PTI GUIDE SPECIFICATION

ACCEPTANCE STANDARDS
for
POST-TENSIONING SYSTEMS

ftti POST-TENSIONING
I:'" INSTITUTE
1717 W. Northern Avenue, Suite 114 • Phoenix, AZ 85021
Telephone: (602) 870-7540 • FAX: (602) 870-7541
 Prepared by
PTI Committee for Post-Tensioning System Certification

J.L. Plaehn, Consultant

Committee Chairman

Bezzone, Bert Consultant

Breen, John E. University of Texas at Austin
Draginis, Randy Precision Screw Products Corporation, Inc.
Fuzier, Jean-Phillippe Freyssinet International
Hoblitzell, James R. Federal Highway Administration
McCrossen, Bob Rorida Wire and Cable, Inc.
McGuire, Gerard J. Post-Tensioning Institute
Micklus, Drew CCS Special Structures
Quintana, Jose Luis Mexpresa
Siccardi, Joe Figg Engineering, Inc.
Williams, Jim L. Williams Fonn Engineering Corporation
Nicki, Toshi Sumiden Wire Products Corporation

This publication is intended for the use of professionals competent to evaluate and implement the significance and
limitations of its contents and who will accept responsibility for the application of the contents. The incorporation
by reference or quotation of material in this publication in any specifications, contract documents, purchase orders,
drawings, product details, and job applications shall be undertaken at the sole risk of those persons, companies, or
agencies making such reference orquotation and shall not subject the Post-Tensioning Institute, its Board ofDirectors,
its members, and the PTI Committee for Post-Tensioning System Certification to any liability, and those persons,
companies. or agencies making such references or quotation waive any claims against the Post-Tensioning Institute,
its Board of Directors, its members, and the PTI Committee for Post-Tensioning System Certification. Neither the
Post-Tensioning Institute ("PT!") nor the PTI Committee for Post-Tensioning System Certification in creating this
publication makes any representation or warranty, express or implied, regarding the statements contained herein,
including warranties of quality, accuracy, workmanship or safety, further including, but not limited to, implied
warranties of merchantability and fitness for a particular purpose. THE POST-TENSIONING INSTITUTE, ITS
BOARD OF DIRECTORS, ITS MEMBERS, AND THE PTI COMMITTEE FOR POST-TENSIOr-.'ING
SYSTEM CERTIFICATION SHALL NOT BE LIABLE FOR ANY DAMAGES, INCLUDING CONSE­
QUENTIAL DAMAGES WHICH MAY RESULT FROM USE OF ANY INFORMATION OR RECOMMEN­
DATION PROVIDED IN THIS PUBLICATION.

Copyright © 1998
By the Post-Tensioning Institute
First Edition, First Printing, Sept. 1998
Printed in U.S.A.

All Rights Reserved. This publication or any part thereof may not be reproduced
in any form without the written permission of the Post-Tensioning Institute.
• SYSTEM APPROVAL TEST REQUIREMENT SllMMARY . . . . . . . . . . . . . . . . . . .. iii

1 SCOPE 1
1.1 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
1.2 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
2 PRESTRESSING MATERIALS 8
2.1 Strands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
C 2.1.1 ASTM A 416 Strand 8
C 2.1.2 Strand Size Tolerances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
C 2.1.3 Workability of Strand 8
C 2.1.4 Bending of Strand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
C 2.1.5 Bond of Strand to Cement Grout 9
C 2.1.6 Fatigue of Strand 10
C 2.1.7 Stress Corrosion and Hydrogen Embrittlement. . . .. . . . . . . . . . .. . .. 10
C 2.1.8 Packaging of Strand. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. II
C 2.1.9 Corrosion Protection of Strand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. II
C 2.1.10 Plastic-Coated Strand for Unbonded Tendons 12
C 2.1.11 Galvanized Strand 12
C 2.2.12 Epoxy-Coated Strand. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 13
2.2 Bars 14
C 2.2.1 Bar Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
C 2.2.2 Hot Rolled Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
C 2.2.3 Cold Drawn Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
C 2.2.4 Corrosion Protection of Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
C 2.2.5 Galvanizing of Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
C 2.2.6 Bars Grouted Inside Plastic Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16
2.3 Special Prestressing Materials 16
3 BEARING PLATES 17
3.1 Basic Bearing Plates Design Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
3.2 Special Bearing Plates Testing Requirements " 20
3.2.1 Test Block 20
3.2.2 Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21
3.2.3 Acceptance Criteria 22
C 3.2.3.1 Concrete Crack Width 22
4 CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
4.1 Strand-Wedge Connections 24
4.1.1 Wedge Plate Test Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
4.1.2 Wedge Performance Requirements 25
C 4.1.2.1 Typical Wedge 26
C 4.1.2.2 Cracks in Wedges 26
4.1.3 Strand-Wedge Connection Performance Requirements 26
C 4.1.3.1 Strand-Wedge Connection Performance Requirements , 28
C 4.1.3.2 Strand-Wedge Connection Variables 28
C 4.1.3.3 Single Strand-Wedge Connection Tests 29
C 4.1.3.4 Multi-Strand Tendon Tests 30
C 4.1.3.5 Actual Ultimate Tensile Strength. . . . . . . . . . . . . . . . . . . .. 30
C 4.1.3.6 Tests on Lubricated and Non-Lubricated Wedge Holes. . .. 30
C 4.1.3.7 Fatigue Tests of Strand-Wedge Connections 31
4.2 Bar-Anchor Nut and Bar-Coupler Connection Performance Requirements 33
 5 SIIEATllING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3S
5.1 Duct for Bonded Tendons General Perfonnance Requirements 35
5.2 Duct for External Tendons 36
5.3 Sheath for Ground Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 37
5.4 Transition , 37
5.5 Grouting Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 37
C 5.6 Duct Information 36
C 5.6.1 Performance Requirements for DlKts 38
C 5.6.2 Typical Strand Tendon Duct Sizes 38
C 5.6.3 Metal Duct 38
C 5.6.4 Plastic Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39
C 5.6.5 Typical Plastic Material Properties. . . . . . . . . . . . . . . . . . . . . . . . . . .. 40
C 5.6.6 HDPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40
C 5.6.7 PVC 41

6 QUALIFICATION TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42
6.1 Number of Required Component Qualification Tests. . . . . . . . . . . . . . . . . . . . . .. 42
6.1.1 Strand Tests 42
6.1.2 Bar Tests 42
6.1.3 Special Prestressing Material Tests 42
6.1.4 Bearing Plate Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42
6.1.5 Wedge Plate Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43
6.1.6 Strand-Wedge Connection Tests 43
6.1.7 Bar Connection to Anchor Nut and Coupler Tests 43
6.1.8 Duct Tests 43
6.2 System Qualification Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44
6.2.1 Static System Qualification Test for Bonded and Unbonded Systems. .. 44
6.2.2 Dynamic System Qualification Test for Unbonded Systems 44

7 INSTALLATION EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4S
7.1 Stressing Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45
7.2 Strand Installation Equipment 46
7.3 Grouting Equipment 47
• IN'DEX 0" • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • "49

ii
 SYSTEM APPROVAL TEST REQUIREMENT
SUMMARY
STRAND SYSTEMS
Infonnation on: Test Requirements Number of Tests
1 Static Component Tests
• Bonded and Unbonded Systems
Strand Tests ------------------------------------ Section 2.1 ----------------- Section 6.1.1
Special Bearing Plate Tests -------------------------------------------------- Section 6.1.4
Test Block Size -------------------------- Section 3.2.1
Test Procedure --------------------------- Section 3.2.2
Acceptance Criteria --------------------- Section 3.2.3
Wedge Plate Tests ----------------------------- Section 4.1.1 -------------- Section 6.1.5
Strand-Wedge Interaction Tests ------------ Section 4.1.3 -------------- Section 6.1.6
[Requirement (1)] [Requirement (1)]

2 Dynamic Component Tests

• UnbondedSystems
Strand-Wedge Interaction Tests ------------ Section 4.1.3 -------------- Section 6.1.6
[Requirement (2)] [Requirement (2)]

3 System Qualification Tests

• Bonded and Unbonded Systems
Static Tests ------------------------------------- Section 6.2.1 -------------- Section 6.2.1
• Unbonded Systems
Dynamic Tests --------------------------------- Section 6.2.2 -------------- Section 6.2.2

BAR SYSTEMS
Infonnation on: Test Requirements Number of Tests
1 Static Component Tests
• Bonded and Unbonded Systems
Bar Tests ---------------------------------------- Section 2.2 ----------------- Section 6.12
Special Bearing Plate Tests -------------------------------------------------- Section 6.1.4
Test Block Size -------------------------- Section 3.2.1
Test Procedure --------------------------- Section 3.2.2
Acceptance Criteria --------------------- Section 3.2.3
Anchor Nut and Coupler ConnectionTests -- Section 4.2 ---------------- Section 6.1.7
[Requirement (1),(2),(3)] [Requirement (1)]

2 Dynamic Component Tests

• Unbonded Systems
Dynamic Tests --------------------------------- Section 4.2 ---------------- Section 6.1.7
[Requirement (4)] [Requirement (2)]

3 System Qualification Tests

• Bonded and Unbonded Systems
Static Tests ------------------------------------- Section 6.2.1 -------------- Section 6.2.1
[Requirements (1),(2),(3)]
• Unbonded Systems
Dynamic Tests --------------------------------- Section 6.2.2 -------------- Section 6.2.2

DUCTS ---------------------------------------------- Section 5.1 ---------------- Section 6.1.8

[Requirements (4),(5),(6),(7)]

11l
 SPECIFICATION COMMENTARY

1 SCOPE C1 SCOPE
These Acceptance Standards for Post-Tensioning PTl developed this specification as part of a Post­
Systems provide generally applicable technical Tensioning System Certification Program proposal to
requirements for post-tensioning systems used in the U.S. Federal Highway Administration (FHWA)
bridges, buildings, ground anchors, and other and American Association ofState Highway Officials
structures. Special project related requirements, which (AASHTO). The purpose of that program is to assure
are not addressed herein, must be supplemented in the high technical standards and quality, to create unifonn
project's Special Provisions. For such cases the standardsfor the approval ofpost-tensioning systems,
commentary gives technical background information. and to eliminate conflicting requirements by various
authorities.
The requirements herein are not intended to be applied Until such Certification Program isfully implemented,
to unbonded monostrand post-tensioning systems. this specification provides guidance to engineers,
authorities, and post-tensioning system suppliers on
the technical requirements for Post-Tensioning
Systems.

1.1 References C 1.1 References

National, regional, and international specifications, Information from the following references has been
as well as state-of-the-art industry practice, form the used to prepare this specification:
basis for this specification.
I AASHTO, "Guide Specification for Design and
Construction of Segmental Concrete Bridges, "
1989
2 AASHTO, "1997 Interim Revisions to the Standard
Specifications for Highway Bridges, Sixteenth
Edition 1996"
3 ASTM A 416-96, "Standard Specification for Steel
Strand, Uncoated Seven- Wire for Prestressed
Concrete"
4 ASTM A722-97, "Standard Specification for
Uncoated High-Strength Steel Bar for
Prestressing Concrete"
5 ASTM A 8821A 882M-96, "Standard Specification
for Epoxy-Coated Seven- Wire Prestressing Steel
Strand"
6 ASTMA886IA886M-94, "Standard Specification
for Steel Strand, Indented, Seven-Wire Stress­
Relieved for Prestressed Concrete"
7 ASTM A98I-98, "Standard Test Method for
Evaluating Bond Strength for 0.6 in. Diameter
Prestressing Steel Strand used in Prestressed
Ground Anchors"
8 "Anchorage Zone Reinforcement for Post­
Tensioned Concrete Girders," NCHRP Report
356, National Academy Press, Washington D. c.,
1994.; NCHRP Project 10-29; J. E. Breen, O.
Burdet, C. Roberts, D. Sanders, G. Wollmann;
Ferguson Structural Engineering Laboratory;
The University of Texas at Austin

1
 SPECIFICATION COMMENTARY

9 "CEB-FIP Model Code," Comite Euro­

International Du Beton, Thomas Telford Services
Ltd, London, 1993
10 "Laboratory Bond Strength Testing of 0.6"
7- Wire Strand from 7 Different Manufacturers, "
for Post-Tensioning Institute by A. 1. Hyett,
S. Dube & W F. Bawden, Derpartment ofMining
Engineering, Queen's University, Kingston,
Ontario
11 PTl, "Guide Specifications for Post-Tensioning
Materials," Post-Tensioning Manual, Fifth
Edition, 1990
12 PTJ, "Recommendations for Stay Cable Design,
Testing and Installation," 1998
13 PTJ, "Recommendations for Prestressed Rock
and Soil Anchor," 1996
14 PTl, "Specification for Unbonded Single Strand
Tendons," 1993
15 PTl, "Guide Specification for Grouting of Post­
Tensioned Structures," 1998
16 State ofCalifornia Department ofTransportation
(Caltrans) "Standard Specifications," 1995
17 "Stress-Corrosion Cracking in High Strength
Steels and in Titanium and Aluminum Alloys, "
Naval Research Laboratory, Washington, DC,
1972
18 "The Bearing Strength of Concrete Loaded
Through Rigid Plates, " N.M. Hawkins, Magazine
of Concrete Research, Vol. 20, No. 62, March
1968, pp 31-40
19 "The Bearing Strength of Concrete Loaded
Through Flexible Plates," N.M. Hawkins,
Magazine of Concrete Research, Vol. 20, No. 63
June 1968, pp 95-102
20 Washington State Department of Transportation
(WDOT) "Standard Specification," 1998
1.2 Definitions C 1.2 Definitions
Anchorage assembly Anchorage assembly
The hardware at the ends of a tendon, which A strand tendon anchorage assembly includes:
transfers the tendon force into a structure or the wedges, wedge plate, bearing plate, duct transition,
ground. grouting attachment, and system dependent
confinement reinforcement in the local zone.
A bar anchorage includes the anchor nut and the
bearing plate plus duct and grouting attachments and
system dependent confinement reinforcement.
Anchor nut Anchor nut
The threaded device that screws onto a threaded The anchor nut is part of a bar tendon anchorage
bar and transfers the force in the bar to the bearing assembly and transfers the forces by mechanical .
plate. interlock.

