufacturer is verified and records kept in site
office.
d. An area for cutting of strands shall be prepared near the site and the cutting bench is set up which
consist of stationery Un-coiler. We shall adhere to the following precaution and protection during
cutting of strand.

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 i) Strands coil and Un-coiler shall be kept on wooden planks/ supports, wrapped with
polythene sheet.
ii) Entire length of strand, after cutting shall be stacked on supports/ wooden sleeper.
iii) Proper safety will be practiced during work, as fixing of handrail all area, if found necessary
or restricting, the movement of personnel around the area.

e. The coil is loaded on to the stationary un-coiler with help of crane and then the packing strips are cut.
The strand from the strand bundle is pulled out manually till the required length is drawn and cut
with abrasive cutter.
f. The requisite number of cut strands as the case may be are bundled together and tied at intervals with
a binding wire. An identification tag is attached to each bundle, indicating the girder number /coil no
for which this is formed. These particulars are recorded in a register kept in the site office. These tags
removed from bundle at the time of insertion in the casting bed. The tags removed from the bundle
are kept safety in the office for some time interval.
g. The strands bundle with tags are kept free of dust, sand and covered till they are shifted to work
location. In case of any dust / dirt found on the strands, the same shall be wiped using cotton waste
and if necessary with water soluble solution.

4.1.2 Profiling

a. The strands are placed into the re-bar cage in the casting bed, to required spacing and dimensions.
b. The ends of the strands are pulled through the anchor wall at either ends.
c. For de-bonding lengths as specified in the working drawings, HDPE pipes are inserted at either ends
of girder.

4.1.3 Stressing

a. The strands at either ends of the anchor wall are fixed to the loading frames with barrels and wedges.
b. At one of the anchor wall, the strands are stressed (Initial tension) using mono jack. The initial
slackness in the strands is removed.
c. Profiling is checked for correctness, if necessary, the error found is corrected.
d. Multi-pulling jacks at one end of the frames are operated with a common pump. The stressing is
carried out to the required force in increments and the elongations are recorded in the format. The
tendons are locked at this force.
e. Clearance is given by the engineer of the Consultant to carry out the concreting of the girder.
f. Utmost safety precautions shall be taken before, during or after stressing to prevent accidents.
g. Sand bags / timber shields shall be placed in line with pre stressing steel and behind the jacks so as to
protect personnel.
h. Only trained persons are allowed to conduct the stressing operations, and shall protect themselves be
wearing helmets and other safety device.
i. Full and accurate records of all operations connected with the prestressing are maintained. These
records shall include the jack pressure, extension and the slip, if any of each prestressing tendon.
j. No De –tensioning of the steel shall take place until the concrete has attained the specified strength
as ascertained from tests on cylinders cured and hardened under the same conditions as concrete of
the member.
k. The required elongation and corresponding or appropriate prestressing force shall be as shown on the
drawings.

4.1.4 Equipment of stressing

 Hydraulic jack- Mono Jack

 Multi pulling jack with Jacking Unit incl. Wedges Seating Devices and Ancillary Components

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  Hydraulic Pumps

4.2 Stressing Operations for strands

4.2.1 Introduction

The steel frames are positioned against the anchor wall with proper supports. Macaloy bar is passed through
the hole in the anchor frame to which the strands are fixed. The other end of the pull rod passes through the
reaction frame which seats against the anchor wall. The overall arrangement is the stressed using multi-
pulling jacks.

4.2.2 Procedure

 The steel frame is positioned to the exact location, aligining with the insert holes in the frames and
as per drawings.
 The macaloy bar is threaded through the hole in the steel frame.
 At one end macaloy bar is fitted with lock nut.
 On the face of the jack (ram of jack), a seating plate is fitted with lock nut and secured.
 The tendon is stressed to the required force. During which time the steel frame which hold the
strands of the girder slides along the rail / strands elongate. The measurements are recorded.
 The pull rod is locked in position with nut.
 The stressing equipment is released and removed from position.

4.3. De –Tensioning of Strands

 Before de-tensioning the strand, ends of the strands are marked with marker, to measure the slip in
the strands. This is observed during de-tensioning process and the measurements are recorded.
 Release of prestressing force in the prestressing jacks gradually.
 The recorded measurements are checked with the engineer for his approvel, this value is also
checked with respect to the values given in in the drawings.
 Cutting the ends of prestressing strands end of girder and applying epoxy coat on the face of strands
and applying epoxy sealing inside of HDPE de-bonding tube.

SECTION-05: CONTROLS DURING CONCRETE POURING

Although concreting is not a part of stressing, but it plays a vital role in successful stressing of structure. One
prestressing technician shall be present during the concrete pouring, to assure that the tendons ducts are not
damaged during this operation.
It is important that the following precautions are observed when concreting:

 Use suitable vibrators passing through the vibration gap available..

 It shall be noted that the needle vibrator is not placed directly on strand and HDPE de-bonding pipe
which may damage the strand and HDPE de-bonding pipe
 Due care should be taken while concreting in the end block portion. Proper compaction of concrete
should be ensured to avoid honeycombing.

SECTION-06: SAFETY REQUIREMENTS AND HEALTH PROTECTION

Special attention is drawn to the safety and health protection during stressing.

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  An attention sign “Stressing Operations in Progress” shall be put up at places where stressing
operation have to be carried out.
 Strand bundles protruding from the bearing plate must be encased in plastic or sheet metal pipe to
prevent injury by the sharp ends of the strands..
 Only intact and tight pressure hoses shall be used.
 When stressing of tendons is carried out, it must be assured that no person is staying behind or in line
with the prestressing unit.
 The personnel operating the pump and jack shall stay at the side of the jacking unit.
 The operators shall wear protective helmets during stressing.
 Any leakages of oil shall be cleaned.
 Jack should never be handled by hoses.
 Do not permit welding near high tensile Pre-stressing steel. A drop of molten metal, if applied to the
strand, will change its mechanical properties and promote the possibilities of premature failure.
 Hogging of the girder during pre-stressing operation should be observed & recorded.

SECTION – 7: QUALITY ASSURANCE AND QUALITY CONTROL

Quality control and assurance shall be strictly followed as per the check list provided by XXXX.

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