Flexible Filler. Policy for Post-Tensioning Tendons. By Rick W. Vallier, P.E. FDOT Structures Design Office
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1 Florida Department of TRANSPORTATION Policy for Post-Tensioning Tendons Flexible Filler By Rick W. Vallier, P.E. FDOT Structures Design Office FTBA Construction Conference February 17 18, 2015
2 Presentation Outline 1. Why Transition to Flexible Filler? 2. What is Flexible Filler? 3. Where is Flexible Filler Used? 4. How is Design, Construction and Maintenance Affected by Flexible Filler? 5. What are the Policies and Procedures of Flexible Filler?
3 Why is the FDOT Transitioning to Flexible Filler?
4 Conventional Post-Tensioning
5 Tendon Corrosion in Florida 1. Niles Channel Bridge, Florida Keys 2. Mid-Bay Bridge, Destin 3. Sunshine Skyway Bridge, Tampa 4. Seabreeze Bridge, Daytona Beach 5. Ringling Bridge, Sarasota 6. Wonderwood Bridge, Jacksonville 7. I-4 / Crosstown Connector, Tampa 8. I-95 / I-295 Interchange, Jacksonville
6 Tendon Corrosion Excess Bleed Water Grout Voids Soft Grout Contaminates
7 France External Cement-Grouted Tendon Failures No Observable Warning Prior to Failure Excess Bleed Water Soft Grout
8 France External Tendon Regulations in 2001 Avoid Sudden Breakage of Tendons Easily Replaceable Tendons Result of 2001 Regulations Flexible Filler No Reported Tendon Failures Using Flexible Filler
9 What is Flexible Filler?
10 Flexible Filler Properties Microcrystalline Wax Homogeneous Hydrophobic Metal Adhesion Properties
11 Where is Flexible Filler Used?
12 Corrosion Protection Naval propulsion machinery after WWI During WWII to coat coastal artillery Nuclear power facilities for corrosion protection of post-tensioned tendons since 1969 Used in France for corrosion protection of post-tensioned tendons in bridge applications Used in cable-stayed anchorages Underground Utility Casing Filler
13 Use Flexible Filler External Tendons
14 Use Flexible Filler Continuity Tendons
15 Use Flexible Filler Post-Tensioned I-Beam Tendons
16 Use Flexible Filler Post-Tensioned U-Girder Draped Tendons
17 Use Flexible Filler Hammerhead Pier
18 Use Flexible Filler Straddle Pier
19 Use Flexible Filler Cantilever Pier Vertical Strand Tendon
20 Cement Grout May Use Cement Grout Post-Tensioning Bar Tendons Straight Tendons in U-Beams and Girders Must Use Cement Grout Transverse Tendons in Top Slabs Cantilever Tendons in Top Slabs
21 What are the Design Implications?
22 Flexible Filler PT System Similar to Cementitious Grouted PT Systems Tendons are Replaceable
23 Diabolos Permanently Embedded Diabolo Assembly Reusable Diabolo Inserts
24 Design Methodology Unbonded Tendon Design Similar to Grouted External Tendon Design
25 Prestress Behavior of Local Failure Internal Grouted Tendons Tendons Redevelop Prestress External Grouted Tendons Strands Redevelop Prestress Within Duct Little to No Warning of Failed Tendon Little to No Warning Prior to Tendon Failure Internal and External Waxed Tendons Strand Failure Leads to Incremental Prestress Loss Progressive Warning Before Tendon Failure
26 Cross-Section Potential Implications Voids Duct Spacing Web Width Slab Thickness
27 Service III Longitudinal Stress
28 Strength I Moment AASHTO LRFD Bridge Design Specifications Capacity Decreases for Unbonded Design
29 Cracking Moment AASHTO LRFD Bridge Design Specifications Minimum Reinforcement Cracking Moment Decreases for Unbonded Design
30 Fatigue & Deflection Strand Fatigue & Fretting Low Stress Range Creep & Shrinkage Not Expected to Change Significantly Between Bonded and Unbonded Design
31 What are Construction Implications?
32 Wax Installation Equipment Pumping Equipment Heater
33 Equipment & Safety Protection Protective Clothing Face Mask Temperature Gauge Drill with Paddle Blade
34 Inlets and Vents
35 Example Wax Injection Methodology 1. Heat Wax to 221 F 2. Pressure Test Duct 3. Pump Wax between 40 and 70 Feet Per Minute 4. Maximum Injection Pressure of 75 PSI 5. Vent 2 Gallons of Wax at Outlets
36 Injection
37 Venting
38 Wax Injection Results
39 Construction Cost Estimate Post Tensioning Pay Item Cost 15% to 26% above similar grouted systems Superstructure Cost 0.5% to 2.4% higher than a similar grouted system Total Project Cost Less than 1% increase compared to a grouted system
40 What are Maintenance Implications?
41 Maintenance Inspection Areas Cracking at Maximum Bending Moment Locations Loose Strands in Duct Replaceable Tendons Access
42 What are FDOT Policies and Procedures for Flexible Filler?
43 Terminology Injection Process of Pumping Filler into Duct Filler Grout or Flexible Filler Flexible Filler Grease, Wax, Gel, or other Pliable Filler Tendon Bar or Strand Example: Inject filler into duct.
44 FDOT Structures Design Guidelines SDG 4.5 Post-Tensioning Replaceable Tendons Access to Anchorages Duct Spacing Diabolos Wax and Grout Use Locations
45 FDOT Design Standards Index Series Post-Tensioning Profiles Post-Tensioning Protection Post-Tensioning Anchorage and Injection Details Instruction for Design Standards IDS for Index Series Post-Tensioning
46 FDOT Specifications Specification 462 Construction Post-Tensioning Details Specification 938 Materials Post-Tensioning Grout Specification 960 Materials Post-Tensioning Components
47 Schedule Design and Detailing Criteria, Standard Drawings, Construction and Material Specifications March Draft Versions for Industry Review May 2015 Completed Versions Requirements Apply To: Design-Bid-Build 30% or Less as of January 30, 2015 Design-Build RFP Release Date after June 1, 2015
48 FDOT Research Un-bonded Tendon System Practices for Bridges in Europe July, 2012 Parametric Study of Unbonded Post-Tensioning Systems December, 2012
49 FDOT Research Replaceable Unbonded Tendons for Post-Tensioned Bridges Literature Review December 2013 Mock-up Wax Injection October 2014 Internal Tendon Testing Summer 2015 External Tendon Testing Summer 2015 Final Report Early 2016
50 FDOT Contacts Structures Design Engineer: Construction Structures Engineer: State Structural Material Systems Engineer: Senior Structures Design Engineer (Research): Rick Vallier (850) Dan Hurtado (850) Paul Vinik (352) William Potter (850)
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