2
 SPECIFICATION COMMENTARY

Anchorage zone Anchorage zone

The general expression for combined general and See General zone
local zones See Local zone
AUTS AUTS
Acronym for Actuall!ltimate Tensile Strength, Actual breaking strength obtained in tests ofa single
measured as a force. representative strand or bar, breaking outside the
anchorage. For multi-strand or bar tendons, AUTS
equals the AUTS of a single tendon element (strand,
bar) times the number ofsuch elements in the tendon.
The representative samples must be taken from the
same coil ofstrands orfrom the same bar length from
which the strands or bars are cut and then used in the
connection efficiency tests, which establish
conformance to the Section 4 requirements. (See also
commentary on MU1S.)
Basic bearing plate Basic bearing plate
Flat plate bearing directly against concrete Covered by this definition are square, rectangular, or
meeting the analytical design requirements of round plates, sheared or torch cut from readily
Section 3.1. available steel plate, normally ASTM A 36. They do
not require testing since they can reliably be designed
using the formulae given in Section 3.1.
Bearing plates bearing against steel members or other
structures must be designed by appropriate rational
analysis.
Bearing plate Bearing plate
Any hardware that transfers the tendon force into Following References (l,2,8) this specification
a structure or the ground. distinguishes between "basic" and "special"
bearing plates. (See Section 3.)
Confinement reinforcement Confinement reinforcement
Non-prestressed reinforcement in the local zone. The confinement reinforcement in the concrete ahead
oftendon anchorages is limited to the local ~one. The
confinement reinforcement consist of spirals,
orthogonal reinforcing bars, ora combination ofboth.
(See also definitions for Local and General zone.)
For basic bearing plates confinement reinforcement
is required in that volume of concrete in which
compressive stresses exceed acceptable limits for
unreinforced concrete as determined by rational
analysis. (See Section 3.1.)
For special bearing plates the confinement
reinforcement is system dependent as determined by
tests on individual anchorages. The test block
reinforcement, in the portion surrounding the special
bearing plate and immediately ahead ofit, essentially
represents the confinement reinforcement required in
the local zone for that particular system. (See also
Section 3.2.)

3
 SPECIFICATION COMMENTARY

General zone General zone

The region in which the concentrated prestressing Originally defined by Reference{ 8 ) and adopted by
force spreads out to a more linear stress distribution AASHTO(l· 2) "anchorage zone" and "general zone"
over the cross section of the structural member are identical. The distinction between '~general
(Saint Venant Region). It includes the local zone. zone"and"local zone" permits a clear responsibility
The general zone extends from the anchorage allocation between designer and post-tensioning
along the axis of the member for a distance equal system supplier.
to the overall depth of the member. The height of The bursting forces are essentially limited to the
the general zone is equal to the overall depth of general zone. Those forces are primarily a function
the member. of the total prestress forces for which the structure is
designed and ofthe superimposed stresses from other
design loads. Stresses in the general zone normally
are not significantly altered by the particular post­
tensioning system selected. Therefore. the design
responsibility for the bursting reinforcement. rests
with the designer and not with the post-tensioning
system supplier. For post-tensioning system
acceptance testing general zone design requirements
are not applicable.
Ground anchor, prestressed Ground anchor, prestressed
A post-tensioned tendon inserted into a drilled or Requirements for anchorage assemblies, prestressing
augured hole. The tendon is anchored to the materials (strands or bars), and stressing equipment
ground within the bond length by cement or resin are essentially the same for ground anchor and
grout. prestressed concrete tendons.
Duct Duct
Material forming a conduit to accommodate post­ Post-tensioning ducts consists of spiral-wound
tensioned tendon installation. corrugated sheet metal, corrugated plastic tubing,
metal pipe, or plastic pipe. Post-tensioning ducts are
used for external and internal tendons. Ducts for
ground anchors are usedfor corrosion protection and
to contain grout.
Hydrogen embrittlement Hydrogen embrittlement
Brittle cracking process caused by the conjoint See also definition of "stress corrosion cracking," a
action of tensile stress and hydrogen ions (atomic similar phenomenon{J7).
hydrogen).
Local zone Local zone
The local anchorage zone is the volume ofconcrete The definition follows AASHTO(2) requirements of
surrounding and immediately ahead of the Section I - 9.21.7. The overload requirement to at
anchorage device where concrete compressive least 120% MUTS provides at least a 1.5 safetyfactor
stresses exceed acceptable values for unconfined against maximum temporary jacking forces at 80%
concrete (concrete without confinement MUTS. Increasing the test load to failure is very
reinforcement). desirable in order to observe and evaluate the failure
mode. Test block dimensions specified in Section 3.2.1
The local zone is defined as a rectangular prism
essentially represent the local zone for special bearing
of concrete surrounding the bearing plate and any
plates. (See also confinement reinforcement.)
integral confining reinforcement.
Local and general zone for closely spaced groups of
The transverse dimensions of the prism are equal
anchorages are determined on the assumption of a
to those ofthe bearing plate, including any integral
single bearing plate for the group.
confining reinforcement, plus the supplier's
specified minimum edge covers.

4
 SPECIFICATION COMMENTARY

The length of the local zone extends over the The length of the combined local zone is the length
confining reinforcement. For anchorage devices over which concrete stresses exceed acceptable limits
with multiple bearing surfaces, the local zone for unconfined concrete. This length reduces as edge
extends over the distance from the loaded concrete distance and center to center spacing of individual
surface to the bottom of each bearing surface of anchorages increase. However, for groups of special
the anchorage device plus the maximum bearing plates the length of the local zone will be at
dimension of that bearing surface. least equal to the length ofthe local zone for a single
anchorage.
MUTS MUTS
Acronym for Minimum 11.1timate Tensile MUTS and A UTS are used by the PTl to allow precise
Strength-measured as force-for a single strand description of strand, bar and tendon forces. As
or bar breaking outside of the anchorage; or the further discussed below, it is necessary to specify
multiple of those single strand or bar forces for strand, bar and tendon properties either as "nominal"
multi-strand or bar tendons. unit-stresses, or as MUTS and AUTS, which are
measured as forces.
MUTS is the force equal to the nominal cross­ Because of dimensional tolerances tendons are not
sectional area ofstrand, or bar, times theirnominal sized on the basis ofspecified tensile unit stresses but
ultimate tensile unit stress. are sized, tested and evaluated as multiples ofMUTS,
which for a single strand or bar is equal to their
specified minimum breaking force.
For instance, the dimensional tolerances allowed by
ASTM A 416 for 0.5 in. (12.70 mm) strand, Grade
270 ksi (1,860 MPa), permit tensile unit-stresses
between 244 and 277 ksi (1,682 and 1,910 MPa) for
a strand with MUTS = AUTS of 41.3 kip (183.7 kN).
Since ASTM allows higher values for AUTS, actual
maximum unit-stress of up to about 300 ksi
(2,070 MPa) may occur.
The literature uses a variety of terms and notations
to specify the ultimate strength of tendons and their
elements (bar, strands), and they leave room for
different interpretations:
ASTM A 416 specifies strands in terms of "minimum
breaking strength," measured as force. ASTM A 722
specifies bars in terms of "minimum ultimate tensile
strength, " measured in unit-stresses.
AASHTO and ACl 318 have notations and definitions
for ultimate prestressing steel unit-stresses f pu andf~
respectively), which must be understood as "nominal"
unit-stresses, based on "nominal" steel areas, as
necessary for design purposes.
AASHTO also uses for design purposes 'factored"
tendon forces (P u)' which are not identical to tendon
forces expressed as MUTS. ACl318 does not have an
expression for tendon forces.
AASHTO also expresses ultimate tendon forces as Fpu'
However, it is not clear if this expression defines

5
 SPECIFICATION COMMENTARY

ultimate tendon forces as the multiple of the tendon

element's (strand, bar) minimum ultimate tensile
forces, or if it takes the reduction of tendon capacity
due to anchorage efficiency into account.
Post-tensioning system Post-tensioning system
A particular size tendon, including prestressing Different size tendons may have similar features, but
material, anchors, local zone reinforcement, duct for the purpose of this specification they are defined
and stressing equipment. as separate systems, each requiring testing as
specified herein.
Prestressing material Prestressing material
High strength steel strand, bar, or other suitable Other suitable materials include wire conforming to
materials. ASTM A 421, which are normally anchored with
button heads. Button-headed wires are seldom used,
therefore, this specification does not provide detailed
requirementsfor such systems. Nonmetallic materials
are covered by this definition for prestressing
materials.
Sheathing Sheathing
General term for the material surrounding the Sheathing used as conduit is herein referred to as duct.
prestressing element to provide corrosion This definition of sheathing also covers transitions.
protection or conduit for installation.
Special bearing plate Special bearing plate
Any hardware that transfers tendon anchor forces Covered by this definition are devices having single
into the concrete and does not meet the analytical or multiple plane bearing surfaces, and devices
design requirements of Section 3.1. combining bearing and wedge plate in one piece. They
normally require confinement reinforcement.
Stress corrosion cracking Stress corrosion cracking (SCC)
Brittle cracking process caused by the conjoint SCC is a complex phenomenon, influenced by the
action of tensile stress and a corrodent. metallurgy of the material, the chemistry of the
environment, and the stress field. Generally,
susceptibility ofhigh strength steels to SCC increases
with increasing yield strength, exposure to marine
environment, to solutions containing chloride and, in
some cases, S04' P0 4 , NO] ions, and possibly
others (l 7).
Tendon Tendon
Assembly of prestressing elements and their A tendon consists of a single tendon element (strand
anchorage assemblies, which imparts prestress to or bar) or a bundle of such elements. The tendon is
a structural member or the ground. Also included stressed by a hydraulic jack and the reactions impart
are ducts, grouting attachments, grout, and compression forces on the structure or ground to
corrosion protective filler materials or coatings. which they are anchored. Tendons are most widely
used in prestressed concrete structures andfor ground
anchors. They are also used to increase the strength
capacity of masonry, steel and timber structures, and
for rehabilitation and retrofitting of structures.

6
 SPECIFICATION COMMENTARY

Wedge Wedge
A conically shaped device which anchors the Strands are anchored by wedges, which have serrated
strand in the wedge plate. surfaces (teeth) in contact with the strands and smooth
cone shaped outside surfaces, which bear against the
smooth cone shaped wedge holes in the wedge plate.
Two or three part wedges grip each strand and anchor
the strands by friction. The friction is enhanced by
the indentations the wedge teeth bite into the strands.

Wedge plate Wedge plate

The hardware which holds the wedges of a For a multi strand tendon this is a machined,forged,
multi- strand tendon and transfers the tendon or cast metal disks with multiple conical wedge holes.
force to the bearing plate. A mono strand tendon normally has cast ductile iron
anchors, which combine wedge and bearing plate.
Single strands are also anchored in doughnut shaped
chucks, which peljorm the function ofa wedge plate.

7
 SPECIFICATION COMMENTARY

2 PRESTRESSING MATERIALS C2 PRESTRESSING MATERIALS

2.1 Strands C 2.1 Strands
Steel strand shall confonn to ASTM A 416 "Standard C 2.1.1 ASTM A 416 Strand
Specification for Steel Strand, Uncoated Seven-Wire
For most applications strand conforming to
Strand for Prestressed Concrete."
ASTM A 416 is adequate. The specification provides
minimum requirements for mechanical properties
Epoxy-coated strand shall conform to ASTM A 882
(yield, breaking strength, elongation) and maximum
"Standard Specification for Epoxy-Coated Seven­
allowable dimensional tolerances.
Wire Strand." The strand shall meet ASTM A 416
Strand from different sources meeting ASTM A 416
requirements.
requirement, however, is not necessarily identical in
all respects. For special applications it may be
Indented strand confonning to ASTM A 886 can be
necessary to select strand, which has more closely
used for ground anchors.
defined properties. The following provides additional
information to assist in evaluating specific project
The referenced ASTM specifications apply to the
related requirements, which may exceed the scope of
latest editions.
this specification.
C 2.1.2 Strand Size Tolerances
Diameter tolerances allowed by ASTM A 416 in
combination with the minimum breaking strength
requirement, result in some strands being
manufactured consistently on the small side (with high
unit tensile strength) while others are produced on
the large side (with low unit strength). See also
Commentary on MUTS, Section C 1.2.
Size differences may effect the strand-wedge
connection performance (Section 4.1.3). Strand­
wedge connections normally are designed and tested
to work with average commercially available strand
sizes. It should be realized, however, that a strand­
wedge connection developed for a particular strand
with properties at one end of the tolerance band may
not suit a strand with properties at the other end of
the tolerance band. Mismatch can result in strand slip,
wire breaks and reduced fatigue resistance of the
strand-wedge connection.
C 2.1.3 Workability of Strand
ASTM A 416 does not provide requirements for
workability, which depends on the strand's
straightness, stiffness, stability of stranded wires not
to unravel at cut ends, and how the strand is coiled.
Strand produced by different processes varies in
regard to these characteristics. Ifand how workability
relates to other strand properties is uncertain, but it
is normally assumed, that once installed and stressed,
workability has no effect on performance in the
structure, provided the strand meets the requirements
ofASTM A 416.

8
SPECIFICATION COMMENTARY

During strand installation, workability can have a

significant impact on getting the work done. It is
advisable to specify, for critical applications,
properties affecting workability.
C 2.1.4 Bending of Strand
Sharply bending strand, or its individual wires,
requires good ductility ofthe strand material to avoid
wire breaks. Sharp bends may occur at anchorages
with short transitions (as the strands flare from the
duct into the wedge plate), at deviators (which are
placed at locations of angle changes for unbonded
tendons), in small diameter loops, or at upset strand­
wire cages, (which occasionally are used for
embedded fixed-end anchor).
The FIP developed the "One Pin Test" for measuring
the ductility ofstrand. The PTl "Recommendation for
Stay Cable Design, Testing and Installation, Appendix
A" (121, adopted this test as a requirement for strand
used for stay cables. Stressing strand while bent
around a small pin without breaking wires, is a good
indication ofgood quality strand, including resistance
to notches, good fatigue strength and workability.
C 2.1.5 Bond of Strand to Cement Grout

Strand conforming to ASTM A 416 does not have

uniform bond characteristics. Different manu­
facturing processes produce different surface texture
and coatings, which greatly influences the bond. Also
variations in the pitch of the helical outer wires, as
permitted by ASTM A 416, effects the bond. A 1995
PTl study (101 showed that the bond strength between
strand and the surrounding concrete or grout varied
by as much as a factor of eight, depending on the
source of the strand. The required bond length to
develop a strand is an important consideration for
tendons with bond-anchors and for determining the
necessary anchorage length of ground anchors.
ASTMA 981-98(71 provides a method to test the bond
characteristics of0.6 in. (15.24 mm) strand, which is
based on the test procedure described in the PTl
"Recommendations for Rock and Soil Anchors" (13).
The test method can be adapted to test strand with
0.5 in. (12.7 mm) diameter. The test is performed on a
18 in. (457 mm) long strand encased in a 5 in. (127
mm) outside diameter and J/s in. (3 mm) thick steel
pipe, which is filled with 3,000 to 3,500 psi (20 to 24
MPa) cement grout.

9
SPECIFICATION COMMENTARY

C 2.1.6 Fatigue of Strand

Tendons in prestressed concrete structures and ground
anchors normally do not experience stress cycling
significant enough to cause fatigue problems. For
those applications where fatigue is a concern, such
as cable stay bridges, fatigue resistance can be
increased by proper material selection and anchorage
design measures.
Tendon fatigue resistance depends on the properties
of the strand, the features of the tendon, and special
conditions in a particular structure.
Variables influencing fatigue behavior of strand:
Steel quality, (ductility, notch-sensitivity),
Pitch ofouter wires (increased stresses, side
pressure)
Surface condition (rust reduces fatigue life)
Tendon:
• Strand-wedge connection (notches)
• Flare at anchorages (combined bending and
axial stresses)
Number of strands per tendon (unequal
stresses, side pressures)
• Duct size, material, and surface condition
Structure:
Tendon curvature (side andcontactpressure)
Range between upper and lower stresses,
and stress cycles
C 2.1.7 Stress Corrosion and Hydrogen
Embrittlement
Strand conforming to ASTM A 416 is known to be
relatively resistant to stress corrosion and hydrogen
embrittlement, due to the cold drawing process. But
since susceptibility to these embrittlement phenomena
increases with the tensile strength of the materials
and the stress levels to which they are subjected,
caution is advised if the strand may be exposed to
conditions, which could produce stress corrosion or
hydrogen embrittlement conditions. (See also Section
1.2, definition for stress corrosion cracking.)
FIP provides recommendations for approval, supply
and acceptance ofsteelsfor prestressing tendons (FIP
Reports #524 and #544). They also provides a method
for testing prestressing steels for stress corrosion and
hydrogen embrittlement by subjecting the steel
samples to a solution ofAmmonium-thiocynide.

