Post tensioning company method statement | shivforce.in

Method Statement for SF Post Tensioning System (SFEC/WP/01)
1
SF ENGINEERING SYSTEMS (INDIA) PVT LTD
PROJECT :
REVISION :
DATE :
Checked by : Approved by :
Mr. S. Durai Pandian
(Executive Director)
1
PROJECT :
REVISION :
DATE :
1
PROJECT :
REVISION :
DATE :

2
METHOD STATEMENT
CONTENTS
1 General 3
2 Scope of Work 3
3 References 3
4 Design data 4
5 Handling and storage of materials 4
6 General work procedure 5
7 Installation Procedure 5
8 Stressing Procedures 7
9 Grouting Procedure 12
Annexure 1 P.T Work Sequence- flowchart 16
Annexure 2 P.T Components and Equipments 21
Annexure 3 Checklist 28
Annexure 4 Admixture 32
Annexure 5 Safety 35
Annexure 6 Quality Assurance Policy (QAP) 39
2
METHOD STATEMENT
CONTENTS
1 General 3
2 Scope of Work 3
3 References 3
4 Design data 4
2
METHOD STATEMENT
CONTENTS
1 General 3
2 Scope of Work 3
3 References 3
4 Design data 4

3
1. General:
SF Post Tensioning Systems are developed and maintained by SF
Engineering Systems (India) Pvt Ltd.
Our systems comply with international specifications and recommendations
e.g. BS, EUROCODE, FIP, IS CODE, etc. The quality of SF products and
services is in full compliance with the above.
This method statement has been developed to provide a clear guidance for
all individuals involved in the project in using SF systems which covers the
installation, stressing and grouting activity.
2. Scope of work:
a) Supply of required Pre stressing components like anchorage head, Wedge
Plates, Sheathing, Wedges and miscellaneous materials as per the
specification.
b) Assembling of tendon units in the Post Tensioning slab
according to the drawings provided.
c) Supplying necessary hydraulic jacks & stressing all the
tendons to the required pressure
d) Supplying the grout pump & complete grouting all the tendons.
e) To verify the quality of Pre stressing components delivered
to site & ensure that the entire process is done as per the
specification.
3. References:
Drawing no
Design Report
Prestressing notes and procedure.
Codal provision (IS 1343: 2012 , IS 456 : 2000, BS 8110)
3
1. General:
2. Scope of work:
specification.
specification.
3. References:
Drawing no
Design Report
3
1. General:
2. Scope of work:
specification.
specification.
3. References:
Drawing no
Design Report

4
4. Design data:
Coefficient of Friction (µ) 0.2 (As per Consultant Requirement)
Wobble Factor (k) 0.0017 / m
Draw in wedge 6mm
Stressing Anchorage Flat Anchorage , Multi Anchorage
Loss in Jack 2% (Varies from 0 – 2)
5. Handling and storage of materials:
a) The pre-stressing strands shall be free of grease and corrosion enhancing
materials.
b) No flame cutting of strands is allowed.
c) Care should be taken in the handling of strands in order to avoid
mechanical damage to the strands.
d) Strands should be raised above ground to avoid contamination.
e) Webbing slings shall be used for loading and unloading in order to avoid
mechanical damage to the strand coils.
f) All Post Tensioning components must be handled and stored such that any
contamination, mechanical damage or corrosion can be avoided.
4
4. Design data:
Draw in wedge 6mm
materials.
4
4. Design data:
Draw in wedge 6mm
materials.

5
6. General Work Procedures:
6.1 Pre requisite for commencement of P.T Activity:
a) Shuttering work for the intended P.T slab to be casted
has to be made ready in all respect.
b) Bottom layer of the slab reinforcement & perimeter RCC
beam reinforcement has to be in place / fabricated in
accordance with the approved drawing.
c) Required numbers of pre fabricated bar chairs &
bursting links should be made available
6.2 Preparation:
a) H.T Strand will be uncoiled using coil dispenser.
b) Ensure the straightness of the strand and cut the
strand as per the required length using disc Cutter /
cutting Wheel.
7. Installation Procedures:
For PT Slab Tendons:
 Mark the anchorage position onto the reinforcement links / bottom
shuttering as per the approved tendon profile drawing.
 Secure the anchorage head (pre assembled with recess former) either by
placing of horizontal support bars across the links (if required) or by tying
directly to the top reinforcement bars of perimeter RCC beam.
 Lay the empty GI sheathing in one direction and joint them with the
couplers & connect the same with the anchorage head to form a tendon.
 Care should be taken to avoid other trade laborers stepping on to the
empty sheathing laid / formed tendons.
5
6.2 Preparation:
cutting Wheel.
5
6.2 Preparation:
cutting Wheel.

