INDIAN RAILWAYS INSTITUTE OF CIVIL ENGINEERING PUNE

SESSION NO. 824 Senior Professional Course (Bridges and General) From 01.12.08 to 26.12.08 (4 weeks)

PROJECT REPORT

Method Statement for Construction of PSC Girde rs Brijesh Kumar Mishra

Dy. Chief Engineer/P&D North Central Railway, Allahabad.

1. General Extensive use of PSC gird ers has been started in Railway s as a superstructure for the Bridges. PSC Bridges are now being constructed even for larger sp ans. Steel Girders have been extensively used in the past and enough exp ertise is available within the Railways for fabrication and launch ing of steel girders. PSC girders are now being cast on several Bridges and it is necessary to share the exp erience and methodology for execution to avoid p roblems durin g construction and subsequent difficulties in maintenance. In this p ap er, effort has been made to list out different asp ects which are to be kep t in mind while executin g the works involvin g PSC gird ers. Exp erien ce gained during construction of the PSC girders for viaduct in zone E-18 on Jammu Udhamp ur Rail Link Project has been used to p rep are this method statement. Salient features of PSC girder used on v iaduct zone E-18 are as given below: 1. Clear sp an 2. Effective sp an 3. Len gth of Girder 4. Depth of Girder 5. Deck width inside ballast retainer 6. Girder width at bottom 7. Height of ballast retainer 8. Concrete mix 9. Weight of girder At the time of launching Comp lete 10. Reinforcement 11. Quantity of HTS wires 12. No. of Cables Workin g cab les Future cables Emergency /dummy cables 13. Pre-stressing strand p er cable Cable no. 6 Cable no. 3 All other cables 14. Total p re-stressing force Cable no. 3 Other cables 15. Pre-stressing system 16. No. of stages in concretin g 17. Sheathin g 18. Sp an arran gement 19. Standard of load in g 26.18 m 27.33 m 29.68 m 3.034 m 4.7 m 3.03 m 0.765 m M 40 385 MT 416 MT 18.5 MT 5600 m (4.35 MT) 8 nos in each web 20 (10 on each side of centre lin e) 1 in each web Dummy 9 nos 12 nos 126.56 MT 168.75 MT Frey ssinet Sin gle Bright metal sheathing Inner dia 75 mm Outer dia 76 mm 40x29.68 m MBG 1987

2. Records to be maintained at site It is necessary to maintain the record of each activity at site. It is help ful not only to ensure the quality of construction but also to assess the behavior of the girder and to decide the remed ial action in case of problems in maintenance. Followin g registers are to be maintain ed at site: i. Site order Book ii. Labour register iii. M achinery register iv. Cement Register v. Steel register vi. Cube testing register vii. Fine aggregate register viii. Coarse Aggregate Register ix. Pre-stressing record register x. Batching p lant register xi. Trial mix register xii. Concrete sup ervision register xiii. Shuttering register xiv. Girder cable profilin g register xv. Girder History sheets 3. Collection of drawings All the drawings p ertainin g to the work should be collected and kep t at site in a separate file/folder in sequen ce. It should be ensured that drawings are as p er the latest revision. A list of drawing for Viaduct at E-18 is indicated below:
Sheet 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Name of draw ing General Arrangement (A2 to P34) General Arrangement &Sections Details of Foundation (P35 to P39) Dimensional details of superstructure Details of piers (P35 to P39) General arrangement (P33 to P16) Details of Foundation (P24 to P34) Details of piers (P24 to P34) General Arrangement (P15 to P0) Details of casting yard Sheet 1 of 2 Dimensional details of abutment A2 Details of free bearing (Pier P39 to P22) Details of free bearing (Pier P39 to P22) Details of fixed bearing (Pier P39 to P22) Details of staging- pier cap Details of Foundation (P9 to P23) Details of free bearing abutment A2 Rev. R5 R5 R1 R1 R3 R1 R1 R1 R1 R1 R1 R3 R2 R1 R2 Date Remarks

26.11.96 26.11.96 12.12.96 31.12.96 Changed 16.01.97 17.01.96 19.02.97 27.02.97 25.02.97 06.03.97 Changed 21.03.97 Changed 26.05.00 26.05.00 11.04.97 Changed 03.05.97 26.05.00