10
SPECIFICATION COMMENTARY

C 2.1.8 Packaging of Strand

ASTM A 416 requires that strand must be well
protected in shipping against mechanical injury,
which includes damage from corrosion, stress
corrosion, or hydrogen embrittlement through contact
with deleterious chemicals. ASTM A 416, leaves the
prescription of the necessary level of protection to
the project specifications, which should take the
special structural and environmental project
conditions into account.
Strand manufacturers, in cooperation with the
California Transportation Department, developed an
effective corrosion protective packing, known in the
trade as CALWRAP, which meets the corrosion
protective requirements of Caltrans Standard
Specification. Section 50! 16). CALWRAP provides long
term corrosion protection for strand if stored off the
ground and in a dry place. For most bridge projects
equivalent packaging is specified. For building
projects standard packaging provided by the strand
manufacturers is normally adequate.
C 2.1.9 Corrosion Protection of Strand
It is a rule of thumb that the higher the strength of
steel the more susceptible it is to corrosion damage.
Strand, having very high strength and relatively large
ratio of surface to cross-sectional area, has to be
protected against corrosion at all times. The necessary
corrosion protection depends on environmental
conditions and varies from project to project.
Long term corrosion protection ofgrouted tendons is
provided by the concrete cm'er. ducts, and primarily
by the alkaline environment of the cement grout
surrounding the strands. For ground anchors and
unbonded tendons the type of corrosion protection
needed varies with the environment, type ofstructure,
and durability requirements. The engineer specifies
in the contract documents what type of protection is
required. It is then the supplier s responsibility to meet
these requirements.
Contract performance specifications, in regard to
c.orrosion protection, should be avoided, since they
lead to compromise between cost and quality. It is
recommended that the designer specifies detailed
corrosion protective requirements and enforces them.
Saving on corrosion protection can become very costly
in the long run.

11
SPECIFICATION COMMENTARY

Post-tensioning system suppliers normally have

incomplete information on the corrosive environment
and other project requirements, and often they do not
control the installation. Furthermore, suppliers
normally compete on the basis of price and the
effectiveness and reliability of corrosion protective
measures is normally proportional to the cost.
C 2.1.10 Plastic-Coated Strand
for Unhonded Tendons
Strand coated with a special corrosion inhibiting
compound, and protected by a high density plastic
coating (HDPE or HDPP), is widely used for
unbonded monostrand tendons and in the unbonded
portion of ground anchors. The plastic coating is
seamlessl)' extruded directly over the coated strand.
The strand conforms to ASTM A 416. The
requirements for the corrosion inhibiting coating
compound and for the extruded plastic are covered
by the PTI "Specification for Unbonded Single Strand
Tendons" (14J.
Applying the corrosion protective compound to strand
prior to inserting the strand into plastic duct, or
inserting strands while the compound is pumped into
the duct, is likely to leave voids inside the ducts. The
strand may be left unprotected as the corrosion
inhibiting compound flows to low points. This could
lead to corrosion damage, especially if moisture could
enter into the voids.
C 2.1.l1 Galvanized Strand
Few manufacturers supply galvanized strands. It is,
therefore, necessary to verify availability and type
prior to specifying galvanized strand.
Zinc coated strands can have different physical and
surface properties depending on the manufacturing
process. Presently no U.S. specification exists, which
specifies the properties ofgalvanized strands suitable
for post-tensioning applications and which specifies
the zinc coating thickness requirements. The
requirements ofASTM A 475 and ASTMA 641 provide
galvanizing guidelines.
Galvanized strand producedfrom 270 ksi (1,860 MPa)
strand material, normally has a reduced 240 ksi
(1,655 MPa) tensile strength and does not meet
ASTM A 416 requirements. The approximately 8000F
(426°C) temperature of the hot dipped galvanizing
process changes the properties of the cold drawn
steel wires.

12
SPECIFICATION COMMENTARY

Galvanized strand, meeting the 270 grade

requirements ofASTM A 416, is either producedfrom
higher than 270 grade ungalvanized material, or the
wires, after galvanizing, are further reduced in size
by drawing them through a die or several dies.
Wedges for anchoring galvanized strand must have
large enough teeth to bite through the zinc layer into
the steel to avoid strand slip.
C 2.2.12 Epoxy-Coated Strand
ASTM A 882 is the standard specification for epoxy
coated strand. It provides requirements for the epoxy
coating and specifies that the strand must meet the
requirements ofASTM A 416. The epoxy coatingforms
a moisture barrier to protect the steelfrom corrosion.
Special handling is required during fabrication.
storage, shipping and installation to prevent damage
to the moisture barrier.
For anchoring epoxy-coated strands, special wedges.
installation equipment and techniques are required.
For wedges to be effective the teeth have to bite
through the epoxy coating. To assure proper strand
anchorage-especially if the wedges are seated at less
than the maximum allowable jacking force-it is
necessary to power seat the wedges in a separate post
blocking operation. (Such post blocking power seating
is also recommended for uncoated strand if it is
anchored at aforce level lower than necessary to fully
seat the wedges.) Removal of the epoxy coating from
the strand circumvents the special wedge seating
requirements. Such coating removal is difficult and
requires special equipment. it also removes the
corrosion protection in the critical anchorage area.
Two types of epoxy coated strands are commercially
available. One type coats the strand's outer surface
with epoxy but leaves the interstices between outer
and inner wires void. Through flaws or breaks in the
outer coating moisture could enter into the voids and
produce corrosion damage along the inner
unprotected surfaces of the strand wires. The second
epoxy coated strand type has all spaces between wires
filled with epoxy. Such strand provides substantially
improved corrosion protection.
Both types ofepoxy-coated strand are available either
with a smooth surface texture or with a special high
bond surface, which consists ofsilicon sand, which is
bonded to the outside of the epoxy coating. The later
is neededfor ground anchors, to bond the strand with
cement grout to the ground.

13
 SPECIFICATION COMMENTARY

2.2 Bars C2.2 Bars

Steel bars shall conform to ASTM A 722, ASTM A 722 covers plain (Type I) and deformed
"Specifications for Uncoated High-Strength Bar for (TYPE II) hot rolled, cold stressed and stress relieved
Prestressed Concrete," including its "Supplementary bar. The ASTM specification is interpreted as a
Requirements" Sl and S2. performance specification for physical bar properties
and covers various manufacturing processes, as hot
rolled, cold drawn, and cold defonned bars.
Bar confonning to the broad requirements ofASTM A
722 nonnally is adequate. However, as with strands,
different manufacturing processes produce different
material characteristics, which are not covered by the
ASTM specification. The suitability of a particular
type of bar for a particular application has to be
judged on the basis of all of its typical properties.
Properties to be considered in the selection of bars
include: ductility, (especially at cold temperatures)
bending radii, bond strength, sensitivity to notches,
stress corrosion, hydrogen embrittlement, fatigue,
relaxation, and weldability. These properties can be
quite different for different types of bar, depending
on the manufacturing process. Those properties are
important for certain applications.
C 2.2.1 Bar Grade
ASTM A 722 refers to bars with a minimum breaking
strength of 150 ksi (1,035 MPa) and specific bar
diameters. Bars with higher strength than Grade 150
and with intennediate or larger diameters are not
specifically excluded from ASTM A 722. They must,
however, have comparable properties to Grade 150
bars in respect to ductility, notch sensitivity, stress
corrosion, hydrogen embrittlement, relaxation,
fatigue, and bond. These properties are not explicitly
covered by ASTM A 722.
C 2.2.2 Hot Rolled Bar
ASTM A 722 specification requires, that u • • • the bars
shall be subjected to cold-stressing to not less than
80% ofthe minimum ultimate strength, and then shall
be stress relieved." The cold-stressing exceeds the
yield of the as-rolled material. It raises the yield and
produces an essentially linear stress strain
relationship in the elastic range (constant E-Modulus),
as desirable for calculating stressing elongations.
Most importantly, the cold-stressing also perfonns the
function ofproofloading the bar. This process is likely
to eliminate bars having rolling or metallurgical
defects.

14
SPECIFICATION COMMENTARY

C 2.2.3 Cold Drawn Bar

Cold-drawn bars must be subjected during the cold
drawing process to cold stressing ofnot less than 80%
of their minimum ultimate tensile strength. This is a
requirement ofASTM A 722. It serves the purpose of
proofloading the base material against metallurgical
or mechanical defects. The bars are then stress­
relieved. The threads or deformations are produced
in a subsequent cold rolling process.
C 2.2.4 Corrosion Protection of Bar
Bars are not as easily damaged by corrosion as
strands because oftheir relatively low strength, large
diameter, and relatively small ratio ofsurface area to
cross sectional area. Hot rolled bars also obtain,
during the rolling process, a natural protective layer
of surface oxidation. The naturally rough surface
texture remains unaffected by non pitting rust. Bars,
therefore, normally do not require special corrosion
protection during shipping and handling.
When bars are exposed for extended periods to the
weather, an application of water soluble corrosion
protective oil has been proven to be effective to prevent
pitting rust damage. Clearly visible rust pits must be
avoided since they act as stress raisers and can initiate
bar failures.
Various methods are available to provide lasting
corrosion protective coatings for bars. They can be
galvanized, sandblasted and painted, epoxy coated,
or covered with a thick extruded or heat-shrink plastic
material. Placing bars inside duct andfilling the void
between bar and duct with cement grout has proven
to be a reliable long term corrosion protection.
C 2.2.5 Galvanizing of Bar
Hot dip galvanizing is frequently used for corrosion
protection of post-tensioned bars. Galvanizing high
strength steel bar requires very careful and specialized
galvanizing procedures. Sandblasting is substituted
for the usual acid pickling to prevent hydrogen
embrittlement. Special precautions are necessary
when galvanizing cold worked bars to prevent
reduction of yield strength through the normalizing
effect caused by zinc bath temperatures in excess of
800°F (426°C). Maintaining threadability of hot
dipped galvanized bars also requires special expertise.
Heating bar ends with a torch and removing zinc by
brushing will cause severe metallurgical damage to
high strength steel bars and must not be used under
any circumstances.

15
 SPECIFICATION COMMENTARY

C 2.2.6 Bars Grouted Inside Plasm Duct

Effective long-term corrosion protection, as required
for permanent ground anchors or unbonded bar
tendons, is provided by grouting bars inside plastic
duct. The alkaline cement grout passivates the bar
surface and the plastic duct acts as a moisture barrier.
Such corrosion protection requires special anchorage
details to maintain threadability and corrosion
protection.
2.3 Special Prestressing Materials C 2.3 Special Prestressing Materials
Prestressing materials not conforming to sections 2.1 This section applies to post-tensioning steel in sizes
or 2.2 are acceptable, provided such materials are and grades which ASTMA 416 andA 722 do not cover,
extensively tested to establish that their properties are it also covers wire conforming to ASTM A 421. This
equal to or better than those specified in this document. section also applies to nonmetallic materials, which
Such materials and their anchorage must be thoroughly are under development and may find wide range of
tested and evaluated for ductility, bending properties, applications in the future.
fatigue, relaxation, bond, susceptibly to mechanical Glassfiberand carbonfiber tendons (Aramid, Kevlar)
damage, effect of hot and cold temperatures, and have been installed in a few prototype structures.
chemical attack.

16
 SPECIFICATION COMMENTARY

3 BEARING PLATES C3 BEARING PLATES

The requirements for bearing plates apply equally for The same requirements are used for bonded and
bonded and unbonded tendons. unbonded tendon anchorage assemblies, including
bearing plates. Both tendon types usually experience
Basic bearing plates shall meet the design criteria of the highest tendon forces at time of stressing.
Section 3.1. They do not need testing. Thereafter forces reduce because of seating losses,
creep, shrinkage, and relaxation. The safety factors
Special bearing plates require testing in conformance built into the criteria provide adequate margins
with Section 3.2 and Sections 6.1.4. against material defects and force increases.
Dynamic testing of bearing plates usedfor unbonded
tendons is part ofthe dynamic system test specified in
Section 6.2.2.
3.1 Basic Bearing Plates Design Criteria C 3.1 Basic Bearing Plates Design Criteria
Basic bearing plates, designed to meet the design The design ofsingle and grouped basic bearing plates
criteria (1) to (8) of this Section 3.1, do not require depends on the size of the distribution area, which is
testing. governed by the criteria 3.1 (1).
Notations: (for Section 3.1)
The equations in this section are equally applicable
ax dimension of distribution area in x direction for the US and Sf Units of Measurement, provided
ay dimension of distribution area in y direction consistent units are used for "lengths" and "forces"
andfor the derived units as "areas" and "stresses."
A distribution area within the supporting concrete,
concentric with the bearing plate and with sides
parallel to it; maximum width of either side to
be twice the distance from center of bearing
plate to edge of concrete, but not more than
twice the parallel bearing plate width
Ab net bearing plate area, after deduction of center
hole area
gross bearing plate area
dimension of bearing plate in x direction
dimension of bearing plate in y direction
maximum assumed edge cover of bearing plate
in distribution area
minimum actual edge cover of bearing plate
elasticity modulus of steel bearing plate [30,000
ksi (207,000 MPa)]
fc 28 day concrete cylinder strength
f.et concrete cylinder strength at time of stressing
average uniform concrete bearing stress under
bearing plate prior to seating, produced by
Pjack = 80% MUTS
permissible concrete compressive stress at time
of jacking
bending stress in steel bearing plate

17
 SPECIFICATION COMMENTARY

allowable steel bearing stress under p.Jac kbetween

wedge plate and bearing plate
yield stress
equation (3-5): bearing plate material
equation (3-7): yield stress of bearing plate or I
777~177777in:
I

wedge plate material, whichever is lower DISTRIBUTION

,Ij : AREA
I I
n largest distance from outer edge of wedge plate . ,Ij I BEARING PLATE
I
to outer edge of bearing plate I
I

PJack jacking force, but not less than 80% MUTS

~ :
ay 4ct ,;
uniform thickness of bearing plate /j :
/1 :
orthogonal reinforcement ratio in each of two
~ !
directions (vertical and horizontal) expressed
as a percentage of distribution area
----'--
ct
FLL'LL'LL'LL'.L1
~ I
:
I
I
- -----------.. ,,---------4-­
I