6
 Inserting in / threading of strands into the empty sheathing will be
commenced.
 Ensure enough stressing length (400mm) of strand has been allowed to
protrude outside the perimeter RCC beam.
 Make bulb on to the other end of the strand to form as the dead end of
the tendon.
 Mark the profile of the other direction tendons at the crossover points
either on the shuttering / upon the tendon already laid.
 Lay the empty GI sheathing in other direction and joint them with the
 Ensure the layer of tendons as per the profile drawing is achieved on site.
 Seal off all the coupler joints of sheathing laid with the help of OPP tape to
ensure the cement slurry shall not ingresses through these joints.
 As per the approved tendon profile drawing, elevate the assembled
tendons to the required height with the help of the bar chairs & secure
them with the binding wires.
 Spread the bulb formed strands at the dead end to have 450mm in width
& tie them on to a horizontal bar resting on the required profile bar chair.
 Erect the side shuttering with holes for protruding strands & complete the
same to receive concrete.
For PT Beam Tendons:
 Install bottom reinforcements, side reinforcements and shear links. But no
capping links shall be installed till the commencement of tendon
installation.
 Install tendons in accordance with the shop drawings.
 Install top reinforcements and capping links of the beam.
6
commenced.
the tendon.
installation.
6
commenced.
the tendon.
installation.

7
7.1 Tolerance:
Vertical Tendon Profile ± 5mm (For High and Low Points)
Horizontal Tendon Profile ± 150mm (To avoid M& E openings)
Note:
Designer shall be consulted for tolerance more than ± 150mm.
7.2 Points to be taken care while Concreting:
 Care should be taken to ensure that the sheathing does not get
damaged during concreting.
 All the strands projecting outside the slab will be covered with an
empty short sheathing to protect it from the spilled concrete falling on
to it.
 Ensure the minimum grade of concrete for Post – Tensioning work
should be M – 35.
8. Stressing Procedures:
Stressing shall not commence unless the main contractor has confirmed the
member has achieved its minimum cube strength at transfer stage.
Compressive strength required for commencing the stressing activity shall be
minimum 27N/mm2
for M – 35 grade of concrete (75 % of fck is required).
8.1 Preparation of Stressing:
 Immediately after the removal of side shuttering, the recess former
shall be removed.
 The strands projecting outside the anchorages will be cleaned and the
anchor block along with the wedges shall be slotted on to them.
7
7.1 Tolerance:
Note:
to it.
should be M – 35.
minimum 27N/mm2
shall be removed.
7
7.1 Tolerance:
Note:
to it.
should be M – 35.
minimum 27N/mm2
shall be removed.

8
 Wedges shall be mildly rammed with a steel pipe to ensure for their
even seating.
8.2 Pre requisite for Stressing:
 Jacks used for stressing should be supplied with necessary calibration
certificate.
 All stressing equipments will be cleaned and checked before put into
operation.
 Theoretical elongation calculation shall be prepared and put forwarded
to the consultants review & kept ready.
 Compressive strength of concrete should be confirmed to have
achieved 27N/mm2
8.3 Sequence of Stressing:
For Flat Anchorage (FA) System
 Each strand in the tendon shall be stressed to 25% of the jacking force
and the datum shall be marked.
 The stressing jack has to be inserted back to its position and each
strand has to be stressed for its final pressure.
 The elongation for each strand will be checked by measuring the mark
datum.
 Measure the distance of the datum mark to the wedge plate. This will
reflect the strand’s elongation from 25% to 100% force. ( assume X
mm )
 Add the wedge draw-in of 6mm to the X.
 Effective strand’s elongation from 25% to 100% stressing force, Y
Y = X + 6mm (Wedge Draw in)
8
even seating.
certificate.
operation.
achieved 27N/mm2
datum.
mm )
8
even seating.
certificate.
operation.
achieved 27N/mm2
datum.
mm )

9
 The total elongation (from 0% to 100% force) shall be calculated by
extrapolation of the value Y.
Total elongation = (Y / 75) X 100
 The value will be recorded & documented duly signed by P.T Engineer
/ Clients / Consultants.
 Strands will be cut after 24 hrs from completion of stressing activity.
 Strand protruding beyond the wedge will be cut 2 times the diameter
of the strand or 25mm away from wedge face using cutting wheel.
For Multiplane Anchorage (MA) System
 The multistrand jack shall be secured and hoisted to the anchorage’s
level by chain blocks or crane.
 All strands shall be inserted through the jack’s guide pipes.
 Connect jack to hydraulic pump.
 At the beginning of stressing the strands are locked in the jack pulling
head.
 The pressure readings and the measured elongation are recorded in
the stressing report.
 Stress initially to 10Mpa to remove slack in the strands.
 Proceed stressing and record the strands’ elongation for every
incremental of 10MPa pressure.
 When the jack has reached the end of its stroke or the desired force
has been obtained, the pressure in the jack is released and the strands
will locked uniformly by the wedges in the wedge plate.
 The jack piston returns.
 Stressing is continued in as many stages as are necessary to obtain
the required forces.
Note: De-Shuttering at pour strip area can be carried out after completion of
concreting in that area and after achievement of required compressive strength.
9
head.
9
head.