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

Details of Foundation (P5 to P8) Reinf. details of foundation, abutment A2 Dimensional details of abutment A2 Reinf. details of abutment A2 Dimensional details of pier cap, straight span Details of free bearings (Pier P9 to P21) Details of fixed bearings (Pier P9 to P21) Details of piers (Pier P9 to P23) Details of piers (Pier P5 to P8) Details of staging- pier cap, sheet 1 of 2 Details of staging- pier cap, sheet 2 of 2 Reinf. details of pier cap (P39 to P22) Dimensional details of superstr. straight span Pier layout P3 to P20 Details of launching girder sheet 1 of 2 Details of launching girder sheet 2 of 2 Details of foundation P2 to P4 Details of piers P2 to P4 Reinf. details of pedestal (P39 to P22) Cable layout for straight span Details of guide bearings (Pier P9 to P39) Reinf. Details of superst. Sheet1of2, A2toP21 Reinf. Details of superst. Sheet2of2, A2toP21 Details of anchorages and future external prestressing, span A2 to P21 Details of trolley refuge Details of ladder inside pier P9 to P39 Reinf. details of pier cap (P39 to P22) Details of pin bearing P9 to P39 Details of misc. items Details of guide bearings abutment A2 Details of abutment cap A2 Sheet 1 of 2 Details of abutment cap A2 Sheet 2 of 2 Details of pipe staging for pier cap P39 to P9 Arrangement for lowering of box girder Sheet 1 of 2 Arrangement for lowering of box girder Sheet 2of 2 Scheme for load testing of trolley and launching girder Details of abutment cap A2 Cable layout for span A2 to P22 Reinf. Details of superst. Sheet1of2 Reinf. Details of superst. Sheet2of2 A2 to P21 Reinf. Details of pedestal abutment cap A2

R1 R3 R8 R1 R1

08.05.97 13.09.97 13.05.97 13.05.97 27.05.97 29.05.97 29.05.97 29.05.97 31.05.97

R1 R1

R2 R3 R1 R5 R3 R1 R1 R3 R4 R1

12.06.97 24.06.97

Changed Changed

23.06.97 24.06.97 24.06.97 25.06.97 25.06.97 22.07.97 31.07.97 Changed 10.06.97

R3 R1 R3 R2 R3 R2 R4 R2 R5

19.08.97 03.09.97 04.12.97 30.05.97 16.03.98 24.03.98 22.04.98 22.04.98 21.03.98 23.11.98

Changed

R4 R8 R6 R8 R2

04.02.99 27.02.99 05.03.99 29.03.99 18.03.99

59 60 61 62

Arrangement for launching of PSC box girder straight span Details of piers P6 Details of foundation P6 Installation scheme for bearings

R5 R3 R3 R4

26.03.99 07.04.99 06.04.99 13.04.99

4. Testing of material for concrete As soon as the drawing for the girder is received, it should be studied in detail to know about the grade of concrete to be used for casting of gird er. In case the drawin g is old or it has been issued for another site, latest p rovisions of Concrete Bridge Code should also be referred to ensure that the p rovisions regarding minimum grad e of concrete as p er the exp osure conditions at the site are followed. Contractor should be asked to select the source for the in gredients of the concrete i.e. aggregate and water. Samp les should be taken and these should be sent to any reputed laboratory for testing. All the tests to be carried out should be sp ecifically mentioned and all tests should be got done in one go to avoid delay in decidin g the source of material. Tests which are generally to be carried out are discussed in followin g paras. 4.1. Coarse Aggregate: SN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13 Descrip tion of test Deleterious materials Clay lump s Materials finer than 75 micron IS sieve Aggregate crushin g v alue Aggregate Imp act Value Aggregate Abrasion Valu e Soundness (for con crete liable to be exp osed for frost action) When tested with Na2So4 and Mg So4 Size and Gradin g Flakiness Index Elon gation Index Water absorp tion test Sp ecific gravity Alkali aggregate reaction Chloride contents Sulp hate contents Reference to code for procedure IS:2386 Part II IS:2386 Part II IS:2386 Part IV IS:2386 Part IV IS:2386 Part IV IS:2386 Part V IS:2386 Part I IS:2386 Part I IS:2386 Part I IS:2386 Part III IS:2386 Part III IS:2386 Part VII

Code for accep tance values- IS: 383

Instructions in Para 4.2 of IRS Con crete Bridge Code should be followed regarding the p rop erties of aggregates. 4.2. Fine Aggregate: SN 1. Descrip tion of test Deleterious materials Clay lump s Materials finer than 75 micron IS sieve Soundness (for con crete liable to be exp osed for frost action) When tested with Na2So4 and Mg So4 Size and Gradin g Sp ecific gravity Alkali aggregate reaction Chloride contents Sulp hate contents Reference to code for procedure IS:2386 Part II IS:2386 Part I IS:2386 Part V IS:2386 Part I IS:2386 Part III IS:2386 Part VII

2. 3. 4. 5. 6. 7.