Fig. C 3-1- Bearing Plate Distribution Area

Criteria:
Criterion 3.1 (1)
(I) The relationship between gross bearing plate area The 3 limiting criteria also apply for groups of
and distribution area shall meet in x and y direction closely spaced individual bearing plates, which are
the following conditions, analyzed as a single bearing plate. Minimum edge
if e min > 0.5 b then a = 2b distances establishedfor individual plates need to be
if e min < 0.5 b then a = (b + 2e min ) (3-1) increased for groups.
but e max < 4 e min The criterion that a (ax' a y ) shall be smaller than two
times the respective dimension b (bx' b) ofthe bearing
plate, limits the allowable bearing stress to 1.0 rei
for equation (3-1) and to 1.5 rei
for equation (3-3).
These values are smaller than the 1.6 rei
permitted
by the equivalent AASHTO equation (2), Section
1- 9.21.7.2.
The criterion e max < 4e min . is based on research
performed at the University of Illinois (18. 19).
Criterion 3.1 (2)
(2) Allowable bearing stress under f]ack = 80% MUTS This criterion is based on extensive research by The
(prior to seating), without special local zone University of Texas (8) on bearing plates without
reinforcement, Ps = 0%, special confinement reinforcement in the local zone.
f cpI. = 0.5 f' Cl. (NA g )\12 < f' c.. (3-2) The equation (3-2) is presented in thefamiliarformat
of the PTI Guide Specijication (11) but is identical to
where: (see sketch above) equation (9-39) of AASHTO(2), Section I - 9.21.7.2,
distribution area A=a x a using a Load Factor = 1.2; I/J =0.85fornormalweight
bearing plate gross area Ag = x x b b y concrete, and <p = 0.7 for light weight concrete.
Criterion 3.1 (3)
(3) Allowable bearing stress under P.Jac k= 80% MUTS The criterion takes into account the much improved
(prior to seating), with minimum local zone bearing capacity of a reinforced local zone. The
reinforcement of Ps > 2.0%, equation (3-3) is similar to the one recommended in
the PTI Guide Specijication(11), but is written in the
f cpi = 0.75 f'ci (NAg>'h < 1.5 f~i (3-3)

18
 SPECIFICATION COMMENTARY

The confinement reinforcement needs to be more rationalformat ofequation (3-2). The PTI Guide
placed in that volume of concrete in which the Specification, however, had no explicit reinforcement
concrete stresses exceed acceptable values for requirements.
unconfined concrete (local zone). The forces may
For basic bearing plates the length of the local zone
be assumed to spread from the faces ofthe bearing
can be determined by analysis, it decreases with
plate at a 1:2 slope (the value 2 is measured
increased edge distance. (See also Section 1.2,
parallel to the tendon path).
definitions for Confinement reinforcement, and for
The confinement reinforcement shall be Local zone.)
distributed uniformly throughout the local zone
Confinement reinforcement for basic bearing plates
in x and y direction.
normally consists of orthogonal reinforcing bars
A group of closely spaced anchorages shall be .spaced preferably not more than 4 in. (100 mm) apan
analyzed on the basis of a single bearing plate in each direction. The bars extend beyond the local
covering the group. zone by their bond development length.
Criterion 3.1 (4)
(4) For Ps between 0% and 2% the allowable bearing This fills the gap between the requirements 3.1 (2)
stress (f'e) may be linearly interpolated between and 3.1 (3) in regards to plate size and reinforcement
values obtained from equations (3-2) and (3-3). requirements.
Criterion 3.1 (5)
(5) The above equations (3-2) and (3-3) are valid for To reduce allowable bearing stresses for light weight
normal weight concrete. For light weight concrete, concrete by 18% is based on the difference of the
the allowable bearing stresses shall be reduced by strength capacity reduction factors for anchor zones
at least 18%. specified in AASHTO(2), Section 1 - 9.14.
Criterion 3.1 (6)
(6) Average concrete bearing stress on net bearing This is based on the prescribed value for Ejack = 80%
area at time of jacking, with Pjaek = 80% MUTS, MUTS, rather than the design jacking force. This
provision assures, that bearing plate sizes will have
(3-4) adequate ultimate capacity should the specified
jacking force be lower than 80% MUTS. This
requirement also eliminates the needfor the separate
service design equation given in the PTl Guide
Specification! 11I.
Criterion 3.1 (7)
(7) Bending stress in bearing plate at 80% MUTS, For ASTM A 36 steel bearing plate, andfor average
bearing stressesfbi > 4 ksi (27.6 MPa) at 80 % MUTS,
(3-5) equation (3-5) fulfills the stiffness requirement of
equation (3-6). The equation also fulfills the often
specified requirement, thatfor tendon forces equal to
95% MUTS the bending stresses in A 36 steel bearing
plates will not produce yielding or produce permanent
deflections! 16).
For rectangular or square bearing plates the analysis
assumes an equivalent square wedge plate.
Criterion 3.1 (8)
(8) Stiffness at 80% MUTS, Equation (3-6) prevents the substitution of thin and
flexible high strength steel plates for standard
nit < 0.08 (EsIfbY"
I
(3-6) ASTM A 36 plates. This equation also governs for
A 36 plate with bearing stressesfbi < 4 ksi (27.6 MPa).

19
 SPECIFICATION COMMENTARY

The equation is based on the AASHTO equation

(9-41)12>, Section 1 - 9.21.7.2.3, but uses Pjack rather
than the factored tendon force. The 6.2% difference
in plate thickness is negligible. Es = 30,000 ksi
(207,000 MPa) may be used.
Criterion 3.1 (9)
(9) Allowable bearing stresses between bearing plate This limits the allowable bearing stress between
and wedge plate under Pjack bearing plates and wedge plates. The allowable value,
exceeding yield by 50%, is based on the fact, that very
(3-7) high localized bearing stresses are acceptable if the
stresses can spread out into the adjacent material,
localizing the highly stressed area. Hertz stresses in
spherical bearings and high stresses under the heads
ofhigh strength bolts are other examplesfor such high
localized stresses.
3.2 Special Bearing Plates C 3.2 Special Bearing Plates
Testing Requirements Testing Requirements
Adequacy ofspecial bearing plates shall be established Most suppliers have developed special bearing plates.
by tests. Sections 3.2.1 to 3.2.3 specify test block, They have special shapes, frequently have multiple
size, test procedure, and acceptance criteria. Section bearing surfaces, and often are ductile iron castings.
6.1.4 specifies number of tests. Such bearing plates normally produce very high local
bearing stresses on the concrete and, therefore,
require spirals or equivalent confinement reinforce­
ment in the local zone. They are not readily amenable
to rational stress analysis and their adequacy must
be established by tests.
3.2.1 Test Block C 3.2.1 Test Block
The test block shall be a square or rectangular prism, The test block requirements essentially conform to the
depending on the shape of the bearing plate, and shall AASHTO requirements 12 ), Sections 11 - 10.3.2.3.1 to
contain representative embedded tendon components, 10.3.2.3.5.
including transitions and duct.
Test block shall further meet the following
requirements:
Requirement 3.2.1 (1)
(1) Test block width and depth in each direction shall This requirement represents the cross section of the
be the smaller of: local zone. The 3 inches (75 mm), added to the
a) Two times the minimum edge distance from anchorage center to center spacing, is necessary to
the centerline of bearing plate to the face of accommodate the test block surface reinforcement
concrete. and its concrete cover. The additional strength
b) The minimum center to center spacing of the provided by the 3 inches (75 mm) can be considered
bearing plate plus three inches. to represent the higher confined concrete strength
ahead of closely spaced bearing plates.
Testblock dimensions depend on system specific
values:
ax' a y = test block cross-sectional dimensions
cx ' c y = minimum bearing plate center to center
spacing
dx' d y = minimum bearing plate center to edge
distances

20
 SPECIFICATION COMMENTARY

TEST BLOCK
BEARING
PLATE

if then
2d < c a = 2d
2d> c a = c + 2x 3 in.

Fig. C 3-2-Test Block Cross Section

Requirement 3.2.1 (2)
(2) The length of a test block containing a single This requirement is based on uniform force transfer
anchorage and local zone-loaded in a testing over the total cross sectional test block area at the
machine-shall be at least two times the larger testing apparatus' reaction end. The stresses in the
cross-sectional test block dimension. tendon anchorage s local zone will then be similar
to those obtained in a test block with tendon anchors
on both ends.
Requirement 3.2.1 (3)
(3) The length of a test block with an anchorage and This requirement is applicable also for the system
local zone on either end-loaded by stressing a test required by Section 6.2. Longer test blocks than
test tendon-shall be at least four times the larger the specified minimum length may be used. (See also
cross-sectional test block dimension. Commentary, Section C 4.1.3.4, "Multi-Strand Tendon
Tests. ")
Requirement 3.2.1 (4)
(4) The reinforcement in the local zones shall This requirement applies only to the local zone. The
represent the local zone reinforcement required test block portion between the two local zones may
in actual structures. be reinforced as needed to prevent any distress along
this length. Such reinforcement does not need to be
represented in real structures.
Requirement 3.2.1 (5)
(5) The concrete strength at time of testing shall not AASHTO, Section II - 10.3.2.3.5 (2 ) requires that the
exceed either the minimum strength specified for concrete strength at time offield stressing shall be
the system at time of tensioning, nor 85% of the larger than the concrete strength ofthe test specimen
28 day cylinder strength for normal weight at time of testing. The 85% and 70% represent the
concrete or 70% for light weight concrete. capacity reduction factors specified by AASHTO,
Section 1 - 9.14.

3.2.2 Test Procedure C 3.2.2 Test Procedure

The test force shall be applied to the wedge plate, or The test procedure is similar to the monotonic loading
anchor nut, either in a testing apparatus or through an test specified by AASHTO, Section II - 10.3.2.3.9,

21
 SPECIFICATION COMMENTARY

oversized tendon. The force shall be applied in stages which is the most practical of the three choices given
to 40% and then to 80% of MUTS. At 40% the force by AASHTO. (See also Commentary, Section C 3.2.3.)
shall be held for 10 minutes to allow inspection for Anchorages meeting the FlP "Recommendations for
cracks. At 80% the force shall be held for one hour. Acceptance of Post-Tensioning Systems, 1993
Thereafter the force shall be increased to at least 120% Edition" can be expected to also meet these
MUTS, and then to failure, or to the limit of the testing requirements.
equipment.
The overload requirement to at least 120% MUTS
provides at least a 1.5 safety factor against maximum
temporary jacking forces at 80% MUTS. Increasing
the test load to failure is very desirable in order to
observe and evaluate the failure mode.
The 120% MUTS test force requires either a special
testing apparatus, or an oversized tendon. The force
transfer to the special bearing plate, however, must
simulate actual conditions, i.e., the force must be
applied to a wedge plate of same size as the one
belonging to the system being tested. (See also Section
6.2 for system test requirements.)
3.2.3 Acceptance Criteria C 3.2.3 Acceptance Criteria
Criterion 3.2.3 (1)
(l) For forces up to 40% MUTS crack width shall not This criterion recognizes, that some very small cracks
exceed 0.002 in. (0.05 mm). are unavoidable under concentratedforces and where
the non-prestressed reinforcement will elongate
under stress.
Criterion 3.2.3 (2)
(2) After holding the force at 80% MUTS for one Holding the jacking force for one hour at 80% MUTS
hour the width of concrete cracks shall not exceed and then measuring crack width is more realistic than
0.010 in. (0.25 mm). AASHTO's requirement to measure the crack width
after holding the jacking force at 90% MUTS for one
hour. In normal operation loading to 80O/C occurs only
for a very short time prior to seating, measured in
seconds or at most a few minutes. Thereafter, the
tendon force normally is locked offat 70% MUTS and
will further reduce in time as a result of concrete
creep, shrinkage and steel relaxation. Also, measuring
cracks while the tendon and the test block is under
stress at more than 80% of MUTS increases
unnecessarily the safety risk for the technician.
Criterion 3.2.3 (3)
(3) The test block shall not fail prior to reaching This is the AASHTO, Section 11 - 1O.3.2.3.1O(2},
120% MUTS. criterion for monotonic loading.
C 3.2.3.1 Concrete Crack Width
The CEB-FlP Model Code classifies five exposure
conditions (where exposure level 4 is sea water
exposure) and accordingly recommends limiting the
crack width (91, Sections 1.5 and 7.4.2: "In the absence
of specific requirements (e.g. watertightness), it may

22
SPECIFICATION COMMENTARY

be assumed that for exposure classes 2 - 4 a crack

width limitation equal to 0.30 mm (0.012 in.) under
the quasi-permanent combination of actions is
satisfactory for reinforced concrete members with
respect to both appearance and durability." For
prestressed members under frequent load
combinations the CEB-FlP code limits the crack width
for exposure classes 1- 4 to 0.20 mm (0.008 in.).
Small concrete cracks in conventional reinforced
anchorage zones cannot be completely prevented,
since the confinement reinforcement has to elongate
to become effective. To prevent corrosion damage to
reinforcing bars in aggressive environments, it is
advisable to use larger than minimum edge distances
for the tendons. to use more than minimum concrete
cover, and to provide closely spaced relatively small
size crack distribution steel in the anchorage zone.
Such measures must be incorporated into the design.
For aggressive environments project plans must
provide larger than minimum areasfor placing tendon
anchorages. Specifying "basic bearing plates" in lieu
of "special bearing plates," may also help to keep
crack widths small.

23
 SPECIFICATION COMMENTARY

4 CONNECTIONS C4 CONNECTIONS
4.1 Strand-Wedge Connections C 4.1 Strand-Wedge Connections
The performance of the strand-wedge connection
depends on the interaction of wedge plate, wedges,
and strands.
4.1.1 Wedge Plate Test Requirements C 4.1.1 Wedge Plate Test Requirements
Adequacy of wedge plates shall. be established by Wedge plates have very complex loading conditions
static tests. The number of tests are specified in and internal stresses. Their safety margins against
Section 6.1.5. The following requirements shall be failure can only be established by destructive tests,
met: which simulate the actual loading conditions. Section
6.1.5 specifies 3 static tests to failure.
Dynamic testing of wedge plates used for unbonded
tendons is part of the dynamic tendon test specified
in Section 6.2.2.
Requirement 4.1.1 (1)
(I) After loading to 95% of tendon MUTS and This requirement is based on the essentially "no
subsequence force release, the permanent deflection" provision (16), which has proven to provide
deflection of the wedge plate's top surface shall reliable safety margins against failure for wedge
not be more than 1/600 of clear span (equal to plates machined from high strength steel with good
bearing plate hole diameter). The load test shall ductility. Limiting wedge plate deflections also limits
be performed with the wedge plate support wedge hole deformations, which influences the
simulating conditions in the anchorage assembly. performance of the strand-wedge connections.
The force shall be applied by pulling on a sample The deflection limitation requirement, however, while
tendon using the standard system wedges. useful, does not assure adequate safety margins for
wedge plates madefrom relatively brittle high strength
materials, such as frequently used ductile iron
castings, or for some heat-treated steel castings and
forgings. Tests have shown, that the failure mode of
brittle wedge plates is explosive, without prior
warning by observable deflections.
Requirement 4.1.1 (2)
(2) Wedge plates shall be tested to failure in static The requirement is consistent with the requirements
load tests, or to the loading capacity of the testing for bearing plate in Section 3.2.3 and AASHTO's
equipment. The tests shall simulate actual tendon requirement for special anchorage devices(2), Section
forces applied to the wedges. The failure force II - 10.3.2.3.9. It establishes safety margins for wedge
shall be at least 120% MUTS. plates, and preferably theirfailure mode. The required
minimum failure force of 120% MUTS provides a
safety factor at maximum allowable jacking force of
at least 1.5.
The destructive tests must simulate the lateral forces
the wedges exert on the wedge plate. Replacing the
strand with high strength bolts of equivalent
diameter and loading the assembly in a testing frame,
over a relatively soft steel distribution plate, provides
adequate realism to such tests. The Fig. C 4-1 shows
how this test can be performed.