10
SAMPLE JACKING FORCE CALCULATION
 UTS of Strand=183.7 KN (for 0.5” Strand)
260.7 KN (for 0.6” Strand)
 Jack Loss = 2%
= 1+ 2 = 1.02
100
 Applying force = 75% of UTS
 Ram Area of SF T-25 Jack = 3300 mm2
(or) 33cm2
Formula
Jacking force = Pressure X Jack Loss
Area
(Nos of Strands X UTS X 75% X Jack Loss)/Jack Ram Area
Jacking force = (1x183.7 x 100) x 75% x 1.02 = 425.85 Kg/cm2
(For 0.5” Strand) 33
Note:
The Jacking force value may change depending upon the type of Hydraulic Jack and
its Ram Area used at site.
10
 Jack Loss = 2%
= 1+ 2 = 1.02
100
(or) 33cm2
Formula
Area
Note:
10
 Jack Loss = 2%
= 1+ 2 = 1.02
100
(or) 33cm2
Formula
Area
Note:

11
INTERPRETATION OF STRESSING RESULTS
Note:
(P) The Engineer shall be informed and consulted for more investigation and design
check
Check Elongation (X) for
individual Tendon
Within ±
8%
ok
Average deviation
per pour/over beam
section within ±8%
ok
11
Note:
check
Check Elongation (X) for
individual Tendon
Not Within
± 8%
X< -8%
Average deviation
per pour/over beam
section within ±8%
Average deviation
per pour/over beam
section < 8%
stress the tendon with X<-8%
to max of 80% UTS
Average deviation per
pour/over beam
section within ± 8%
ok
pour/over beam
section< 8%
See (P)
Average deviation
per pour/ over
beam section
within ±8%
ok
11
Note:
check
pour/over beam
section< 8%
X> +8%
Average deviation
per pour/ over
beam section
within ±8%
ok
Average
deviation per
pour/over beam
section > 8%
Hold the
final
pressure for
15 sec

Project :
Location:
Date:
Sheet: 1 of 2

Project :
Location:
Date:
Sheet: 2 of 2

12
9. Grouting Procedures:
 After the stressing and trimming of strands are completed, sealing of
tendons recesses will be done using cement mortar as per specifications.
 Water will be potable, free from impurities and cement (OPC – 53 grade)
will be used and the same should be free from any lumps.
 Water and cement will be mixed as per the details given in the Codal
specification using mixer and agitate the mix continuously.
 The W/c ratio will be kept as 0.45 and mixing time of grout will be 2 – 3
minutes and approved non-aluminum based expanding agent may be
added as per Codal specifications.
 Grout in the collection drum will be kept in continuous slow agitation by
means of agitator until pumped into the duct.
 Grout will be pumped into the duct by inlet.
 Start filling the duct with the specified grout mix, consistency of the grout
has to be checked from the other end grout vent, and if it reaches the
same, close both the vent. Build the grout pressure from 3 to 5kg/cm2
and maintain the pressure for 15- 20 seconds and seal the other end by
tying with binding wire.
 The inlet will be closed and pressure will be released from grout pump by
releasing the return valve in the grout pump.
 Same procedure will be adopted for remaining cables.
 During grouting workers will wear protective goggles, helmets, and hand
gloves.
 All the data will be recorded in the format.
12
gloves.
12
gloves.

13
GROUT MIX
 Cement = Ordinary Portland Cement (53 – grade) 50 Kg
 Water = 0.45 x 50Kg (Per bag of cement) = 22.5 litres
 Per Batch = 3 bags of cement
 Admixture = Conplast P 211M (Fosroc) 0.2% weight of cement (50Kg)
Cebex 100 (Fosroc) 225g per bag of cement (50Kg)
 Mixing Sequence = Water – Cement – Admixture
 Mixing Time =2 – 3 min
a) For Conplast P 211 M: (Refer Annexure – 4)
Cement Required = 3 bags (150 Kg)
Water Required for 3 bags of cement = 68 litres
Admixture Required for 3 bags of cement = 300ml
b) For Cebex 100: (Refer Annexure – 4)
Admixture Required for 3 bags of cement = 675g
13
GROUT MIX
13
GROUT MIX