Code for accep tance values- IS: 383 Instructions in Para 4.2 of IRS Con crete Bridge Code should be followed regarding the p rop erties of aggregates. 4.3. Water SN 1. 2. 3. 4. 5. 6. 7. 8. Descrip tion of test Physical Character Organic solids Inorgan ic solids Sulp hates (as SO4) Chlorides (As Cl) PH Value Limit of acidity (with N/10 NaOH) Limit of alk alin ity (with N/10 HCL) Reference to code for procedure

IS 3025

Code for accep tance values- IRS Con crete Brid ge Cod e Instructions in Para 4.3 of IRS Concrete Brid ge Code should be followed regarding the p rop erties of water. 4.4. Cement

Cement test certificate is received alon g with the rake of cement. In addition, testing should be done at site to confirm that it has not deteriorated during transp ortation and storage. So me of these tests are as under: Initial setting time Final setting time Comp ressive strength Fineness Soundness Chemical co mp osition

Instructions in Para 4.1 of IRS Con crete Bridge Code should be followed regarding the p rop erties of aggregates. 4.5. Admixtures Admixtures are used fro m followin g considerations: To imp rove the workability To increase initial setting time. This help s in avoidin g the cold joints. Large no. of products are available in the market but it is necessary to select the correct p roduct since a wrong admixture may affect the life of concrete. Admixture should be comp ly ing to IS : 9103 and it should b e co mp atible to the cement bein g used for concretin g. Instructions in Para 4.4 of IRS Con crete Bridge Code should be followed regarding the use of admixtures. 4.6. Other Materials Testing of other construction materials has to be carried out as p er relevant codes. Instructions in Para 4.5&4.6 of IRS Concrete Bridge Code should be followed regardin g the p rop erties of Reinforcement and p restressing steel. A typ ical format for the letter to the testing laboratory , regardin g concretin g materials, is shown in Ann.-A. 5. Collection of Codes, manuals and technical literature Codes and other such literature p ertainin g to the method of testing the materials and concrete should b e collected and one cop y of each code should be kep t at site for reference. Similarly , codes p ertaining to accep tance criteria are also to be kep t at site. 6. Set up of Testing laboratory

Several tests p ertaining to materials and finished p roduct are to be carried at site. Testing laboratory should be set up at site to facilitate the testing. 7. Mix Design As soon as the source for the in gredients of the concrete are decided, d esign of concrete mix has to be done. Specified procedure should be followed to decide the ingredients of the mix. Help may also be taken from the mix used at other sites, with the same source of materials. Trial may be carried out at site and op timum mix should be decid ed as p er provisions for strength, durability and workability . Mix adop ted for the work on viaduct zone E-18 was as under; Grade of concrete Cement CA 20 mm 10 mm FA Water Admixture W/C ratio M 40 500Kg 768.4 Kg 512.3 Kg 438.2 Kg 185.0 litres 0.8- 1.2% 0.37

8. Assessment of Material Required for Casting Drawing of the girder should be studied in detail to list out the requirement of material for the castin g of girder. All the activities involved for the work should be discussed with the site sup ervisors along with the requirement of material for the same. All the material should be brou ght in advan ce to avoid the shortage at the time of execution. A typ ical list of material required for casting of P SC girder is shown below: SN Descrip tion Quantity Major Items 1 Cement 1360 2 Steel reinforcement 17.5 3 20& 10 mm aggregate 115 4 Fine aggregate(sand) 60 5 Admixture 650 6 Bearin g Temp lates 6 7 Guide tubes + Bearing p lates + 36 stressing wedges 8 Sheathing p ip e 600 9 HT Strands 5 Unit Bags MT Cum Cum Ltr Nos Nos M MT

Misc. Items 1 Insulation tap e 35 2 Grease (ordinary) 25 3 HSD 40 4 Hy draulic oil (for stressing and side 15 shifting) 5 Foam sheets 12 6 Adhesive 10 7 Shuttering p utty 20 8 Grease (sp ecial) for side shifting 10 9 Wire Brush 20 10 GI p ip e (35 mm OD) 30 11 PVC p ipe (40 mm OD) 35 12 Cutting wheel (dia 180 mm) 5 13 Grinding wheel 2 14 Hand glov es 6 15 Bindin g wire 150 16 Cutting oil 10 17 Hacksaw blade 15 18 Nuts and bolts 10 19 Weldin g rod 3.15 mm 6 20 Weldin g rod 4 mm 2 21 Paint 1 22 M Seal (for groutin g) 3 23 Patrol (for stressing) 7 24 Wooden p lanks for p acking LS 25 Fuel for Machinery Generator sets (90 hrs x 12) 1080 Tipp ers (100 hrs x 5 ) 500 Crane (60 hrs x 6) 360

Nos Kg Ltr Ltr Nos Kg Kg Kg Nos m m nos nos Nos Kg Ltr Nos Kg Pkt Pkt Ltr Kg Ltr Ltr Ltr Ltr