24
 SPECIFICATION COMMENTARY

ALTERNATE TO WEDGECONE
HIGH-STRENGTH
• BOLT
~:'. .
..... ~' 'f'.:'.

STANDARD
f...
- \ WEDGE .

STIFF LOAD
TRANSFER PLATE
MILD STEEL
DISTRIBUTION PLATE
( A36 OR SOFTER)
HARDENED WEDGECONE
OR STANDARD WEDGE
____ WEDGE PLATE
-BEARING PLATE

Fig. C 4-1-Wedge Plate Test

4.1.2 Wedge Performance Requirements C 4.1.2 Wedge Performance Requirements
Each type of wedge must meet the performance Wedges are used in vary large quantities, measured
requirements of Section 4.1.2. in hundreds of thousands per type, and several
Manufacturing quality control must be adequate to millions total per year. It is, therefore, statistically
assure uniform quality of the essential manufacturer unavoidable that occasionally a strand will slip
specified wedge properties including: through a wedge.
a) Dimensions and tolerances Experience shows, however that in most cases rust,
b) Minimum specified surface hardness sand or dust in the wedge holes causes strand slip,
c) Minimum depth of surface hardness rather than wedge manufacturing defects.
(case depth)
d) Maximum core hardness
For each lot of 3,000 wedges (not wedge segments),
or for each heat-treatment batch, whichever is smaller,
manufacturers shall perform the following tests and
certify compliance with the minimum requirements
of this specification:
Requirements 4.1.2 (1) to (4)
(1) 5% of wedge segments shall be visually inspected These requirements are based on industry practice
for dimensions and surface defects. and experience. Adherence to the herein specified
minimum quality control testing will provide quality
(2) 2% of wedge segments shall be checked for
products.
surface hardness.
(3) 1% of wedges shall be checked for dimensional
compliance.
(4) Three cut and polished wedge segments shall be
micro-hardness tested to determine case depth,
case hardness, and core hardness. The serration
profile shall be checked for dimensional
compliance.
All test samples must meet the manufacturers specified
wedge properties. If any sample fails any of the above
specified quality control tests, then all wedge segments
or wedges shall be inspected and those not in
compliance shall be rejected for use.

25
 SPECIFICATION COMMENTARY

C 4.1.2.1 Typical Wedge

Suppliers and manufacturers have developed a
variety of different types of wedges for particular
systems and specific applications. A standard wedge,
which fits all systems and applications, has not
evolved; but most wedges have certain features in
common.
A typical wedge has a five to seven degree angle and
has a length of at least 2.5 times the nominal strand
diameter: It is manufactured from low carbon steel
(AISI I2-LI4 or I I-LI7) or alloy steel (AISI 86L20),
which are suitable for case-hardening while
maintaining a ductile core. After machining, the wedge
is case-hardened to at least 58 HRC measured at 113
case depth (or equivalent hardness scale), and an
effective case depth of at least 0.008 in. (0.20 mm),
while maintaining a ductile core hardness less than
46 HRC.
C 4.1.2.2 Cracks in Wedges
Wedges are designed to have hard surfaces, as
required for the wedge teeth to bite into the high­
strength strand. Wedges are also designed to have
ductile cores, which allow' the wedges to adjust to
irregular strand shape and the form of the wedge
holes. As wedges deform their outer hard surfaces
may crack, while the ductile cores prevent wedges
from breaking into pieces.
Surface cracks have caused concern and acceptance
problems on some projects. Experience has shown,
however, that surface cracks are not a safety hazard
and do not effect the performance of strand-wedge
connections adversely. Surface cracks signify hard
and brittle surfaces.

Not acceptable are wedges that have broken into

several pieces, signifying not only hard surfaces, but
also brittle cores. Nevertheless, wedges broken
longitudinally into several slices perform adequately.
Horizontal or inclined breaks, however, are
considered unacceptable.
4.1.3 Strand-Wedge Connection C 4.1.3 Strand-Wedge Connection
Performance Requirements Performance Requirements
Strand-wedge connection shall be tested in single Single strand-wedge connection tests are best suited
strand-wedge tests. Separate tests are required for each to optimize and establish the performance of the
strand and wedge type combination, considering as connection under the many variables.
variables: The full sized tendon system tests specified in
Section 6.2 include the effects of the strandjlare and

26
 SPECIFICATION COMMENTARY

Wedge properties how the strand enters into the wedge plate. The
Strand size Commentaries below provide additional information.
Grade
See also the Commentary, Sections C 4.1.3.3, "Single
Manufacturer
Strand- Wedge Connection Tests" and C 4.1.3.4,
For testing purposes strand and wedges shall be "Multi-Strand Tests. "
installed in wedge plates made from identical material
and shall have identical wedge hole dimensions and
surface finish as the tendon system wedge plates.
The number of tests are specified in Section 6.1.6. The Commentary Section C 4.1.3.6, "Tests on
50% of those tests shall be performed on wedge holes Lubricated and Non-Lubricated Wedge Holes"
coated with a molybdenum based lubricant; the other discusses the reasons why tests on lubricated and non­
50% shall be performed on non-lubricated wedge lubricated wedge holes are necessary.
holes, representative of the TOughest wedge hole
surface conditions permitted by the system
requirements.
The following test requirements shall be met for
single strand-wedge connections:
Requirement 4.1.3 (1)
(1) Under static forces, single strand-wedge This requirement conforms to AASHTO(2), Section lJ­
connections shall hold 95% of the actual tensile 10.3.2. The strand usedfor approval testing purposes
strength of the type of strand they will anchor and must meet the ASTM A 416 requirements. Actual
reach 2% elongation prior to rupture. tensile strength must be equal or larger than the
minimum specified tensile strength. See Commentary
Section C 4.1.3.5, "Actual Ultimate Tensile Strength. "
Requirement 4.1.3 (2)
(2) Under dynamic forces, single strand-wedge This requirement follows AASHTO, Section II ­
connections shall withstand, without causing wire 10.3.2.2(2) requirements for unbonded tendons. The
failure, at least 500,000 force cycles from 60% to additional requirement herein, to use the actual,
66% of actual strand tensile strength and thereafter rather than the minimum specified ultimate strength
50 force cycles between 40% and 80% of actual of the strand, takes into account that the critical
strand tensile strength. strand-wedge connection efficiency under static
load-and very likely also under dynamic loads-is
a function ofthe actual ultimate strength ofthe strand.
(See also Commentary, Section C 4.1.3.7, "Fatigue
Tests of Strand- Wedge Connection. ")
Four dynamic tests are specified in Section 6.1.6 (2)
on single strand-wedge connections, 2 each with
lubricated and non-lubricated wedge holes. One
dynamic full sized tendon test is specified in Section
6.2.2.

Requirement 4.1.3 (3)

(3) Wedges shall not break into separate pieces. See Commentary Section C 4.1.2.2, "Cracks in
Surface cracks are permitted. Wedges. "
Requirements 4.1.3 (1) and (3) are applicable for Most multi-strand tendons are used for bonded and
strand-wedge connections used for bonded and also for unbonded applications, as for exterior

27
 SPECIFICATION COMMENTARY

unbonded tendons. tendons. It is, therefore, desirable to have the strand­

Requirement 4.1.3 (2) applies to strand-wedge wedge connection qualify to sustain the dynamic
connections used in unbonded systems. loading conditions. Dynamic testing is not mandatory
if the connection is only used for bonded tendons.
C 4.1.3.1 Strand- Wedge Connection
Performance Requirements
Performance objectives for strand-wedge
connections:
Securely anchor the strand without
significantly reducing MUTS and ductility of
strand, or tendon.
Avoid strand slip after anchoring.
Prevent breaking of individual strand wires
in the wedges during stressing.
Achieve reasonable dynamic fatigue and
impact loading resistance without strand
slippage or wire breakage.
C 4.1.3.2 Strand-Wedge Connection Variables
Strand
• Diameter and tolerances
Ultimate tensile unit-stress and hardness
Notch toughness
Pitch of outer wires
Wedge
Length
Diameter (thickness)
• Angle
Inside wedge diameter in relation to the
strand diameter, and their tolerances
Shape and size of the wedge teeth engaging
the strand
Hardness level of wedge teeth
Ductility and toughness ofthe core material
Taper angle at which the teeth are chamfered
at the leading wedge end
Smoothness of the outer wedge surface
Segmentation of the wedges into two, three
or more parts
Wedge Plate
Wedge hole angle
Hardness
• Roundness of wedge hole
• Smoothness of wedge hole
• Wedge hole lubrication
• Wedge hole depth
System (Tendon)
Maximum angle at which the strands flare
from the bundled tendon into the holes ofthe
wedge plate

28
SPECIFICATION COMMENTARY

The many variables effecting a strand-wedge

connection require large test series in order to isolate
the effect of the variables and to optimize the
connection.

C 4.1.3.3 Single Strand-Wedge Connection Tests

Single strand-wedge connection tests are best suited
to establish the efficiency and adequacy of strand­
wedge connections. Single strand tests are easily done.
The effects of the many variables on the connection
performance can be isolated by testing numerous
samples, and the design can be optimized and retested.
Section C 4.1.3.2 lists the variables effecting the
strand-wedge connection.
Single strand-wedge connection tests eliminate the
test sample length as a variable. For multi-strand
tests the length of the test tendon is the most
significant test variable. The shorter the test tendon
the more unreliable are the test results. For single
strand tests, only one significant variable affecting
the connection efficiency in multi-strand tendons is
normally neglected. This variable is the variable
angle change of the strands as they flare from the
compact strand bundle at the end of the duct to the
wider spaced wedge holes in the wedge plates. If
necessary, even this effect can be simulated in single
strand test, but it requires a more elaborate test
apparatus than necessary for straight test samples.
The provision, to establish the fundamental strand­
wedge connection efficiency through single strand
tests and to measure the efficiency against A UTS
rather than MUTS, ensures that actually installed
multi-strand tendons can be expected to achieve 95%
of strand MUTS, and that unbonded tendons will
have adequate ductility. AASHTOI 2J, Section Il ­
10.3.2.2 requires that unbonded tendons must achieve
2% elongation at ultimate, which could be difficult
to achieve otherwise. (See also commentary to Section
1.2, definition for MUTS.)
Making the transition long mn minimi::e rhe ef(ects
of strand flares in multi-sln/nd tendons hy keeping
the flare angle small. Adding (/ thick plastic washer
directly behind the wedge plate ",ill move Ihe portion
of the strand, which is subjected to bending, due to
the angle change. away from the critical location at
the toe of the "'edge 10 the face of the plastic washer.

29
SPECIFICATION COMMENTARY

In order to achieve a 95% strand-wedge connection

efficiency for multi-strand tendons, as required by
AASHTO(2 i , Section II - 10.3.2, it is desirable to
achieve higher efficiencies in single strand-wedge
connection tests. A 98% single strand-wedge
efficiency is a practical optimum, based on the actual
ultimate strength of the test strand. (See also
Commentary, Section C 4.1.3.4 "Multi-Strand
Tendon Tests. ")
e 4.1.3.4 Multi-Strand Tendon Tests
Full sized test tendons normally are relatively short.
They do not represent conditions in actual tendons,
which normally are much longer: Frequently, length
variations between strands in a multi-strand test
tendon are the most critical test variables. However,
they have little practical significance for establishing
the strand-wedge connection performance.
Test tendon installation inaccuracies and non­
uniform seating losses in individual strand-wedge
connections, including those in the stressing
equipment, result in length and force differences of
individual strands, which easily can be large enough
to distort the test results. The strand flares behind
the anchorage further aggravate the non-uniform
tendon force distribution to the individual strands,
and further distorts the test results. Under such
conditions it is difficult to determine the actual force
in the particular strand which breaks first, and which
establishes the breaking force of the tendon.
e 4.1.3.5 Actual Ultimate Tensile Strength
The efficiency ofstrand-wedge connections, and also
the related tendon ductility, are functions of the
strand's AUTS rather than MUTS. Therefore, Section
4.1.3 requires, that single strand-wedge connections
must support in static tests at least 95% of the strand
actual ultimate tensile strength (AUTS). The
distinction between AUTS and MUTS assures, that
single strand test results-on selected strand with
AUTS considerably larger than MUTS-are also
representative of the conditions in real structures.
e 4.1.3.6 Tests on Lubricated and
Non-Lubricated Wedge Holes
Section 4.1.3 requires one to perform 50% of the
strand-wedge connection tests on lubricated wedge
holes and the other 50% on non-lubricated, dry
wedge holes. These two requirements address the two
conflicting requirements strand-wedge connection
have to fulfill:

30
SPECIFICATION COMMENTARY

To prevent strand breaks in the connection

during stressing and later under service loads.
To prevent strand slippage.
Lubricated holes significantly reduce the wedge
friction and increase the side forces with which the
wedge teeth bite into the strand. Strand or wirefailures
normally initiate from such notches at the wedge
entrance face. Strands normally break in the
connection at forces 2% to 10% less than the actual
tensile strength of the strands, depending on the
efficiency ofthe connection design. In actual practice
wedge holes often are not intentionally lubricated to
reduce friction, but to provide corrosion protection
during shipment, storage, and construction.
Strand slippage, on the other hand, is most likely to
occur when the friction between wedge hole and the
wedge is increased by a dry wedge hole surface. Rust,
dust, dirt, and especially sand in wedge holes are the
most common originators of strand slippage, rather
than inadequate wedge teeth hardness. Since
lubrication attracts sand and dust, wedge holes often
are not intentionally lubricated, but are required to
be clean.
C 4.1.3.7 Fatigue Tests of Strand-Wedge
Connections
Tendon fatigue considerations depend on the type of
structure and type of tendon, bonded or unbonded.
The strand-wedge connection is the most sensitive part
of a tendon in regards to fatigue resistance.
For prestressed concrete structures, one can
differentiate between fully and partially prestressed
structures. In this context,fully prestressed structures
are those, which are designed not to experience
concrete cracking at locations of high bending
moments, and actually do not have such cracks.
Partially prestressed structures, on the other hand,
may be permitted to have some cracks in high moment
areas under certain loading conditions.
Fully prestressed concrete structures are well suited
for resisting dynamic load cycling, as for instance in
railroad bridges. For such structures fatigue is not a
controlling criterion. Bonded and also unbonded
tendons experience only small stress changes along
their length as a result of load changes, since stress
changes in the concrete adjacent to the tendons, are
relatively small. Unbonded tendons experience
actually even smaller stress changes at locations of

31
SPECIFICATION COMMENTARY

high moments than bonded tendons, since the tendon

forces even out over the length ofthe tendons. On the
other hand, anchorages of unbonded tendons, and
their critical strand-wedge connections, experience
tendon force changes as a result ofload changes, but
those changes are smaller than force changes in
bonded tendons at locations of maximum concrete
stresses.
Fatigue to anchorages ofbonded tendons is normally
not a critical design consideration. For couplers on
the other hand, fatigue considerations apply
because of the concern with discontinuity· of the
prestressing force. Placing couplers at points of
critical stress should be avoided.
The fatigue conditions in partially prestressed
structures are similar to those in fully prestressed
structures, as far the anchorages and their strand­
wedge connections are concerned. However, the
tendon elements (strands or bars) of bonded tendons
at crack locations could experience, under
unfavorable conditions, potential fatigue conditions,
depending on the depth of the cracks, the range of
stress changes, and the number of load cycles.
Stress cycling, and the associated strain cycling, may
also cause fretting-fatigue damage, enhancing strand
fatigue effects where strand material is in contact
with other materials. Fretting is more likely to occur
in unbonded or external tendons which are subjected
to substantial stress changes in the strand. It can
occur at points oflarge side pressure between strands
and ducts. at deviators. at entrance and exit points
of strand flares, at anchorages, and at the toe of
wedges. (See also Commentary, Section C 5.4,
"Transition. ") Fretting damage is also possible under
dynamic loading cycles between a failed strand wire
and adjacent wires, or between peripheral wires and
the central wire. Awareness, that fretting may cause
fatigue damage in structures subjected to significant
fatigue inducing stress changes, can reduce or
eliminate fatigue problems by appropriate design and
hardware details.
Not all strands conforming to ASTM A 416 can be
expected to have identical fatigue characteristics.
Which type of strand is best suited for a structure
subjected to significantfatigue loading can be judged
from manufacturer:S- typical fatigue resistance test
data. A strand'sfatigue life as afunction ofthe stress
range at various medium stresses is useful
information.