14
9.1 Tests for Grouting:
 Viscosity Test
 Compressive Strength
Viscosity Test:
 Viscosity test will be executed by means of a flow cone.
 Flow time is measured with a stop watch.
 It is the measurement of time that the grout takes to completely
flow out of the cone.
 It is carried out after the 2-3 min minimum mixing time.
 The flow time should be between 10 to 25 seconds.
14
 Viscosity Test
Viscosity Test:
14
 Viscosity Test
Viscosity Test:

15
Compressive Strength:
 6 test cubes of 100 x 100 x 100 mm shall be prepared per grouting
session.
 After 24 hours, remove cubes from mould and store in the water
storage tank.
 Compressive strength at 7 and 28 days for 3 cubes each shall be
tested.
According to specification, average compressive strength of 3 cubes shall be as
follows:
7 - Days 17 N/mm2
28 - Days 30 N/mm2
15
session.
storage tank.
tested.
follows:
7 - Days 17 N/mm2
28 - Days 30 N/mm2
15
session.
storage tank.
tested.
follows:
7 - Days 17 N/mm2
28 - Days 30 N/mm2

16
ANNEXURE – 1
P.T WORK SEQUENCE – FLOW CHART
16
ANNEXURE – 1
16
ANNEXURE – 1

17
Post - Tensioning
Laying
17
Post - Tensioning
Stressing Grouting
17
Grouting

18
Laying
Bottom
Shuttering
Bottom Rebar
18
Bottom Rebar
Installation of
duct with HT
Strands
Fixing of casting
and joining with
duct
Wrapping of
duct joints with
opp tape
Profile chair
fixing
Top Rebar
Casting the
member
18
Top Rebar
Casting the
member

19
Stressing
Removal of side
Shuttering and
recess former
Fixing of wedge plate
and wedges
19
Removal of side
Shuttering and
recess former
Fixing of wedge plate
and wedges
Insertion of jack to
the strands in
position
Initial pressure
25% for slack
removal
Initial marking of
strand with
marker
Final pressure as
per specification
Checking the
elongation and
recording the values
Chopping of protruding
strand after 24 hours
19
Final pressure as
per specification
Checking the
elongation and
recording the values
Chopping of protruding
strand after 24 hours

20
20
Grouting
Patching the
recess pocket with
cement mortar
After 48 hour
preparation of
grouting activity
Mixing (Cement +
Water + Additive)
Mixing the
components in
grout pump for 3 -
5 Min
Inject the grout
through the grout
inlet
Flow of grout
through outlet
with same
consistency
Lock the outlet
and withold
pressure for 3 - 5
bars for 15 sec
Adopt same
procedure for
remaining tendons
20

21
ANNEXURE – 2
P.T COMPONENTS & EQUIPMENTS
21
ANNEXURE – 2
21
ANNEXURE – 2

22
Strands:
Strands 0.50” 0.60”
Nominal Diameter 12.7mm 15.24mm
Nominal Area 100mm2
140mm2
Nominal Weight 0.785kg/m 1.102kg/m
Tensile Strength 1860N/mm2
1860N/mm2
Modulus of elasticity 195kN/mm2
195kN/mm2
Min breaking load 183.7kN 260.7kN
22
Strands:
Strands 0.50” 0.60”
Nominal Area 100mm2
140mm2
1860N/mm2
195kN/mm2
22
Strands:
Strands 0.50” 0.60”
Nominal Area 100mm2
140mm2
1860N/mm2
195kN/mm2

23
GI - Duct:
 Strips Type = GI (Galvanized Iron)
 Duct Type = Flat Duct (FA) , Round Duct (MA)
 Strip Thickness = 0.3mm
 FA Duct Dimension = 5s & 4s (80 x 20mm)
3s & 2s (60 x 20mm)
 MA Duct Diameter = 68mm to 135mm
23
GI - Duct:
3s & 2s (60 x 20mm)
23
GI - Duct:
3s & 2s (60 x 20mm)