9. Bar bending schedule Bar bendin g schedule for the steel reinforcement should be p rep ared as per the details given in the drawin g. Shap e, size and location of each bar should b e clearly mentioned to avoid confusion. Typ ical colu mns in this schedule are shown below: Bar marked as 1 Dia (mm) 16 Sp acin g (mm) 240 Nos. 121x1 Shap e Len gth of Total each len gth bar(mm) (m) 5650 683.65 Remarks Deck top ,

= 121

5650

transverse

10. Assessment of steel Requirement of steel for different diameter bars has to be calculated. It has to be ensured that steel required for the work is collected in adv ance to avoid delay in p lanned activities. Typ ical p ro forma for the requirement of bars is shown below:

Dia of bar

Requirement of steel (MT) Girder Trolley refuge Wearin g coat 6 0.61 8 2.76 0.22 10 4.18 0.029 12 1.886 0.137 16 6.722 20 0.325 25 0.673 28 0.669 Total (MT) 17.215 0.386 0.61 11. Assessment of machinery and operators

Total 0.61 2.98 4.209 2.023 6.722 0.325 0.673 0.669 18.211

Requirement of machinery has to be listed out based on the activities involved during casting of girder. Sup ervisors should be nominated for each shift of working of these machines. A typ ical requirement is listed below: SN 1 2 3 4 5 6 7 8 M achine Crane Batching plant M oving Gantry Tipp ers with concrete bucket Shutter vibrators Vibrators Vibratin g needles Generator Nos Name of operators /sup ervisors 1 1 1 3 20 5 15 1

12. Assessment of Labour

Assessment of skilled, semi skilled and unskilled labour should be made in adv ance so that activities during execution are not hamp ered. A typ ical assessment is shown below: SN Job 1 2 3 4 5 6 7 8 9 10 11 12 13 Cement feedin g to Batching p lant and admixture mixin g Concrete bucket hooking and op ening at p ouring Operation of needle vibrators Top chute p lacin g and clean in g etc. Shutter vibrator changin g etc. Movement of cables during concretin g Masons +help ers for finishing etc. Manual concreting at diap hragm p ortion Leakage control Cleanin g at web Roding Samp lin g Misc. job during concreting Total Requirement of labour skilled Semi unskilled total skilled 0 1 12 13 2 0 0 2 0 4 0 0 0 0 0 2 10 6 6 2 6 2 0 1 4 0 2 2 2 34 0 4 2 0 2 2 5 0 12 0 0 3 42 8 10 4 8 4 6 6 4 12 2 2 7 86

13. Pouring plan Pouring sequence for the concreting of Girder has to be decided in advance. Depth of each layer has to be decided considerin g the p roduction capacity , ease in construction and elimination of cold joints. Pouring plan adop ted on E-18 was as given below: VIII 18cum 90 min VII 7 cum VI 10 cum V 10 cum IV 10 cum III 10 cum II 10 cum I 18 cum Pouring By X 34 cum 180 min 40 min 55 min 55 min 55 min 55 min 55 min 90 min gantry 0.35 m IX 3 cum 0.4 m 25 min 0.4 m 0.4 m 0.4 m 0.4 m 0.4 m 0.25 m

Pouring by Crane

14. Requirements for safe working

Requirements for safe working at site are to be listed out and arran gements should be made in advan ce to avoid any untoward incidence durin g workin g. These arran gements depend up on the working conditions at site and may require helmets, safety belts etc. If the casting is bein g done in situ at high er level, safety nets may be p rovided so that labour and sup ervisors may work without fear. 15. Form wo rk/S huttering Requirement of shuttering h as to be assessed and it has to be collected in advan ce. Some of the p ieces have to be fabricated as p er sp ecial shap e of the girder and this work should be carried out in advance. In the case of E-18, sp ecial collap sible shuttering was designed to facilitate the casting of girder in sin gle stage, excep t for the diap hragm. Detailed drawin g was got p rep ared and shuttering was fabricated at site accordin gly . Instructions in Para 6.2, 6.2 & 6.4 of IRS Concrete Bridge Code should be followed regard in g the finishin g, treatment and stripp ing of formwork. B Detail of co llapsible shuttering used at site of viadu ct zone E-18 is shown in Ann.