32
 SPECIFICATION COMMENTARY

The 500,000 cycle dynamic testing required by

AASHTO(2), Section II - 10.3.2.2 follows industry
precedents. The required tests are non-destructive
and do not establish the fatigue life of the strand, or
of the strand-wedge connections. They reflect the
good experience record of prestressed structures to
resist fatigue loading. They also take into account,
that dynamic tests require special equipment and
are time consuming.
Single dynamic strand-wedge connection tests are
easier to perform than full sized tendon tests. They
also provide more reliable test results since test
sample length and installation inaccuracies have been
eliminated as variables. (See Commentary, Section
C 4.1.3.3 "Single strand-wedge connection tests. ")
4.2 Bar-Anchor Nut and Bar-Coupler C 4.2 Bar-Anchor Nut and Bar-Coupler
Connection Performance Requirements Connection Performance Requirements
Bar-anchor nut and bar-coupler connections shall be Bars normally have threaded connections to anchor
tested for each size, type, and grade. Number of tests nuts and couplers. Such connections rely on
are specified in Section 6.1.7. The following mechanical interlock and have only a few important
requirements shall be met: variables, such as: type of thread, engagement
length, dimensional tolerances, and material
strength. Their performance can be established
reliably by rational analysis and verified by small
test series. Three tests are specified in Section 6.1.7.
Requirement 4.2 (1)
(l) Bar connections shall support 100% ofbar MUTS The 100% MUTS requirement conforms to the
or 95% AUTS, whichever is larger. ASTM A 722 provision for coupled bars. The
95% AUTS requirement specified herein assures that
bar tendons have adequate ductility if actual bar
strength considerably exceeds MUTS. This
requirement is consistent with the AASHTO provision
for unbonded tendons to achieve 2% elongation l2i,
Section II - 10.3.2.2 and the requirement 4.1.3 (1) for
"single" strand-wedge connection tests.
Requirement 4.2 (2)
(2) Bar-coupler connections shall meet requirement This requirement reduces the probability ofpremature
4.2 (1), having at the center a I in. long coupler coupler pullout due to incorrect installation, if the
length which is not engaged. Mo spliced bar ends are not equally engaged. It is
good practice to mark the Mo bar ends at half the
coupler length plus lf4 in. (5 mm), both marks must
then be visible.
Requirement 4.2 (3)
(3) Anchor nuts shall permit a 5° misalignment This requirement takes into account that misalignment
between bar and bearing plate and still support beMeen a relatively stiff bar and its bearing plate
100% MUTS. may cause bending in the bar ifthe anchor nut has no
capability to swivel. Additional bending stresses in

33
 SPECIFICATION COMMENTARY

the bar, added to the tension stresses from prestress,

may cause a bar to break early.
Requirement 4.2 (4)
(4) For unbonded tendons under dynamic loading, This requirement conforms to the requirements of
the connections shall withstand at least 500,000 AASHTO(2J, Section II -10.3.2.2, and to the PT1 Guide
cycles from 60% to 66% of MUTS and thereafter Specification for Post- Tensioning Materials( J 1I,
at least 50 force cycles between 40% and 80% of Section 3.1.8 (2).
MUTS.

34
 SPECIFICATION COMMENTARY

5 SHEATHING C5 SHEATHING
Section 5 covers tendon ducts, sheathing for ground A variety of different types of sheathing are suited
anchors, transitions, and grouting attachments. This for post-tensioning systems, depending on the
Section does not cover monostrand sheathing. particular requirements of an application. Sheathing
and duct selection is mainly based on project related
requirements for installation and corrosion
protection, as expressed in project specifications.
Except for bond, sheathing has little effect on the
structural strength aspects of tendons, which
principally are addressed in this specification.
For additional information see C 5.6, "Duct
Information. "
5.1 Duct for Bonded Tendons C 5.1 Duct for Bonded Tendons
General Performance Requirements General Performance Requirements
Duct may be round, oval or flat. It may be made out of The type ofduct best suitedforan application depends
uncoated, galvanized, coated metal, or plastic. The on project related requirements. Post tensioning
type ofduct selected must be suitable for its application, systems are adaptable to various types of ducts. The
must meet the general performance requirements commentary below provides additional background
specified herein, as well as project specifications. information for evaluating which type of duct is best
suited for an application.
Requirement 5.1 (1)
(1) Duct shall have either spiral or concentric This requirement covers corrugated metal and plastic
corrugations. They shall be either spiral wound ducts. The ducts must have inside and outside
with tightly crimped joints or continuously corrugations to transfer bond stresses by mechanical
welded. interlockfrom the strand to the surrounding concrete.
Requirement 5.1 (2)
(2) Strand tendon duct shall have an inside cross­ This requirement specifies the minimum ratio of duct
sectional area large enough to accomplish strand area to strand's cross-sectional area, which is needed
installation and grouting. The clear duct area to accomplish strand installation. In practice it varies
shall be at least 200% of the strand's cross­ between 200% and 300%, depending on tendon size
sectional area. and length. AASHTO,(2) Section II - 10.8.3, specifies
a minimum ratio of 250% and normally this
requirement is obsen1ed. However, in case of space
limitations a minimum of 200% is acceptable for
short tendons with little curvature, provided it is
assured the duct will not dent and has no restrictions.
The Commentary, Section C 5.6 2, provides
information on typical duct diameters for the most
common strand tendon sizes.
Requirement 5.1 (3)
(3) Bar tendon duct inside diameter shall be at least This requirement takes into account, that bar tendons
1,4 in. (6 mm) larger than the bar diameter. At normally are preassembled inside small diameter
coupler locations the duct diameter shall be at ducts and placed as units. Alternatively, ducts are
least be J.A in. (6 mm) larger than the coupler installed with dummy bars to keep the duct straight,
diameter. as necessary to permit later bar tendon insertion.
Because bars fill most of the void they prevent duct
damage. Therefore, it is also adequate to provide 31
gauge metal ducts and 0.25 in. (6 mm) clearance for
grouting purposes.

35
 SPECIFICATION COMMENTARY

Requirement 5.1 (4)

(4) Duct installed and cast into concrete prior to This requirement provides performance criteria to
prestressing steel installation, must be capable to assure that duct has adequate resistance against
withstand at least 10 ft. (3 m) of concrete fluid damage. The 100 lb (0.45 KN) concentrated test
pressure. Also, such duct shall not dent more than requirement simulates realistic installation conditions
!fa in. (3 mm) under 100 lb. (0.45 kN) concentrated at duct rebar supports. Damaged duct, preventing
forces applied between corrugations. The strand installation, is a fairly common problem. To
concentrated force shall be applied by a #4 avoid such problems it is good practice to always
(#13) reinforcing bar. check each duct's clearance, prior to and again
shortly after placing concrete. (See also Requirement
7.2 (3).)

Requirement 5.1 (5)

(5) Duct for use with preinstalled prestressing steel, This requirement permits less rigid duct for
prior to concreting, shall be capable of preinstalled tendons, which can tolerate dents.
withstanding the equivalent of 5 ft. (1.5 m) of
concrete fluid pressure. Resistance to denting
required under 5.1 (4) is not applicable.
Requirement 5.1 (6)
(6) Duct shall have adequate longitudinal bending The maximum deflection performance requirements
stiffness for smooth, wobble free placement: have proven to be useful restrictions on the
longitudinal duct stiffness, which depends on:
a) Duct with more than 2 in. (50 mm) diameter
diameter, wall thickness, depth and spacing of
shall, under its own weight, not deflect more
corrugations, material properties, and for spiral
than 3 in. (75 mm), when a 20 ft. (6 m) duct
wound duct, on the tightness of the seams.
segment is supported at its ends.
b) Duct of 2 in. (50 mm) or smaller diameter
shall, under its own weight, not deflect more
than 3 in. (75 mm), when a 10 ft. (3 m) duct
segment is supported at its ends.
c) Where duct must be bent in a tight radius,
more flexible duct is permitted.
Requirement 5.1 (7)
(7) Plastic duct must withstand above specified This requirement takes into account that plastic duct
requirements at 1000 F (38 0 C), except that the when hot softens and looses stiffness. Especially for
longitudinal stiffness requirements 5.1 (6) may black duct under sun exposure this can become
be reduced by 50% if installation support spacing problematic. White material reflects the sunlight and
also is reduced by 50% from that required for does not heat up as quickly.
steel duct.
Above requirements 5.1 (4) to (7) do not apply for duct
stiffened with bars, mandrels, or inflatable tubes.
5.2 Duct for External Tendons C 5.2 Duct for External Tendons
Duct for external tendons, including their splices, Spiral wound duct does not satisfy these requirements.
shall be vapor tight, seamless or welded, and be Project specifications need to specify the type ofduct
capable of resisting at least 150 psi (l MPa) grout suitable to the environment. (For additional
pressure. The duct material must be resistant to the information on ducts see Commentary, Section C 5.6.1
particular environment it will be exposed to. to C 5.6.7.)

36
 SPECIFICATION COMMENTARY

5.3 Sheath for Ground Anchors C 5.3 Sheath for Ground Anchors
Sheath for ground anchors shall meet the requirements The main purpose for ground anchor sheathing is to
of the PTI publication "Recommendations for provide reliable long-term corrosion protection. The
Prestressed Rock and Soil Anchors" (13). PTl "Recommendationsfor Prestressed Rock and Soil
Anchors" (/3) specifically deals with ground anchor
requirements. AASHTO(2), Section 6, has similar
requirements.
5.4 Transition C 5.4 Transition
Transitions between ducts and wedge plates shall Most tendon systems have wedge plates with wedge
have adequate length to reduce the angle changes to holes parallel to the tendon axis. In such cases similar
such levels that the effect of angle change on the strand angle changes occur at the base of the wedge
performance of the strand-wedge connection, friction plate and at the joint between duct and transition.
losses at the anchorage, and fatigue strength is not Strand angle changes, especially at the base ofwedge
adversely effected. plates. can adversely effect the strand-wedge connec­
tions during stressing and later in fatigue. (See also,
Section C 4.1.3.7 "Fatigue Tests of Strand- Wedge
Connections. ")
The concentratedfriction caused by the angle change
within or directly behind the anchorage may also
cause stressing problems. Therefore, less than 5° angle
changes are desirable, effecting the length of the
transition.
The effect on strand angle changes on the strand­
wedge connection performance can be minimized if
a plastic spacer, of adequate thickness and material
strength, is placed directly infront ofthe wedge plate.
Such spacer deflects the strand in such a manner that
it enters the wedge plate parallel to the axis of the
wedge holes, reducing the effect of the strand angle
change within the transition length.
5.5 Grouting Attachments C 5.5 Grouting Attachments
Grouting and venting attachments, including seals This section covers accessories, which are necessary
between grout caps and anchors, must be capable of to accomplish the successful grouting operation of
holding at least 150 psi (1 MPa) pressure. bonded tendons. Most importantly, grout provides
long-term corrosion protection for prestressing steel
Provision for venting must be arranged in such a
and, therefore, must fill all voids and cover all
manner that all air and water can escape, assuring that
prestressing steel surfaces.
all voids in anchors and ducts can be filled with grout.
The grout must achieve adequate strength to fulfill its
Valves or plugs are required to close the grout tubes
structural purposes, bonding the prestressing steel to
and vents.
the surrounding concrete' and to enhance the effective
Grout tubes shall have at least '12 in. (12 mm) diameter cross sectional concrete area.
and must withstand 150 psi (1 MPa) pressure, larger
diameters may be used.

37
SPECIFICATION COMMENTARY

C5.6 Duct Information

C 5.6.1 Performance Requirements
for Ducts
Provide an unobstructed conduit for the
installation of tendons. (Duct must not collapse
under fluid concrete pressure, and must have
reasonable resistance against damage during
installation.)
Prevent bond between tendon and concrete
during stressing
Provide corrosion protection
Transfer shear stresses (bond)from surrounding
concrete through the cement grout to the strands
or bars.