24
Anchorage:
Flat Anchorage (FA):
Multi Anchorage (MA):
24
Anchorage:
24
Anchorage:

25
Wedges:
Tendon Sample:
25
Wedges:
Tendon Sample:
25
Wedges:
Tendon Sample:

26
T – 10 Hydraulic Jack:
T – 25 Hydraulic Jack & Pump
26
26

27
Grout Pump:
27
Grout Pump:
27
Grout Pump:

28
ANNEXURE – 3
CHECK LIST
28
ANNEXURE – 3
CHECK LIST
28
ANNEXURE – 3
CHECK LIST

29
SF ENGINEERING SYSTEMS (INDIA) PVT. LTD.
(Reliable Partner in Specialized Engineering )
CHECKLIST FOR INSTALLATION
PROJECT NAME DATE
LOCATION/FLOOR
DRAWING
NO
GRID NO /POUR
DRAWING
REV
Tendon ID :-
S.NO ELEMENTS TO BE CHECKED OK
NOT
OK
REMARKS
1 Placement of Type of Duct
2 Placement of Numbers of Tendons
3 Placement of Tendons Spacing
4 Correct Numbers of strand Installation within duct
5 Length of strands are enough for stressing
6 Position and correct type of casting at live end
7 Position and correct type of dead end
8 Profile of Tendons at supports points
9 Placement of correct type and no of bursting steel
10 Placement of correct spacing links
11 Ensure all grout ports are provided
Comments : (RCC)
SFEC REPRESENTATIVE CONTRACTOR REPRESENTATIVE CLIENT REPRESENTATIVE
NAME :- NAME :- NAME :-
DESIGNATION :- DESIGNATION :- DESIGNATION :-
DATE :- DATE :- DATE :-
SIGN :- SIGN :- SIGN :-
29
PROJECT NAME DATE
LOCATION/FLOOR
DRAWING
NO
GRID NO /POUR
DRAWING
REV
Tendon ID :-
NOT
OK
REMARKS
Comments : (RCC)
29
PROJECT NAME DATE
LOCATION/FLOOR
DRAWING
NO
GRID NO /POUR
DRAWING
REV
Tendon ID :-
NOT
OK
REMARKS
Comments : (RCC)

30
CHECKLIST FOR STRESSING
PROJECT NAME DATE
LOCATION/FLOOR
DRAWING
NO
GRID NO /POUR
DRAWING
REV
Tendon ID :-
NOT
OK
REMARKS
1 Preparation For Stressing
2 Fixing of correct Type of Anchorages
3 Fixing of correct Type of Wedges
4 Applied forces for 75% UTS
5 Elongation to be Measured and For the limit
6 Cut off the Excess Stressing strands.
Comments :
30
PROJECT NAME DATE
LOCATION/FLOOR
DRAWING
NO
GRID NO /POUR
DRAWING
REV
Tendon ID :-
NOT
OK
REMARKS
Comments :
30
PROJECT NAME DATE
LOCATION/FLOOR
DRAWING
NO
GRID NO /POUR
DRAWING
REV
Tendon ID :-
NOT
OK
REMARKS
Comments :

31
CHECKLIST FOR GROUTING
PROJECT NAME DATE
LOCATION/FLOOR
DRAWING
NO
GRID NO /POUR
DRAWING
REV
Tendon ID :-
NOT
OK
REMARKS
1 Filling of the recess pockets left out for stressing
2 W/c ratio Maintained as per the methodology
3 Cement and Admixtures following as per the methodology
4 1st Stage of Tendon flushing with water
5 2nd Stage of Tendon filled with Grout
6 Grouting Completed after cut of the Excess hose
Comments :
31
PROJECT NAME DATE
LOCATION/FLOOR
DRAWING
NO
GRID NO /POUR
DRAWING
REV
Tendon ID :-
NOT
OK
REMARKS
Comments :
31
PROJECT NAME DATE
LOCATION/FLOOR
DRAWING
NO
GRID NO /POUR
DRAWING
REV
Tendon ID :-
NOT
OK
REMARKS
Comments :

32
ANNEXURE – 4
ADMIXTURE
32
ANNEXURE – 4
ADMIXTURE
32
ANNEXURE – 4
ADMIXTURE

Cebex100
Cebex 100*
(Formerly Conbex 100)
Plasticised expanding grout admixture
Uses
Cebex 100 is an admixture for cementitious grouts where a
reduced water/cement ratio and positive expansion is
required. Applications include bed grouting, duct grouting,
non-shrink infilling and jointing.
Advantages
! Gaseous expansion system compensates for plastic
shrinkage and settlement in properly designed
cementitious grout.
! Reduced water/cement ratio mixes in the grout mix
ensures low permeability and long term durability in
service.
! Gives high grout fluidity with low water/cement ratio, thus
making placement or injection of the grout easy.
! No metallic iron content to corrode and cause staining or
deterioration due to rust expansion in the grout.
! Composition allows high early strength development in
grouts, without the use of chlorides.
Standards compliance
Cebex 100 is a suitable pre-stressing grout admixture when
complying with BS 8110 Part 1, 1985, section 8.9.4.6.
Description
Cebex 100 is supplied as a powder admixture. The material is
a combination of a plasticising agent and a gas producing
expansion medium. The plasticising agent allows the use of
a reduced water/cement ratio with consequent increased
strengths and durability. The expansive medium counteracts
the natural settlement and plastic shrinkage of the grout and
aids stability and cohesion.
Sufficient restrained expansion is developed to ensure a high
degree of interfacial contact.
Specification
Performance specification
All grouting (specify details and areas of application) must be
carried out with a cement based grout incorporating a
plasticised, expanding powder admixture. The admixture must
be iron-free and chloride-free and shall be added to the grout
in the proportions 225 g of admixture per 50 kg of cement.
The admixture shall provide an expansion of up to 4% in the
plastic grout, by means of a gaseous system. The admixture
must be stored, handled and mixed strictly in accordance
with the manufacturer's instructions.
Supplier specification
All grouting (specify details and areas of application) must be
carried out using a cement based grout, incorporating Cebex
100 manufactured by Fosroc and applied strictly in accordance
with the manufacturer's technical data sheet.
Properties
Chloride content : Nil to BS 5075
Compressive strength : The plasticising action of
Cebex 100 allows reduction
of the water/cement ratio of
cementitious grouts whilst
maintaining flow properties.
This gives improvement in
strength and long term
durability when cured under
restraint.
Setting times : Cebex 100 does not
significantly affect the
setting times of cement
based grouts.
Expansion characteristics: The controlled positive
expansion in unset grouts
incorporating Cebex 100
overcomes plastic
settlement when measured
in accordance with
ASTM C827. An
unrestrained expansion of
up to 4% is typical.
Time for expansion : 15 minutes - 2 hours.
Temperatures above 20°C
may slightly reduce these
times.
Compatibility : Cebex 100 is compatible
with all types of Portland
cement. Cebex 100 may be
used in mixes containing
certain other Fosroc
admixtures. Consult Fosroc
for further information.