16. S taging If the gird er is to be caste in situ, stagin g has to be erected for shuttering. Detailed checkin g of stagin g should be done and followin g items should necessarily be checked : a. Members in stagin g should be as per approved drawing. Drawing no. should be sp ecifically recorded. b. Deviations from the drawin g should be recorded and these should not be allowed unless app roved. c. Condition of weldin g should be checked. Sometimes, tack weldin g is done in p lace of structural weld in g to facilitate the reuse of the same member in next stagin g. This p ractice should not be allowed. d. All the packing should be of h ard wood. e. Verticality of the members should be check ed f. All the nuts and bolts should be tight. 17. Level of Casting Bed/ Bottom Shuttering In case the casting is in situ, level of bottom shuttering has to be taken to ensure that the gird er is as p er drawin g. Similarly , level of casting bed should b e taken in case of casting in y ard. A typ ical format for recording the levels is as indicated below:

Distance from JAT end 0 5 10 15 20 25 28.33 Centre Left Right 18. Check lists Detailed check lists have to be p rep ared for various stages of construction. Contractor should check and fill up the details in ch eck list and it should be submitted to Railway sup ervisor for allowing further work. Entries should be checked by the Railway officials and necessary rectifications should be got done, if required. Further activity should be allowed only after ensuring that arrangements are as p er app roved drawings/code p rovisions. 19. Placing the inside shuttering Check list used for allowin g the p lacing of inside shuttering on E-18 is attached as Ann- C. It indicates the checks to be made before allowin g the p lacin g of inside shuttering. M ajor items to be checked are listed below: a. b. c. d. e. f. Level and condition of casting bed Align ment, verticality and condition of formwork Position of Bearings Reinforcement, cover to reinforcement and cov er blocks Inserts and fixtures (as p er drawing) Cable profilin g, condition, adequ acy and testing of p re stressing material (Typ ical p rofile shown in Ann. D)

20. Casting of Girder Check list used for allowin g the concreting on E-18 is attached as Ann- E. It clearly indicates the checks to be made before allowin g the concreting. M ajor items to be checked are listed below: a. b. c. d. Align ment, verticality and condition of formwork Reinforcement, cover to reinforcement and cov er blocks Inserts and fixtures (as p er drawing) Requirement and availability of concreting material along with testing certificates e. Requirement and availability of manp ower and machinery , along with stand by arrangements

Prestressing cables should be moved during the concretin g to avoid jammin g due to leakage of cement slurry inside the sheathing. Concreting in the end portion should be done carefu lly with the concrete havin g desired workability. This p ortion of girder consists of heavy reinforcement includ in g the p restressing cones, helical

reinforcement etc. Lot of effort and close sup ervision is requ ired to avoid any hollow p ortion in this area. Instructions in Para 8 of IRS Concrete Bridge Code should be fo llowed regardin g transp ortation, p lacement, comp action and curing of concrete. 21. Casting of Diaphragm Casting of Diaphragm is done in the next p hase. Check list used for allowing the casting of Diap hragm is shown in Ann. F. 22. Removal of shuttering & Curing Shuttering should be removed as p er sequence decided in advan ce, in the p resence of Railway s representative. Concrete surface should be insp ected for any defect/deficien cy and rectification measures should be taken, if required. Prop er curing of the gird er is essential for p reventing evap oration from the surfaces. It is normally done by establishing a high humidity environment. Curing comp ounds may also be used in p lace of traditional methods such as continuous water curing. Instructions in Para 8.4 of IRS Concrete Bridge Code should be followed regardin g curin g of concrete. 23. Prestressing S tudy the drawing Instructions regardin g the p restressing of girder are mentioned on the drawin g. It is sp ecified that how much time/strength is required before allowin g the p re stressing. It is also to be checked whether stressing is to be done in single or double st stages. Generally, 1 stage p re stressing has to be done b efore allowin g the movement of girder/remov al of bottom shuttering. Sometimes, it is sp ecified that wearin g coat has to be done before second stage of p restressing. Exact p rocedure is generally mentioned on the drawing and it is to be strictly followed. Prestressing steel Prestressing steel to be used in gird ers is specified in Para 4.6 of IR S Concrete Bridge Code. However, drawing should be studied to know regardin g the exact quality of steel considered while designin g and only that steel should be allowed. Every Coil of steel comes with a tag for identification of coil. This tag should be checked and carefully kep t for reference. In case this tag is lost, it may not be p ossible to know about the exact p rop erties of the steel. A test certificate is sent by

the manufacture alon g with the material. This certificate should be kept in record as these p roperties are required while calculatin g the actual elon gation and p restressing force in field. Generally , uncoated stress relieved low relaxation strands conforming to IS : 14268 are used for the PSC girders. A samp le test rep ort for p restressing steel and sheathing is shown in Ann. G & H. Prestressing operation Check adequ ate reserve of p ump ing fluid Fix jack at both the ends Check that all strands are p rojecting outside by sufficient margin Tighten the master wedges of jack Close the entry to back side of the strands because sin ce in case of breakage, strands may hit the working staff. App ly initial p ull 5-15 kg /cm2 to take out slackness Put markers & markin g distances from jack face App ly 20 kg/cm2 pressure and take first readin g of elongation Further readings also at interval of 20 k g/cm2 Conscious efforts to make uniform elon gation at both ends.