C 5.6.2 Typical Strand Tendon Duct Sizes

0.5" Strand 0.6" Strand DuctID

(12.7mm) (15.24mm)
5 4 2"
(50mm)
12 9 2W't03"
(65 to 75 mm)
19 12 3" to 3Vz"
(75 to 90mm)
27 19 3W'to 4"
(90 to 100 mm)
31 22 4" to 4W'
100 to 115 mm)
34-38 24-27 4W' to 5"
(115 to130 mm)

Table C 5-1-Typical Tendon Duct Sizes

C 5.6.3 Metal Duct

Ductfor strand tendons normally is madefrom spiral­
wound galvanized sheet metal. Such duct is
semirigid. It has sufficient longitudinal stiffness to
achieve a smooth duct profile, but is flexible enough
to form common duct profiles without pre-bending.
The wall thickness varies with the duct diameter, depth
and spacing of spiral ribs, and sheet metal hardness.
It is determined by the requirement to resist fluid
concrete pressure, denting during handling and
installation, and damage from concentratedforces at
support points.
Typical ducts have wall thicknesses between 24 and
28 gauge (0.6 to 0.35 mm). AASHTOI21, Section II ­
/0.8.3, requires 26 gauge (0.45 mm)forduct less than

38
SPECIFICATION COMMENTARY

2% in. (65 mm) diameter, 24 gauge (0.6 mm) for duct

greater than 2% in. diameter. For preassembled bars
AASHTO allows a minimum of 31 gauge (0.25 mm)
thickness.
Spiral duct is normally grouttight but not necessarily
water or vaportight. Where watertight duct is
desirable, asfor external unbonded tendons, seamless
or welded duct is needed.
Most specifications require galvanized duct. The zinc
coating prevents duct corrosion and reduces friction
losses during stressing. Hydrogen generation by
chemical action between the zinc and fluid alkaline
cement grout normally is not a problem. However, in
a few instances, delayed prestressing steel failures
occurred during grouting when the prestressing steel
was especially susceptible to hydrogen embrittlement.
C 5.6.4 Plastic Duct
Plastic duct is normally used where special corrosion
protection is desirable, asfor ground anchors, bridge
decks; and external tendons. Bridge decks subjected
to deicing salt require special precautions against duct
corrosion and penetration of chlorides to the post­
tensioning steel. Such duct must not only be leaktight
but vaportight and impermeable to chloride ions..
Plastic duct is also used to avoid stray currents, which
could cause corrosion damage to tendon materials, a
demanding requirement.
The performance requirement for the duct 10 protect
the tendons from damaging external influences
requires, that plastic duct must not be damaged during
handling, installation and stressing. It is necessary
to evaluate those installation conditions to assure, that
the duct can perform as intended.
Plastic duct heated by sunlight gets soft and in cold
climate it may get brittle. Large thermal expansions
and contractions under temperature changes can
cause splices to disengage. Large radial tendonforces
in curved ducts tend to deform, or even cut through
the duct wall. It is necessary 10 limit radial forces
bearing on plastic duct. Bearing values on HDPE
duct ofless than 250 lb/in (44 N/mm), as exerted by a
single strand on the duct wall material, may be
acceptable. However, the performance ofa particular
duct is best determined by representative tests, which
also must simulate the abrasion caused by the
prestressing steel during stressing. Also, the strand
installation method must be carefully planned to avoid

39
SPECIFICATION COMMENTARY

duct damage. For instance, pulling large and long

cables into the duct is likely to cause abrasion
damage. Pushing individual strands at high speed
into the duct requires special bullets for capping the
strand ends, to prevent their hang up in duct
deformations and tearing them apart. Plastic duct
normally also has limited strength to resist large fluid
concrete pressures, which may require mandrels, or
inflatable tubes, to prevent duct collapse.
C 5.6.5 Typical Plastic Material Properties
The most common materials for plastic ducts are
HDPE, HDPP, and PVc. Their properties vary
considerably, depending on compositions.
The Table C 5-2 provides approximate guide values
for typical properties for HDPE and PVc.

HDPE PVC
Specific gravity 0.95 1.4
Density [g/mm 3 ] 0.95 x 10­ 1.4 X 10-3
Tensile stress [ksi] 3 6
[MPa] 21 42
Modulus [ksi] 80 360
[MPa] 550 2500
Safe stress* '. [hi] 0.7 1.6
{MPa] 5 11
Thermal [in/inJOF] 110 x 10-6 40x 10-6
Expansion [mm/mm/°C] 200 x 10- 6 72 X 10-6

Table C 5-2-Typical HDPE and PVC Properties

* The safe stresses listed above provide approximate
design values, reflecting the susceptibility of the
plastics to temperature effects and creep rupture.
Values herein arefrom the British Standard Institution,
Code of Practice 312.
C5.6.6 HDPE
Material suitable for post-tensioning duct is covered
by ASTM D3350, cell classifications 324422C to
445534C. The "C" describes black material with 2%
minimum carbon as U. V. stabilizer. The relatively low
density and strength of such ducts and related
susceptibility to damage during installation requires
caution, especially for large, long, or curved ducts.
The large thermal expansion of HDPE duct, relative
to the approximately 6xlO- 6 in/in/oF (11 xlO- 6
mm/mm/O°C) of steel or concrete, may require long

40
SPECIFICATION' COMMENfARY

couplers to compensate for temperature differences

between night and day. Softening of the plastic when
hot may cause undesirable sagging between support
points and denting at support points. HDPE ducts
should be hung from support bars in lieu of resting
on top of support bars to reduce the incidence of
damage. Using reflective white or natural color duct,
instead of the more ultraviolet light resistant black
material, has proven to reduce duct temperatures
when duct is exposed to sunlight prior to concrete
placement.

C 5.6.7 PVC
Material suitable for post-tensioning application is
covered by ASTM D1784, cell classification range
12344-B to 13466-B. (For water pipe the typical
classification is 12454-B). PVC has about twice the
strength of HDPE and about one third its thermal
expansion. It performs well as tendon duct material,
except for those rare cases were exposure to fire is a
concern.
Ifexposed to fire, PVC may develop hydrochloric acid,
which could produce stress corrosion problems.
Otherwise, the chloride in the PVC is chemically
bound by polymerization and, therefore, not
detrimental to the prestressing steel. At cold
temperatures PVC duct becomes more brittle than
HDPE. Testing such duct for impact resistance at low
temperatures is advisable if cold temperatures are
anticipated.

41
 SPECIFICATION COMMENTARY

6 QUALIFICAnON TESTS C6 QUALIFICATION TESTS

Section 6.1 specifies the required number of com­ Qualification tests are required for each tendon
ponent tests and Section 6.2 the system tests. All tests component in order to establish each components
shall be performed at established independent performance characteristics. The system qualification
laboratories acceptable to the owner or engineer of test assures that the components as a tendon unit will
record, or they shall be witnessed and certified by a perform as required, including the stressing
laboratory's representative if they are performed at the equipment.
supplier's or manufacturer's facility. The tests shall
meet the applicable minimum requirements of this
specification. All tests shall be documented and records
kept on file for future reference.
If a system has been thoroughly tested to meet
equivalent FlP, national or regional standards, then it
shall be permitted to substitute those tests for the
qualification tests required herein, provided it can be
shown, that their minimum requirements are
equivalent.
6.1 Number of Required Component C 6.1 Number of Required Component
Qualification Tests Qualification Tests
6.1.1 Strand Tests C 6.1.1 Strand Tests
Three successful qualification tests on typical strand See Commentary, Section C 2.1.
samples for each size, grade, and manufacturer-with
each sample taken from a different coil-shall establish
that the mechanical and relaxation properties are in
conformance with the current ASTM A 416
specification, as required by Section 2.1.
6.1.2 Bar Tests C 6.1.2 Bar Tests
Three successful qualification tests for each size, See Commentary, Section C 2.2.
grade and manufacturer-with each sample taken
from a different heat-shall establish that mechanical
material properties are in conformance with the current
ASTM A 722 specification, as required by Section
2.2.
6.1.3 Special Prestressing Material Tests C 6.1.3 Special Prestressing Material Tests
Successful qualification tests for special materials, This specification is open to new products, which
which may become available, shall establish proof advancing technology may offer, provided all their
that those materials have equal or better characteristics characteristics are well understood and long term
than materials conforming to ASTM A 416 or A 722. performance can be assured.
Section 2.3 provides guidelines for testing
requirements.
6.1.4 Bearing Plate Tests C 6.1.4 Bearing Plate Tests
Three successful qualification tests for special bearing To achieve the required minimum test of 120% MUTS
plates per tendon size shall establish that they meet of Section 3.2.2, it is necessary to perform the tests in
the requirements of Section 3.2. Each of the samples a testing apparatus with adequate capacity, or to use
shall be taken from a different heat. (Basic bearing an oversized tendon, which must simulate the trans­
plates meeting requirements of Section 3.1, do not fer from the wedge plate, or anchor nut, to the bear­
require qualification tests.) ing plate of the standard tendon.

42
 SPECIFICATION COMMENTARY

6.1.5 Wedge Plate Tests C 6.1.5 Wedge Plate Tests

Three successful qualification tests on wedge plates See Commentary, Section C 4.1.1 for test procedure.
for each tendon size, shall establish that they will meet
the requirements of Section 4.1.1. Each sample shall
be taken from a different heat.
6.1.6 Strand-Wedge Connection Tests C 6.1.6 Strand-Wedge Connection Tests
Tests on single strand-wedge connection samples­
for each typical strand, wedge and wedge hole
combination-shall meet the requirements herein.
Requirement 6.1.6 (1)
(1) Static tests for bonded and unbonded systems: Single static strand-wedge connection failure tests are
Each test sample of a series of at least thirty easily accomplished and provide meaningful results.
consecutive tests shall establish conformance to Because of the many variables effecting such
Section 4.1.3, (1). The tests shall be performed connection, it is necessary to perform relatively large
using identical hardware and test procedures, test series for each combination of variables. (See
except that fifteen tests shall be done on lubricated Commentary, Section C 4.1.3.3, "Single Strand­
wedge holes and the other fifteen tests on non­ Wedge Connection Tests," and Section C 4.1.3.5,
lubricated, rough wedge holes. "Actual Ultimate Tensile Strength. ")
Requirement 6.1.6 (2)
(2) Dynamic tests for unbonded systems: See Commentary, Section C 2.1.6, "Fatigue of
Four consecutive tests shall meet the requirements Strand," and Section C 4.1.3.7, "Fatigue Tests of
of Section 4.1.3, (2). The tests shall be performed Strand-Wedge Connections. "
using identical hardware and test procedures,
except that two tests shall be done on lubricated
wedge holes and the other two tests on non­
lubricated, dry wedge holes.
6.1.7 Bar Connection to Anchor Nut and C 6.1.7 Bar Connection to Anchor Nut and
Coupler Tests Coupler Tests
Three successful tests, on each size and type of bar The normally threaded connections to nuts and
nut connection and bar coupler connection, shall couplers rely on positive mechanical interlock. Such
establish conformance to the requirements herein. connections can be designed by rational analysis and
Each test bar, nut or coupler shall come from a have only a few variables-as size and material
different heat or lot. Test samples may combine anchor tolerances, and engagement length. The performance
nut and coupler. of such connections can reliably be established by
series of three test, as specified herein. Should bars
(1) Static tests for bonded and unbonded systems:
be anchored by wedge connections the more frequent
Three identical consecutive tests shall meet the
test requirements for wedge strand connections should
requirements of Section 4.2, (I) to (3).
be used.
(2) Dynamic tests for unbonded systems:
Three identical consecutive tests shall meet the
requirement of Section 4.2, (4).
6.1.8 Duct Tests
Three successful successive qualification tests for
each type of duct shall show conformance to the
requirements of Section 5, as applicable. The supplier
shall perform these tests at an established independent
laboratory acceptable to the owner or engineer of
record, or have them witnessed by a representative of
such a laboratory.

43
 SPECIFICATION COMMENTARY

6.2 System Qualification C 6.2 System Qualification

Tests Tests

6.2.1 Static System Qualification Test C 6.2.1 Static System Qualification Test
for Bonded and Unbonded Systems for Bonded and Unhonded Systems
For each tendon size one qualification test is required Static system tests demonstrate that all tendon system
of a representative full size tendon embedded in a components, including jacking equipment, perform as
concrete block. The test shall establish that all tendon a unit under working conditions. The full sized tendon
parts including reinforcing bars in the local zone, such system tests can only be performed to 95% MUTS,
as spirals, orthogonal and surface reinforcing bars, because the normal tendon anchorage efficiency sets
will perform as required. The test force shall be this limit. Such tests, therefore, do not establish the
applied by the system specific jacking equipment, safety margins against failure. Those margins are
establishing its suitability. established by the destructive component tests
specified in Sections 6.1.4 to 6.1.7 (for bearing plates,
(1) Test block size shall conform to requirements of
local zones, wedge plates, single strand-wedge
Section 3.2.1.
connections, and for the equivalent bar tendon
(2) Test procedure shall conform to requirements of components). Because of these component tests a
Section 3.2.2, except that after the jacking force single system test is adequate.
has been increased to 80% MUTS the force shall
(See also Commentary, Section C 4.1.3.4, "Multi­
be further increased to at least 95% MUTS.
Strand Tendon Tests. ")
(3) Concrete crack sizes shall conform to
requirements of Section 3.2.3.

6.2.2 Dynamic System Qualification Test C 6.2.2 Dynamic System Qualification

for Unbonded Systems Test for Unhonded Systems
For each tendon size one qualification test is required This Section meets the requirements for unbonded
ofarepresentative full size tendon, including anchorage tendons of the "PTl Guide Specifications for Post­
assembly and coupler, if couplers are used. The tendon Tensioning" (II), and of AASHTO(2), Section
shall withstand, without failure, 500,000 cycles from 1I-10.3.2.2. Full sized tendon tests for each size are
60% to 66% MlJTS, and also 50 cycles from 40% to necessary. Adequacy of wedge plates and couplers,
80% MUTS. can not be established on scaled down tendons. The
one system test is supplemented by the required 4 or
3 dynamic tests on single strand or bar samples.
(Requirements 6.1.6 (2) and 6.1.7 (2).

44
 SPECIFICATION COMMENTARY

7 INSTALLAnON EQUIPMENT C7 INSTALLATION EQUIPMENT

This section provides general requirements for system Stressing equipment is system related. A jack
related jacking equipment, and equipment for designed for one particular system is unlikely to fit
installation, stressing, and grouting. another without major modifications.· The design of
the tendon anchorage assembly has to be
coordinated with the design of the jack chair, wedge
seating devices, tube bundles, and automatic or
manual jack stressing heads.
Strand installation and grouting equipment on the
other hand are not system dependent.
7.1 Stressing Equipment C7.I Stressing Equipment
Jacks shall meet the following requirements:
Requirements 7.1 (l) and (2)
(I) Stressing equipment shall be capable to produce Requirement 7.1 (1) assures that jacks can safely and
jacking forces of at least 80% of tendon MUTS. routinely produce the operating pressures necessary
to produce temporary jacking forces of 80% tendon
(2) Jacking force test capacity shall be at least 95% of
MUTS. A jack, which can not safely withstand the
tendon MUTS.
95% MUTS system test, has inadequate safety margins
for normal tendon stressing operations.
Requirement 7.1 (3)
(3) Jack cylinder area shall be permanently identified This requirement permits an easy and reliable field
on the jack. check. Serious stressing problems can be prevented if
operating personnel routinely compares the
calibration charts with on site calculation:
Pressure = Jacking Force / Jack Area.
Under normal conditions jack friction losses at Pjack
amount to only about 2 to 3% , which can be factored
into the simple computations.
Requirements 7.1 (4),(5), and (6)
(4) Wedge seating methods shall assure uniform Proper strand anchoring requires that wedges
seating of wedge segments and uniform wedge segments seat equally. Power seating is the most
seating losses on all tendon strands. effective method to achieve this and simultaneously
to control seating losses.
(5) Accumulation ofdifferential seating losses during During power seating the wedge segments are
cycling must be prevented by proper devices. uniformly pushed with moderate forces into the wedge
holes in order to engage the strands. Thereafter the
(6) Jacks used for stressing tendons less than 20 ft. jack pressure is released and the strain energy in the
(6 m) in length shall have wedge power seating strands pulls the wedges deeper into the wedge holes.
capability. This wedge movement produces the clamping forces
to anchor the strands by friction. With power seating
the tendon prestress force seating losses are kept
small. The power seating losses normally will be
equivalent to less than 0.25 in. (6 mm) reduction of
strand elongation.
When stressing without power seating, a retainer plate
restricts outward wedge movement during jacking to
0.25 to 0.375 in. (6 to 9 mm), which is adequate