Instructions for use
Mixing
For best results Fosroc MR3 mixer must be used. For
quantities up to 50 kg a slow speed drill fitted with a high
shear paddle is suitable. Larger quantities will require a high
shear vane mixer.
It is essential that machine mixing capacity and labour
availability is adequate to enable the grouting operation to be
carried out continuously. This may require the use of a holding
tank with provision for gentle agitation to maintain fluidity.
The selected water content should be accurately measured
into the mixer. Slowly add the cement (and sand if required)
and Cebex 100. Mix continuously for 5 minutes, making sure
that a smooth even consistency is obtained.
Application
Areas to be grouted should be prepared to ensure substrates
are clean, sound, and then pre-wetted. The unrestrained
surface area of the grout must be kept to a minimum. Place
the grout within 20 minutes of mixing to gain the full benefit
of the expansion process. Adopt usual placing or pumping
procedures ensuring a continuous operation.
Curing
On completion of the grouting operation, any exposed areas
which are not to be cut back should be thoroughly cured by
means of water application, Concure* curing membrane or
wet hessian.
Cleaning
Grouts mixed with Cebex 100 should be removed from tools
and equipment with clean water immediately after use.
Remove cured material mechanically or with Fosroc Acid Etch.
Limitations
Cebex 100 is not compatible with High Alumina Cement.
Estimating
Supply
Cebex 100 : 5 kg packs & 225 g tins
Dosage
OPC Concreting Water Conbex Approx
sand 100 yield
50 kg - 20-22 litres 225 g 36 litres
50 kg 50 kg 22-24 litres 225 g 57 litres
Note: For grout, mortar or concrete mixes with an aggregate/
cement ratio more than 1, use 4x225 g units or 900 g
of Cebex 100 per 100 kg of cement.
Effects of overdosing
Overdosing of Cebex100increases expansionand maycause
frothing.
Storage
Cebex 100 has a shelf life of 12 months if kept in a dry store in
its original packaging. High temperature and humidity storage
may reduce this period.
Precautions
Health and safety
Cebex 100 is of low hazard.
Contact with the skin and eyes, or inhalation of dust should
be avoided. Wear suitable protective clothing, gloves, eye/
face protection and dust mask. After contact with skin, wash
off with clean water. In case of contact with eyes, rinse
immediately with plenty of water and seek medical attention.
For further information see Product MaterialSafetyDatasheet.
* Denotes the trademark of Fosroc International Limited
†
See separate data sheet
Al Gurg Fosroc LLC REGIONAL SALES OFFICES IN :
P. O. Box 657
Dubai
United Arab Emirates
TEL : (04) 858606
FAX: (04) 859649
DUBAI
Al Gurg Fosroc
TEL : 858787
FAX : 852023
ABU DHABI
Al Gurg Fosroc
TEL : 731779
FAX : 731449
BAHRAIN
YBA Kanoo
TEL : 735454
FAX : 732828
KUWAIT
Boodai
TEL : 4817618
FAX : 4832124
OMAN
GETCO
TEL : 7715080
FAX : 7717554
QATAR
Tadmur
TEL : 4413628
FAX : 4440812
Important note
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard terms and conditions of sale, copies of
which may be obtained on request. Whilst Fosroc endeavours to ensure that the technical information on this data sheet is correct at the time of printing,
it is the customer’sresponsibility to satisfy himself, by checking with the company that this information is still current at the time of use, that the product is
suitable for the intended application, and that the actual conditions of use are in accordance with those recommended. Because Fosroc has no control over
the conditions of use of its products, all recommendations or suggestions regarding the use of these products are made without guarantee.
www.fosrocgulf.com UAE/0321/00/A