Calculations are simultaneously made to decide the p ressure and elon gation at which lockin g has to be done. All the details should be directly filled on the register to avoid confusion at a later stage. Actual slip should be measured after 24 hrs of p restressing and it may be used while decidin g the lo cking p ressure in further work. Instructions in Para 7.2 of IRS Concrete Bridge Code should be followed regardin g the tendons, sheathing and p restressing op eration. 24. Measurement of Camber After comp letion of stressing op eration, camb er should be measured. In case of casting in yard, camber can be measured with the help of feeler gau ge. Camber after stressing should be as p er the values mentioned on the drawin g. 25. Grouting Grouting should be done as early as p ossible after stressing. Grouting of lower ducts should be done first to avoid chances of leakage of grout into ducts. Grouting with cement grout is the most widely used method of p rotecting tendons in the ducts of p ost-tensioning systems. The initial disch arge will be contaminated with the oil and discolored: it must be discarded. Grout should be dense and homogen eous so as not to leave voids alon g the steel.

The grout must also be thoroughly mixed by machine to ensure comp lete mixin g and to obtain workable grout for injection. After mixing, the grout should be kep t continuously agitated or movin g. The groutin g p ump should be p ositive displacement p ump , cap able of p roducing the discharge p ressure and havin g adequate seals to prevent introduction of oil, air, or other foreign substances into the grout. The grout should be screened p rior to introduction into the p ump . Standby water flushing equip ment p owered by a sep arate p ower source should be available. Grouting must be continuous until the consistency of the grout emergin g from the vents is the same as that being in jected, without visible slu gs of water or air. Before injectin g the grout, the duct should be cleaned.

Instructions in Para 7.2.7 of IRS Concrete Bridge Code should b e followed regardin g p rotection of p restressing steel and anchorages. Para 9 of IRS concrete Bridge Code deals with the recommend ed p ractice for grouting of cables. 26. Shifting of Girder Shiftin g of girder is generally done after 1 stage p restressing so that the casting bed can be used for the casting of next girder. Ap p roved scheme should be used for lifting and side slewin g of girder to avoid the uneven stresses and subsequent cracks/damage to the girder. 27. Casting of Wearing coat. Casting of wearin g coat should be don e after 1 stage of prestressing or second stage of p restressing, taking guid ance fro m the drawin g. Due care should b e taken for the protection of surface since it is highly p rone to cracking. 28. Acceptance of Girder Samp ling should be done durin g the concretin g and these samples should be tested to get the idea regardin g the quality of construction. Instructions in Para 8.7 of IRS Concrete Bridge Code should be followed regard in g p rocedure, frequency of samp ling and accep tance criteria of con crete. 29. Launching of Girder Girder should be launched as p er the approved scheme. Safety and careful handlin g of girders are the p rime requirements during the op eration Launching scheme used on viaduct zone E-18 is shown in Ann. I.
st st

30. Fixing of Bearings Bearin gs are to be accomp anied with the test certificate from RDSO and markin g from the RDSO should be checked. General checkin g, in cludin g the dimensions, should be done so that there is no problem at the time of fixin g. 31. Other Miscellaneous jobs Other M iscellaneous jobs includ in g casting of Gap slab, Trolley refuge, fixin g of railin gs etc. should be don e and the girder should b e finally finished. 32. Workmanship and Quality It is essential to ensure the desired standard of quality for PSC construction. Some of the imp ortant factors in this regard are: Deputing of qualified sup ervisory staff. Testing and insp ection of each and ev ery material Availability of detailed working drawin gs Set up of laboratory for carry ing out the testing of various materials as well as the finished work Accurate stressing procedure Proper control on dimensions as per sp ecified tolerances Proper p reparation, mixing, handlin g, placin g ,consolidation and curin g of concrete Accurate dimensions, rigidity , p rop er surface of shuttering Proper handling, transp ortation and launchin g of girders Documentation of each activity regardin g the girder in form of Gird er History Sheet

33. Conclusions An attempt has been made in this rep ort to prep are the method statement for PSC girders, based on the experien ce gained during the construction of Viaduct E-18 (cast in y ard) and Bridge no. 100 (cast in situ) on Jammu-Udhamp ur Rail Link Project. Desp ite technical advances, failure of con crete structures is taking p lace. This is p rimarily due to lack of awareness regardin g p rop er p rocedure to be followed during construction. There is a need to create the awareness amon gst Engineers/sup ervisors to follow the p roper p rocedure durin g execution to achieve the desired quality , safety , optimum use of resources, min imizin g delay and sy stematic execution of works.

