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we face a problem in box girder structure were we have 18 tendon of 37T15 system, we completed stressing process and after that we cut the grip length and grout cap was fixed. Prior to grouting we were asked to do air worthiness of the duct but to our suprise we had only 6 passed out of 18 to sustain the air pressure of 4 bar. Is it possible to achieve air worthiness after stressing , concreting of the structure or is it compulsory to do the test. please suggest the best solution.
Do noty have the aashto specks, but am realy interested how did you do it.
Now if it is a box girder there is a posibility that due to improper concreting there are areas around the tentons not properly concreted. This should not happen if everything has been done acordingly to the specs but sometimes due to a verry congested areas voids are formed.
Happened on a project recently, in the areas of the anchors. And we got it after the anchors started failing one after another.
Brake fix recast … the entire show.
Then just changed the concrete mix, intorduced some additional diaphragms etc. and no probs since then.
( course you may gues it was bottom area of a box beam 
)
Regarding you situation it is a bit tricky.
I would suggest ou first make sure you sealedeverything properly.
Then during testing keep somebody pouring a soap water mix over the exposed areas just in case there is still a leak.( or find a way to check on it during the test).
If it still fails. then it gets really S**TY. Some non destructive tests to find where the voids are and then just fill them. ( keep in mind that they my nit be in an areas of a concern.
That's it.
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