35
ANNEXURE – 5
SAFETY
35
ANNEXURE – 5
SAFETY
35
ANNEXURE – 5
SAFETY

36
Safety Work Procedures for Post Tensioning Work
1. Installation of Tendon Operations:
 Lifting of Post Tensioning Materials
Lifting operation to comply with Operation Crane regulations
Ensure Lifting Supervisors / Signal Man are qualified.
To explain about the work process to the workers dealing with
lifting work before the work starts.
 Installation of Strand Dispenser
Ensure the dispenser is sufficiently stable to prevent from collapse.
Ensure no personnel standing in front of dispenser when uncoiling
strand.
Use safety gloves when working.
 Usage of electrical equipments
Ensure proper industrial socket, plug and connectors are used
before starting of work.
The wires should be raised above ground level.
Proper shelter should be provided for all electrical components at
wet weather conditions.
Use safety gloves and shoes at time of work.
 Cutting of PT Strand
Cutting machine should have a safety guard covered to it before
starting the work.
Use gloves and safety goggles at time of work.
36
strand.
starting the work.
36
strand.
starting the work.

37
 Working near edge of the building
Workers have to briefed for working on heights before
commencing the work.
Safety belt connected to jacket has to be anchored to a permanent
structure, if the workers are working at outer periphery of the
building.
Provision of effective barricades.
2. Stressing of Tendon Operations:
 Setting up of Stressing Equipment
Only trained personnel are allowed to install and operate the
equipment.
Ensure the jack and pressure cage are calibrated.
 Stressing area precautions
Stressing area has to be barricaded to avoid other workers entering
the zone till completion of stressing activity.
No workers shall stand behind or at the face of the jack during
stressing.
There should be enough space between the jack and worker who is
handling it at time of stressing the tendons.
building.
37
building.
equipment.
stressing.
building.
37
building.
equipment.
stressing.
building.

38
3. Grouting of Tendon Operations:
 Lifting of cement bags
Lifting operations to comply with crane regulations.
Lifting done manually the worker has to wear safety helmet, gloves
and goggles along with nose mask.
To explain about the work process to the workers dealing with lifting
work before work starts.
building.
 Grouting area precautions
Ensure the workers are wearing safety helmet, gloves and goggles
along with nose mask.
Proper hose cleaning should be done after the completion of stressing
activity.
Safe method to check on pressure grout hose to be briefed to the
workers.
Ensure proper patching is done before the commencement of grouting
activity.
Ensure all the tendons is been grouted individually.
38
building.
activity.
workers.
activity.
38
building.
activity.
workers.
activity.

39
ANNEXURE – 6
Quality Assurance Policy (QAP)
39
ANNEXURE – 6
39
ANNEXURE – 6

40
In House Quality Assurance Policy for SF Systems
Note:
 System acceptance test will be conducted from any of the reputed
lab based on the requirement and the same will be done once in a
year.
 Performance test - Material Test Certificate (MTC) will be issued for
every lot to be used at site.
System
Acceptance Test
Anchorage
Efficiency
Test
Load
Transfer Test
40
Note:
year.
FIP
Recommentations
Load
Transfer Test
Performance Test
(Materials)
Anchorage Sheathing
40
Note:
year.
Performance Test
(Materials)
Strand

41
System Acceptance Test:
Anchorage Efficiency Test
Objective of the test:
This test is conducted to check and verify the performance of the
anchorage assembly and to determine any decrease in breaking load of the
Pre – Stressing steal (Strands) due to the influence of the anchorage, and to
observe the elongation and behavior of the wedges.
Test Remarks:
The test will be conducted at any of the reputed lab based on the
requirement which satisfy FIP recommendations.
Frequency:
The entire test is related to SF system policy and will be conducted
once in a year.
Load Transfer Test
This test is conducted to verify the transfer of the pre stressing force
from the mechanical anchorage and its competency to the concrete without
any failure in the anchorage assembly.
Test Remarks:
Frequency:
once in a year.
41
Test Remarks:
Frequency:
once in a year.
Load Transfer Test
Test Remarks:
Frequency:
once in a year.
41
Test Remarks:
Frequency:
once in a year.
Load Transfer Test
Test Remarks:
Frequency:
once in a year.