Ann.-A

_________Railway No. __________ Material Testing Laboratory , ____________________, ____________. Subject: Testing of M aterial Please find enclosed herewith following sealed samples for conductin g the tests as p er p rocedure given in IS codes. Testing should be don e for jud gin g the suitability of the material for con cretin g and should include the tests given in Annexure-A. SN Samp le no. Description Source Date:__________

Testing charges will b e p aid by(Railways/contractor). Enclosures: As p er Ann-(i) (Name) (Designation)

Copy to: __________________(supervisor) to ensure collection, sealin g and d elivery of material to the testing laboratory. ii. _________________ for information p lease. i.

List of Tests to be conducted A. Coarse Aggregates: 20 mm & 10 mm a. b. c. d. e. f. g. h. i. Siev e Analy sis Alkali - A ggregate reaction Aggregate Imp act Value Aggregate Abrasion value Aggregate Crushin g Valu e Soundness Chloride contents Sulp hate contents Deleterious materials Clay lump s Material finer than 75 micron siev e j. Water absorp tion k. Sp ecific Grav ity l. Flakiness Index m. Elon gation Index

Ann. (i)

B. Fine aggregate ( Riv er Sand) a. Siev e Analy sis b. Alkali Aggregate reaction c. Soundness d. Chloride content e. Sulp hate content f. Deleterious materials Clay lump s Material finer than 75 micron siev e g. Sp ecific Grav ity C. Water a. b. c. d. e. f. g. h. Physical character Organic solids Inorgan ic solids Sulp hate contents (as SO4) Chloride contents (as Cl) PH Value Limit of acidity (with N/10 NaOH) Limit of alk alinity (with N/10 HCl)

Ann. B Detail of Shuttering

Ann.- C Viaduct Zone E-18 Check Request for placing the inside shuttering Girder No.- --------D. Casting Bed a. Centre line of Bed, p osition of deviator blocks b. Cleanin g of b ed by comp ressed air c. Oil used to p revent sticking of concrete d. Levels Distance from JAT end Location 0m 5m 10 m 15m 20m 25m 28.33m Centre Left Right E. Form Work a. Align ment b. Verticality c. Surface condition d. Typ e of shuttering oil used e. Condition of Joints f. Rubber seal/d ense foam alon g the len gth of shuttering g. Sealin g of jo ints with putty h. Dimensions F. Bearin gs a. Position b. Level c. Thickness of p late d. Whether hot dip galvanized e. Fixin g in p osition G. Cover to Reinforcement a. Cover to reinforcement Location Tawi side Grid side Bottom Distance from JAT end 0m 5m 10 m 15m 20m 25m 28.33m

b. Whether cover blo cks tested for strength and found ok c. Thickness of cover blocks d. Bindin g arran gement for cover b locks with reinforcement H. Reinforcement a. b. c. d. Whether reinforcement details submitted Whether reinforcement is as p er app roved drawing Drawing no.. Deviations from ap p roved drawing, if any Deviation App roved by ------------------------------------------------------------------------------------------------Condition of reinforcement Whether binding of reinforcement is ok Whether overlaps are correct and staggered Whether sufficient no. of adequate dia ch airs for supporting the top lay ers of reinforcement in soffit slab are p rovided. Verticality of Web bars Whether web bars are at right an gle to the longitudinal b ars

e. f. g. h. i. j.

I. Inserts and Fixtures a. Whether sufficient no. of sp acer sleeves (ventilation holes) are p rovided in soffit. J. Cable p rofilin g a. b. c. d. Whether actual ordin ates of cable p rofile are taken and recorded Whether sheathing, HTS strands and gu ide tubes are ap p roved Test certificate no. and date for material testing includin g sheathin g Detail of cables Cable no. 1 2 3 4 5 6 7 8 9

e. f. g. h. i. j.

Reel no. Left Right Joint of sheathing with cones Any kink formation in the cable at ant p oint Anti corrosive protection of strands Position of helical reinforcement Provision of GI p ip es in diap hragm for future stressing Whether sheathings are threaded p roperly including correct threading of coup lers

k. l. m. n.

Whether fixin g of cables on sup p orts if firm Fixin g of Guid e cones Whether tap ing of joints is p rop er Whether len gth of the coup lers is adequate Signature of contractor Date.Time. Signature of SE/JE Date.Time.

