BS EN 446-2007 Grout for prestressing tendons - grouting procedures1.pdf

BRITISH STANDARD BS EN 446:2007 Grout for prestressing tendons Grouting procedures The European Standard EN 446:2007 has the status of a British Standard ICS 91.100.10; 91.100.30 ? Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI BS EN 446:2007 This British Standard was published under the authority of the Standards Policy and Strategy Committee on 30 November 2007 © BSI 2007 ISBN 978 0 580 55813 9 National foreword This British Standard is the UK implementation of EN 446:2007. It supersedes BS EN 446:1997 which is withdrawn. The UK participation in its preparation was entrusted by Technical Committee B/525, Building and civil engineering structures, to Subcommittee B/525/2, Structural use of concrete. A list of organizations represented on this committee can be obtained on request to its secretary. This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Standard cannot confer immunity from legal obligations. Amendments issued since publication Amd. No. DateComments Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM EN 446 October 2007 ICS 91.100.30Supersedes EN 446:1996 English Version Grout for prestressing tendons - Grouting procedures Coulis pour câble de précontrainte - Procédures d'injection de coulis Einpressmörtel für Spannglieder - Einpressverfahren This European Standard was approved by CEN on 21 June 2007. CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN Management Centre or to any CEN member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG Management Centre: rue de Stassart, 36 B-1050 Brussels © 2007 CENAll rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 446:2007: E Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI EN 446:2007 (E) 2 Contents Page Foreword3 Introduction.4 1 Scope 6 2 Normative references6 3 Terms and definitions .6 4 Documentation.6 4.1 Execution specification.6 4.2 Quality plan 7 4.3 Execution documentation.7 5 Materials .7 6 Grout assessment8 6.1 Suitability testing.8 6.2 Project specific grouting tests.8 7 Equipment 9 7.1 General9 7.2 Mixer9 7.3 Pump.9 7.4 Hoses 9 7.5 Inlet connections .10 7.6 Stand-by and emergency equipment.10 8 Grouting procedures.10 8.1 Inlets, outlets and tendon anchorages10 8.2 Precautions before grouting.10 8.3 Temperature at grouting .11 8.4 Grouting operations 11 8.5 Precautions after grouting11 9 Quality Management12 9.1 General12 9.2 Personnel12 9.3 Inspection.12 9.4 Conformity criteria.15 9.5 Action in the event of a non-conformity16 Bibliography17 Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI w w w . b z f x w . c o m EN 446:2007 (E) 3 Foreword This document (EN 446:2007) has been prepared by Technical Committee CEN/TC 104 “Concrete and related products”, the secretariat of which is held by DIN. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by April 2008, and conflicting national standards shall be withdrawn at the latest by April 2008. This document supersedes EN 446:1996. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI w w w . b z f x w . c o m EN 446:2007 (E) 4 Introduction In post-tensioned prestressed concrete construction, the grouting of tendons is an important operation. The intention of this European Standard is to provide a specification for grouting, compliance with which will satisfy the requirements in prEN 13670. The main function of grouting is to Provide protection to the prestressing steel against corrosion; Provide a bond between the prestressing steel and the ducts where required for the design of the structure; Allow the transfer of compressive stresses in the structure in a direction transverse to the internal tendons; Fill all voids where water may accumulate and cause frost damage. The testing regimes anticipated by this European Standard include three levels: (1) Initial type and audit testing in accordance with EN 447; (2) Suitability testing for confirmation of the selected grout for a specific project in accordance with this standard; (3) Inspection during the production of grout on a specific project in accordance with this standard. The test methods for each of the regimes are given in EN 445. Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI w w w . b z f x w . c o m EN 446:2007 (E) 5 System of CEN and EOTA documents as basis for design, execution and materials selection for protective measures of prestressing systems (only main modules). EN 1992 Eurocode 2:Design of concrete structures prEN 13670 Execution of concrete structures ETAG 013 Post-tensioning kits for prestressing of structures EN 446 Grout for prestressing tendons Grouting procedures EN 447 Grout for prestressing tendons Basic requirements EN 445 Grout for prestressing tendons Test methods CEN Workshop Agreement CWA 14646 Requirements for the installation of post-tensioning kits for prestressing of structures and qualification of specialist company and its personnel. Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI w w w . b z f x w . c o m EN 446:2007 (E) 6 1 Scope This European Standard gives the procedures to be used for grouting of tendons in post-tensioned prestressed concrete. It is applicable to all types of structures including bridges and buildings. This standard also covers suitability testing and inspection testing for grouts and their component materials used on a project. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 445, Grout for prestressing tendons Test methods EN 447, Grout for prestressing tendons Basic requirements prEN 13670, Execution of concrete structures 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 grout homogeneous mixture of cement and water, it may contain admixtures and additions 3.2 grouting injection of grout into ducts in a continuous operation 3.3 tendon assembly of prestressing steel and sheath with anchorages and all necessary auxiliary components to permit grouting, either placed internally or externally to the concrete structure 3.4 specialist contractor contractor or construction enterprise which carries out grouting of tendons 4 Documentation 4.1 Execution specification Before starting any part of the grouting works, the execution specification relevant to that part of the works shall be complete and available. The following items shall be included in the execution specification: reference to this European standard; Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI w w w . b z f x w . c o m EN 446:2007 (E) 7 reference to other relevant European standards; reference to ETAs for the post-tensioning kit; reference to other relevant national regulations and standards; information and requirements for the particular project prepared to supplement and qualify the requirements of the above listed documents; drawings and other technical documents needed for the execution. In addition where relevant, procedures shall be established for: making alterations to previously agreed requirements; distribution, the filing and recording of technical documents used for the works. 