42
Quality Assurance Policy at Site
Sl.
No
Work Sequence Formats Objective Field Inspection
1
Monitoring of work prior
to concreting
Checklist on
completion of
laying
To check profile ,
spacing and
number of strands
per tendon
Shop drawing
prepared based on
the design
requirement will
serve as basis
2
Post Concreting
Inspection
Concrete cube
strength
minimum
27N/mm2
To check concrete
is ready to
withstand Pre
Stressing Force
Theoretical tendon
elongation report
submission for every
pour/slab
3
At the time of stressing
activity
Stressing records
and elongation
reports has to be
prepared
To check the
satisfactory
performance of
the stressing
carried
On submission of
stressing record , De
– Shuttering
operations can be
carried out
4
At the time of grouting
activity
Field Test such
as Cube Test and
Viscosity Test
To ensure the
flow character of
the grout and to
check the
strength of the
grout
Viscosity test and
compressive
strength are
conducted before
grouting and this
test is truly based
on requirement of
the clients.
42
Sl.
No
1
to concreting
Checklist on
completion of
laying
To check profile ,
spacing and
number of strands
per tendon
Shop drawing
prepared based on
the design
requirement will
serve as basis
2
Post Concreting
Inspection
Concrete cube
strength
minimum
27N/mm2
To check concrete
is ready to
withstand Pre
Stressing Force
Theoretical tendon
elongation report
pour/slab
3
activity
Stressing records
and elongation
reports has to be
prepared
To check the
satisfactory
performance of
the stressing
carried
On submission of
– Shuttering
operations can be
carried out
4
activity
Field Test such
as Cube Test and
Viscosity Test
To ensure the
flow character of
the grout and to
check the
strength of the
grout
Viscosity test and
compressive
strength are
conducted before
grouting and this
test is truly based
on requirement of
the clients.
42
Sl.
No
1
to concreting
Checklist on
completion of
laying
To check profile ,
spacing and
number of strands
per tendon
Shop drawing
prepared based on
the design
requirement will
serve as basis
2
Post Concreting
Inspection
Concrete cube
strength
minimum
27N/mm2
To check concrete
is ready to
withstand Pre
Stressing Force
Theoretical tendon
elongation report
pour/slab
3
activity
Stressing records
and elongation
reports has to be
prepared
To check the
satisfactory
performance of
the stressing
carried
On submission of
– Shuttering
operations can be
carried out
4
activity
Field Test such
as Cube Test and
Viscosity Test
To ensure the
flow character of
the grout and to
check the
strength of the
grout
Viscosity test and
compressive
strength are
conducted before
grouting and this
test is truly based
on requirement of
the clients.

43
HEAD OFFICE:
(Reliable Partner in Specialized Engineering)
No.118, 13th
Cross Street, Sri Sai Nagar,
Thoraipakkam, Chennai – 600097
M - +91 9840066239, + 91 9551635559, +91 8220373680
E – pandian@shivforce.in , rk@shivforce.in , bdtn@shivforce.in
REGIONAL OFFICE:
DEHRADUN NEW DELHI
2nd
Floor, Tilak Plaza, Tilak Road, 220, Ground Floor, Arjun Nagar
Dehradun, Uttrakhand – 248001. Sufdurjung Enclave, New Delhi-
M - +91 9045089020 New Delhi- 110029
E – pragathees@shivforce.in E – pragathees@shivforce.in
PUNE BANGALORE
F – 133, Ashok Mall, 27/53/3, Srinivasa Nilaya,7th
Main
Opp to Sun & Sand Hotel, Bundgarden Road J.P Nagar, 1st
Phase, Sarakki
Pune – 411001 Kanakpura, Karnataka - 560078
M – 9850431195 M - 8600902222
E – vijayan@shivforce.in E - vijayan@shivforce.in
COIMBATORE
No.30, 1st
Floor, Shanthi Nagar,
Vilankuruchi Main Road, Cheran Maa Nagar
Coimbatore – 641035
M – 9994247766
E – kumaresh@shivforce.in
43
HEAD OFFICE:
No.118, 13th
M - +91 9840066239, + 91 9551635559, +91 8220373680
REGIONAL OFFICE:
DEHRADUN NEW DELHI
2nd
M - +91 9045089020 New Delhi- 110029
PUNE BANGALORE
Main
Phase, Sarakki
M – 9850431195 M - 8600902222
COIMBATORE
No.30, 1st
M – 9994247766
43
HEAD OFFICE:
No.118, 13th
M - +91 9840066239, + 91 9551635559, +91 8220373680
REGIONAL OFFICE:
DEHRADUN NEW DELHI
2nd
M - +91 9045089020 New Delhi- 110029
PUNE BANGALORE
Main
Phase, Sarakki
M – 9850431195 M - 8600902222
COIMBATORE
No.30, 1st
M – 9994247766

44
SF Engineering Systems (INDIA) Private Limited
ASSURING OUR BEST SERVICE & SUPPORT AT ALL TIMES
44
44

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