Accep ted and permitted. Signature-------------Designation-------------

Ann. - D Typical Cable Profile

Ann. - E Viaduct Zone E-18 Check Request for Casting of Girder Girder No.- --------A. Form Work a. Align ment b. Verticality c. Surface condition d. Typ e of shuttering oil used e. Condition of Joints f. Rubber seal/d ense foam alon g the len gth of shuttering g. Sealin g of jo ints with putty h. Dimensions B. Cover to Reinforcement a. Cover to reinforcement Distance from JAT end Location 0m 5m 10m 15m 20 m 25m Cantilever -Tawi side Grid side Haunch - Tawi side Grid side Centre b. Whether cover blo cks tested for strength and found ok c. Thickness of cover blocks d. Bindin g arran gement for cover b locks with reinforcement C. Reinforcement a. b. c. d. Whether reinforcement details submitted Whether reinforcement is as p er app roved drawing Drawing no.. Deviations from ap p roved drawing, if any Deviation ------------------------------------------------------App roved by -------------------------------------------

e. f. g. h.

Condition of reinforcement Whether binding of reinforcement is ok Whether overlaps are correct and staggered Whether chairs used are sufficient and as p er sp ecifications

D. Inserts and Fixtures a. Galvanised drainage spout b. Galvanised railin g inserts E. Concreting material SN 1 2 3 4 5 6 7 Material Cement CA-20mm CA-10mm Coarse sand Plasticiser Water Bond solution Requirement Available Last testing done on Test certificate no. Other details

F. Density, M ake, Batch no. & typ e of plasticizer G. Whether strength of cement has been check ed by actual strength test and found ok H. Machinery and other accessories SN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Machine Weigh batcher Batching p lant Mixers Generator Pouring buck et Vibrators Vibrator need les Shuttering vibrators Curing pump Cube moulds Slump cone app aratus Thermometer Hy drometer Tarp aulin Requirement Stand by requirement Availability at site

I. Manp ower for concreting work SN 1 2 3 4 5 6 7 8 J. Safety a. b. c. d. e. f. g. h. i. j. Descrip tion Sup ervisors Masons Mixer operators Vibrator op erators Drivers Winch operators Generator op erator Labour for concreting Required Available

Requirements Helmets Safety belts Fire extingu ishers First aid and stretcher Condition of wire rop e in winch Condition of p ulley s and supports Limitin g switch in p assenger hoist (if availab le at site) Communication with winch operator Railin gs Safety net

K. Concreting p lan k. Total quantity of concreting to be done l. Outp ut of mixture p er hour m. Total time required for concreting n. Total no. of shifts o. Whether p ouring sequence has been submitted p . Whether p ouring sequence has been ap p roved by Engineer in charge q. Whether mix design h as been ap p roved by engineer in charge r. Detail of mix to be used L. Any other detail includin g d eficiency /defect noticed Signature of contractor Date.Time. Signature of SE/JE Date.Time. Accep ted and permitted. Signature-------------Designation-------------

Viaduct Zone E-18 Check Request for Casting of Diaphragm Girder No.- --------A. Prep aration of Construction Joint B. Positioning and straightenin g of existin g bars C. Form Work a. Align ment b. Verticality c. Surface condition d. Typ e of shuttering oil used e. Condition of Joints f. Dimensions g. Sup p orts/Nuts and Bolts D. Cover to Reinforcement a. Cover to reinforcement Location Top Bottom JAT side UDM side E. Reinforcement a. b. c. d. Whether reinforcement details submitted Whether reinforcement is as p er app roved drawing Drawing no.. Deviations from ap p roved drawing, if any App roved by ------------------------------------------Centre Left Right

Ann. - F

Deviation ------------------------------------------------------e. Condition of reinforcement F. Concreting material SN 1 Material Cement Requirement

Available

Last testing done on

Test certificate no.

Other details

2 3 4 5 6 7

CA-20mm CA-10mm Coarse sand Plasticiser Water Bond solution

G. Density, M ake, Batch no. & typ e of plasticizer H. Whether strength of cement has been check ed by actual strength test and found ok I. Machinery and other accessories SN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Machine Weigh batcher Batching p lant Mixers Generator Pouring buck et Vibrators Vibrator need les Shuttering vibrators Curing pump Cube moulds Slump cone app aratus Thermometer Hy drometer Tarp aulin Requirement Stand by requirement Availability at site

J. Manp ower for concreting work SN 1 2 3 4 5 6 7 8 Descrip tion Sup ervisors Masons Mixer operators Vibrator op erators Drivers Winch operators Generator op erator Labour for concreting Required Available

K. Concreting p lan s. Total quantity of concreting to be done t. Outp ut of mixture p er hour u. Total time required for concreting v. Total no. of shifts w. Whether mix design h as been ap p roved by engineer in charge x. Detail of mix to be used L. Any other detail includin g d eficiency /defect noticed Signature of contractor 1 Date.Time. Signature of SE/JE Date.Time. Accep ted and permitted. Signature-------------Designation-------------

Ann. - G Sample test report for Prestressing cables

Ann. - H S ample test report for Sheathing

Ann. - I Launching S cheme