4.2 Quality plan If a quality control procedure for grouting works is required by the execution specification, it shall be available at the site. 4.3 Execution documentation The specialist contractor shall keep available on site written method statements covering materials, equipment, grouting procedures and inspection all adapted to the extent and complexity of the project. Provisions for the case of unusually low or high temperatures or delayed grouting, if likely to occur during the project duration, shall be specified. The specialist contractor shall have shop drawings showing the position and details of the inlets and outlets, and the details of the sealing of the tendon anchorages. The specialist contractor shall keep available on site documented records of: materials and grout used; initial type testing according to EN 447; suitability testing according to this European standard; results of the project specific grouting tests, if specified. The specialist contractor shall keep documented records of the conformity of the materials, equipment, grout, grouting operations, and inspection with this standard and the execution specification according to Table 2, Table 3 and Table 4. These records shall be kept for the duration, as required by national provisions. Any eventual corrective actions taken shall also be recorded. If special documentation beyond the requirements of this European standard is required for grouting works, the type and extent of the documentation shall be stated in the execution specification. 5 Materials The individual materials and the grout to be used shall comply with EN 447. Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI w w w . b z f x w . c o m EN 446:2007 (E) 8 6 Grout assessment 6.1 Suitability testing The suitability of the grout shall be assessed for each project sufficiently in advance of grouting operations, to enable any necessary adjustments to be made in the use of the materials, equipment or personnel. The extent of suitability testing and number of tests shall be in accordance with Table 1. Suitability testing may be waived for structures in Inspection Class 2 subject to there being documented testing during production in accordance with EN 447. Table 1 Extent of suitability testing Test in accordance with EN 445 2) Suitability testing Number of tests Sieve ? ? 1 test Fluidity ? ? 1 test immediately after mixing 2 tests 30 min after mixing Inclined tube Only required if not already subject to initial type testing with the same type of mixer intended to be used on the project 1 test if required Wick-induced bleed 1) ? ? 3 tests Volume change 1) ? ? 3 tests Compressive strength ? ? 3 tests Density ? ? 1 test 1) Tests for bleeding and volume change are performed on the same sample. 2) Other test methods may be used if the correlation or safe relationship between the results of these test methods and the reference methods in EN 445 have been established. The grout assessment shall consist of the preparation of the grout using the materials, equipment and personnel proposed for the project, and testing in accordance with EN 445. The preparation of the grout shall be carried out under the conditions expected on site for the project. The assessed grout properties shall comply with EN 447. The range of acceptable temperatures specified for the particular grout shall be compatible with the expected conditions of the project. 6.2 Project specific grouting tests If required by the execution specification, project specific grouting tests on tendons in representative forms of the project shall be performed. NOTE Such tests should be planned and carried out well in advance of the site operations. Such project specific grouting tests may be advisable, e.g. when tendon geometry and details are specified on the project for which no prior experience for successful grouting is available. Experience has shown that full-scale tests of grout and grouting procedures can be valuable to prove adequacy. Licensed copy:PONTYPRIDD COLLEGE, 05/01/2008, Uncontrolled Copy, © BSI EN 446:2007 (E) 9 7 Equipment 7.1 General Grouting equipment shall consist of a mixer and a pump with all the necessary connection hoses, valves, measuring devices for water, cement, admixtures and additions and testing equipment as required to perform the grouting of the project. The grouting equipment shall be such that the ducts can be filled without interruption and at the anticipated speed. Grouting equipment shall include a storage reservoir if required for continuous filling of the tendons on the project. Such storage reservoirs shall have an agitator to keep the grout moving continually before it is pumped into the ducts. The grouting equipment shall be compatible with the post-tensioning kit provided for the project. 7.2 Mixer The mixing equipment shall be capable of producing grout, which possesses an even distribution of cement, and an even dispersal of admixtures, additions, if any, and water. The mixed grout shall contain no cement lumps as confirmed with the sieve test of EN 445. The mixed grout shall comply with the requirements of EN 447. 7.3 Pump The pump shall be capable to provide a continuous flow of grout and to maintain the anticipated pressure for grouting. It shall be equipped with a pressure gauge and means to prevent unsafe pressure during grouting. The pump shall be constructed in such a way as to prevent introduction of air, oil or other foreign substances into the grout. NOTE 1 Limiting the grout pressure serves to: (a) prevent blow-outs of hoses, inlets and outlets; (b) prevent damage to the concrete structure; (c) protect the equipment and valves from damage; (d) protect the operators. NOTE 2 The use of a pump with a variabl