45
 SPECIFICATION COMMENTARY

for the strand to slip through the wedges as they

elongate. When the jacking force is released the
strands pull the wedge segments back into the wedge
hole, to anchor the strand by friction. This operation
depends on how uniform the strands grab the wedge
segments and how uniform they are pulled back into
the wedge holes. Seating losses between 0.25 and
0.375 in. (6 to 9 mm) normally occur. Project
specifications sometimes make allowance for 0.625
in. (16 mm) average seating losses.
Seating losses normally are not significant, exceptfor
short tendons, which preferably are stressed with jacks
having power seating capability. In long tendons,
which require several stressing cycles, unequal seating
losses between the strands of multi-strand tendon
can accumulate if improper equipment or procedures
are used. This may result in unequal stresses in
strands, overstressing some.
Requirements 7.1 (7) and (8)
(7) Hydraulic power units shall have pressure relief Pressure relief valves are needed for safety reasons,
and check valves to hold the pressure. especially important for jacks with large stress to
return area ratios. A blocked hose connection on the
(8) Hydraulic flow controls shall have features for return side can cause rupture of a jack during
fine adjustment. stressing. A check valve is needed for controlled
stressing and seating. Flow control devices are needed
for controlled stressing and seating operations.
Requirement 7.1 (9)
(9) Hydraulic hoses and fittings shall have a static Stressing equipment operates at high pressures,
bursting pressure at least 4 times the maximum between 5,000 and 10,000 psi (34.5 to 68.5 MPa).
operating pressure. The required safety factor for static pressure of 4 is
standard industrial requirement, it relates to a safety
factor of 2 for dynamic pressure surges.
Requirement 7.1 (10)
(I 0) Gauges shall be at least 6 in. (ISO mm) in 6 in. (150 mm) diameter gauges usually are required
diameter and the display shall be in 100 psi (0.5 by applicable specifications to assure adequate
MPa) increments. reading accuracy.
Requirements 7.1 (11) and (12)
(II) Gauges shall be calibrated (independent of the It is good practice to calibrate gauges to read true
jacks) to read actual pressures at the expected pressures at expected maximum jacking pressures
maximum pressure range. prior to calibrating jacks and gauges as a units. Such
practice allows verification ofcalibration documents,
(I2) Jacks and pre-calibrated gauges shall be and allows gauge replacement. (See also require­
calibrated together as units at least once every ment 7.1 (3).)
six moth and internal friction shall be determined.

7.2 Strand Installation Equipment C 7.2 Strand Installation Equipment

Strands may be installed by pulling or pushing. Pulling Strands are normally installed after concrete
and pushing equipment is not system related. placement, either by pulling preassembled tendons

46
 SPECIFICATION COMMENTARY

Any equipment capable ofperforming the task may be with a win. into the ducts, or by pushing individual
used, provided it does not damage the strands and the strands with a pusher into the ducts.
following requirements are adhered to:
Requirement 7.2 ( 1)
(1) Pulling lines shall have a capacity of at least For safety reasons win. lines must have adequate
2.5 times the dead weight of the tendons when safety margins to assure that they will not break and
used for essentially horizontal tendon installation. endanger the }\lorkmen. Required pulling forces
Where actual weight of the tendon needs to be depend mainly onfriction resistance along the strand
lifted, as in vertical installations, the factor of bundle, the inclination of the structure, and angle
safety on the win. line shall follow applicable changes. Normally, tendons are installed more or less
OSHA safety requirements. horizontally, the usual safety factor of 5 for lifting
cables is then not applicable and can be reduced to
2.5. When tendons are lifted vertically the applicable
safety factor of5 for lifting cables is applicable.
Requirement 7.2 (2)
(2) Pushing wheels made from metal shall not be Pushers insert strand at high speeds, relying on the
used. momentum of the strand mass to overcome friction
losses. When strands meet a blockage the pushing
wheels may slide at high velocity on the strand. Under
such conditions metal wheels driving the cables can
cause heat damage to the strand and are, therefore,
not suitable.
Requirement 7.2 (3)
(3) Bullets for checking duct clearance prior to Damaged ducts cause strand installation problems
concreting shall be rigid and be '/s in. (3 mm) and responsibility conflicts between duct installer and
smaller than the inside duct diameter. Bullets for those trades placing reinforcing bars, formwork and
checking duct after concreting shall be not smaller concrete. Responsibility conflicts can be avoided if
than 1,4 in. (6 mm) of inside duct diameter. each trade checks duct clearances after its work is
completed and performs the necessary repair work.
Experience has shown, that it is prudent for the post­
tensioning system installer to check duct clearances
after completion ofduct installation, but prior to com­
pletingformwork and again after concrete placement.
Because ducts deform under concrete pressure (round
ducts may get slightly oval) different bullet diameters
for the two checks are advisable.
7.3 Grouting Equipment C 7.3 Grouting Equipment
Grouting equipment shall be capable of properly The type and capacity ofgrouting equipment depends
mixing a water and portland cement grout having a on project requirements, as: tendon size, length,
water-cement weight ratio of 0.46. Equipment shall number of tendons to be grouted, temperature, and
be capable of pumping at pressures up to 200 psi access for equipment and operators.
(1.4 MPa). Standby equipment for flushing must be
available.

A new PTI "Guide Specification for Grouting of

Post-Tensioned Structures" is currently under
development. This document, scheduled for
publication in early 1999, win provide additional
information on grouting and grouting equipment.

47
48
:.;.' - ".'<'

Index

A ductility 14
E-modulus 14
AASHfO fatigue 14
1,4, 18,20,21,22,24,27,29,33,34,35,37, heating 15
38, 39, 44 hydrogen embrittlement 14, 39
Actual Ultimate Tensile Strength. See AUTS notch sensitivity 14
Anchor. See Ground anchor; Tendon relaxation 14
Anchor nut 2 stress corrosion 14
Anchorage assembly 2. tensile strength. See AUTS; MUTS
See also Anchor nut; Bearing plate; Grouting weldability 14
attachments; Transition; Wedge; Wedge plate specifications. See Specifications
Anchorage zone 3. tests 42
See also General zone; Local zone type. See ASTM A 722
responsibility 4 I, plain 14
ASTM II, deformed 14
A 416 1,8,10, 11, 12, 16,27,42 Bar connection 33-34
A 421 16 coupler engagement 33
A 475 12 coupier installation 33
A64112 ductility 33
A 722 1,14,33,42 nut alignment 33
A 882 1,8, 13 tests
A 886 1,8 dynamic 34, 43
D 1784 41 number 33, 43
D 3350 40 requirements 33
AUTS 29,30,33. static 33, 43
See also MUTS threaded 33
bar 3,33 variables 33, 43
definition 3 Basic bearing plate 17-20.
strand 3,27,29,30,31 See also Bearing plate; Special bearing plate
tendon 3 allowable stresses
at jacking force 19
B average bearing stress 19
Bar 14-16 bearing 18
corrosion. See Corrosion protection light weight concrete 19
coupler. See Bar connection normal weight concrete 19
grade 14 wedge plate bearing stress 20
manufacture area
cold deformed 14 gross 18
cold drawn 15 net 18
cold stressed 14 rectangular 3
defects 14 round 3
galvanizing 15 square 3
hot rolled 14 confinement reinforcement 3, 19.
process 14 See also Duct: plastic: HDPE
proof loading 14 definition 3
stress relieved 14 design 17
nut. See Bar connection design equations
properties bearing 18
bending 14, 33 bending 18, 19
bond 14 stiffness 19

49
 distribution area ] 8 D
loca] zone. See Local zone
notations 17 Duct. See Sheathing
requirements ]7 corrugation 35
testing 17 damage 36
Bearing plate 17-22. definition 4
See also Basic bearing plate; Special bearing for bar tendon 35
plate for bonded tendons 35
closely spaced 18 for external tendons 36
concrete for ground anchors 37
light weight 18, 19 for preinstalled tendon 36
normal weight 18 for strand tendon 35
definition 3 galvanized 39
distribution area ]8 HOPE 40
edge distance. See Edge distance mandrel 36
local zone 18 plastic 39.
multiple plane. See Special bearing plate See also Materials
reinforcement 18 color 36,41
safety factor 17 curved 39
Bond. See Bars; Ground anchor HOPE 40
Bond-anchor. See Strand: anchorage: bond properties 40
Breaking strength. See AUTS; MUTS; Tensile PVC 40
strength side pressure 39
Bursting forces 4 support 41
temperature 36, 41
c tests 39
PVC 41
Calibration. See Equipment
requirements, 38
Carbon fiber 16
bond 35, 38
CEB-FlP 2
concrete pressure 36
Concrete
corrosion 38
cover. See Edge distance
denting 36
crack 22
installation 38
width limitation 22
shape 35
cylinder strength ]7
size 35
test block. See Special bearing plate
stiffness 36
light weight 18, 19, 21
wall thickness 38
normal weight 18, 21
wobble 36
Confinement reinforcement 3
tests 43
basic bearing plate 19
number 43
Connections 24-34
type 35
bar-anchor nut 33
typical sizes 38
bar coupler 33
Ductile iron. See Material
strand-wedge 24
Corrosion E
protection II, 16
duct 35,39 Edge distance 4, 18, 20, 23
epoxy coating 13 Epoxy coated strand. See Strand: epoxy coated
for bars ]5 Equipment 45-47
galvanizing 12, 15 grouting 47
packaging strand 11 installation 46
project requirement. See Specifications: special duct bullets 47
conditions pulling lines 47
stress corrosion 6 pushing wheels 47
Cracks. See Concrete; Wedges stressing 45

50
 calibration 46 L
hydraulic 46
hydraulic hoses 46 Local zone.
power seating 13, 45 See also General zone
pressure gages 46 definition 4
testing 45 dimensions 20
wedge seating 45 reinforcement 5,20,21
responsibility 4.
F See also Anchorage zone: responsibility
special bearing plate 5
Fatigue 10, 31. width 4
See also Strand: fatigue
FIP 9 M
G Material
ductile iron
Galvanized Strand. See Strand: galvanized special bearing plate 20
General zone 4.
wedge plate 24
See also Local zone prestressing material
responsibility 4 definition 6
Glass fiber 16 special prestressing materials
Greased and plastic coated strand. See Strand:
carbon fiber 16
greased, plastic coated glass fiber 16
Ground anchor tests 42
bond length 9 wire 16
definition 4
MUTS
sheath 37 8, 18, 19,22,24,29,30,42,44,45.
Grouting attachments 37 See also A UTS
grout caps 37
bar 33,34
grout tubes 37 definition 5
pressure 37 strand 8, 24, 29
venting 37
p
H
Packaging. See Corrosion: protection
HDPE (High Density Polyethylene) Poly vinyl chloride (PVC)
classification 40 classification 41
properties 40 fire exposure 41
Hydrogen embrittlement 39. properties 40
See also Strand Polyethylene. See HDPE
definition 4 Post-Tensioning Institute (PTI) 2
I Post-tensioning system. See Tendon
definition 6
Installation Prestressing Material. See Bar; Strand
equipment. See Equipment special 16
Project. See Specification: special conditions
J Proof loading. See BAR
Jack 45.
Q
See also Stressing: equipment
Jacking force 19. Qualification tests 42-44.
See also Stressing See also Testing
system
K bonded tendon 44
Kevlar 16 number 44
static 44
unbonded tendon 44

51
R corrosion protection 11.
See also Corrosion
References 1 epoxy coated 13
Reinforcement confinement. installation 13
See Local zone stressing 13
Rust. See Corrosion types 13
wedges 13
s fatigue 10, 31
Safety factor galvanized 12
bearing plate 4, 17,22 availability 12
tendon 44 coating thickness 12
wedge plate 24 grade 240 12
Sheathing 35-41. grade 270 12
See also Duct produced from 13
definition 6 properties 12
Special bearing plate 20-22. specifications 12
See also Basic bearing plate wedges 13
analysis 20 greased, plastic coated 12
confinement reinforcement 3 packaging 11
definition 6 properties
ductile iron 20 bending 10
multi plane 5, 20 bond 9
safety factor 4, 22 fatigue 9, 10
test block 20 hardness 28
concrete strength 21 hydrogen embrittelement 10
cracks 22 manufacturing 8
depth 20 nominal 5
length 21 notches 10, 28
reinforcement 21 pitch 9, 10, 28
requirements 20 quality 9
width 20 rust 10
test procedure 21-47 side pressure 10
testing 20 size 28
acceptance criteria 22 stability 8
dynamic 17 stiffness 8
equipment 22 straightness 8
failure mode 4, 22 stress corrosion 10
number of tests 20 surface 9
static (monotonic) 21 tensile. See AUTS; MUTS
Specifications. See ASTM tensile strength 28
bar 14, 15 workability 9
corrosion 11 slip 8
duct 35,36 tests
responsibility 11 bond 9
strand 8, 9, 10, 11 requirements 42
Stay Cable 9 tolerances
Strand 8-13, 28. stress range 5
See also ASTM A 416 Strand-wedge connection 24-33.
anchorage See also Strand; Wedge; Wedge plate
bond 9 bonded tendons 28
loop 9 efficiency 29, 30
wedges 13. fatigue 8, 31
See also Strand-wedge connection requirements 28
wire cage 9 strand flare 9, 10,29,37

52
 strand slip 8,25,31 minimum ultimate. See MUTS
testing 27 Test block 20.
dry wedge holes 27 See also Special Bearing Plate
dynamic 27, 43 Testing
lubricated wedges 27, 31 number of component tests
number 27,43 bar 42
requirements 27 bar, coupler connection 43
single strands 26,27,30,43 basic bearing plate 42
static 27, 43 duct 43
tolerances 8 requirements 42
unbonded tendons 28 special bearing plate 42
variables 26, 28, 29 special prestressing materials 42
wire breaks 8, 31 strand 42
Stress corrosion. See Corrosion strand-wedge connection 43
bar 14 wedge plate 43
definition 6 system, tendon 26, 30, 44
strand 11 dynamic 44
testing 10 number 44
Stresses. See Tensile strength short 30
allowable for basic bearing plate 18 unbonded tendon 44
Hertz 20 Transition 37
nominal 5 requirements 9,37
Stressing. See Equipment
post blocking 13 w
seating losses 30
Wedge 25.
short tendon 30 See also Strand-wedge connection
Stressing equipment
cracks 26, 27
testing 22
definition 7
T ductility 26
hardness 26
Tendon 10 properties 28
anchorage. See Anchorage assembly; Strand­quality control 25
wedge connection requirements 25,27
fixed end 9 test samples 25
curvature 10 typical 25
definition 6 Wedge plate 24
duct 35. definition 7
See also Duct ductile iron 24
elongation 29 properties 28
flare 29, 30, 37 round, equivalent 19
force 17 safety factor 24
breaking 30 tendon
minimum ultimate 5 unbonded 24
ultimate strength 5 testing
installation. See Duct: size acceptance criteria 24
stressing. See Stressing deflection 24
tests dynamic 24
dynamic 27,29,32,44 failure mode 24
full size 27, 44 number 43
single strand 27, 44 procedure 24
static 32, 44 static 24
Tensile strength Wire. See ASTM A 421
actual ultimate. See A UTS

53