GAMMON INDIA LIMITED

JOB: 20 BRIDGES ON NH-60 PACKAGE 0R/WB-I

METHODOLOGY OF PSC BEAM

CASTING, STRESSING & GROUTING
FOR ROBS
SOURCE & QUALITY ASSURANCE OF CONSTRUCTION
MATERIALS:
Utmost quality shall be maintained for the following construction materials

Cement
Reinforcement Steel
Coarse Aggregate
Fine Aggregate
Admixture
HT Strands
Sheathing Strip
Pre-stressing Hardware

Cement:
Source: 53 Grade L&T / Grasim / Ambuja
Material shall be tested at the manufacturing source and Test certificate shall be
collected for each lot. In every batch the following test shall be conducted at Q.C.
Lab (Subarnarekha site) to ensure that Manufacturers Test certificate results are
matching Q.C. Lab results.

Consistency
Initial Setting Time
Final Setting Time

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 2 of 16

Fineness Of Cement
Compressive Strength
Soundness Test.
Acceptance Criteria: Test results shall conform to IS 8112.

Reinforcement Steel:
Source: TISCO / SAIL / RINL / SRMB/ IISCO
Chemical and Mechanical properties shall be tested as per IS 1786 at the
manufacturing source & test certificates shall be collected along with the every
consignment of steel. Also steel samples shall be tested randomly in outside
laboratories to check whether the test certificate results match the laboratory test
result.
Acceptance Criteria: Test result shall conform to IS 1786.

Coarse Aggregate:
Source: Durga crusher/ Tarini crusher
Material 40mm / 20mm / 10mm shall be received at ROB sites. Samples shall be
collected for every 200 m3 of aggregate or for any change of source, the following
test shall be conducted in Q.C. Lab as per IS 2386

Gradation Of Single Size Aggregate

Gradation For Graded Aggregate
Elongation Index, Flakiness Index & Combined Index.

Acceptance Criteria: Test results shall conform to IS 383.

Fine Aggregate:
Source: Gobarghata
Material shall be received and screened at the stacking yard of the respective
ROB site. Sample shall be collected for every 200 m 3 of aggregate or any
change of source, the following test shall be conducted in Q.C. Lab

Gradation
Silt content shall be estimated as per IS 2386 & ensured less
than 3%.

Acceptance Criteria: Test results shall conform to IS 383.

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 3 of 16

Admixture:
Source: Chembond, Sika
Admixtures required for different mix grades shall be procured from approved
agencies. Test certificates shall also be collected along with the every
consignment. The following tests are conducted in Q.C. Lab to verify with Test
certificate result

Relative density as per IS 6925

Chloride content Test result shall conform to IS 9163.

HT Strands:
Source: M/s Indore Wire & Tata SSL
12.7mm dia low relaxation 7 ply strands of class II conforming to IS 14268 1995
Random inspection of the materials shall be done by consultants engineer at
factory.

Sheathing Strips/ Ducts

Source: M/s Standard Engineers, Mumbai
Bright material flexible Sheathing strip of 0.4mm thickness and 36mm width
Cold rolled cold annealed mild steel conforming to IS 513 (Bright Material) or strip
36mm width and 0.40mm thickness shall be brought at site. Sheathing pipes of
75mm dia shall be manufactured at respective site and the same will be
transported to casting location site as per requirements.
Physical tests of ducts shall be conducted at site as per MOST 1800 /I

Pre-stressing Hardware
Source: M/s Freyssinet Pre-Stressing Concrete Company Ltd., Mumbai
12 T 13 & 19 K 13 anchorage cone & cir clip
FPCC will supply 19K13 and 12T13 anchorage cones which will be as per
specifications and drawings.
For ROB-1, 19K13 and for all other ROBs 12T13 shall be used.

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 4 of 16

CONSTRUCTION METHODOLOGY:
SALIENT FEATURES OF PSC BEAM OVER OBLIGATORY
SPAN
DETAILS OF SECTION OF PSC GIRDERS FOR

4 ROBS

f
e
c

d
t

175
175

b
a

175
175
115

DETAILS
a
b
c
d
e
f
t
g
Span length

ROB-1

ROB-2

ROB-3

ROB-4

240
200
100
1530
180
1100
275
680
40.50

240
200
100
1080
180
1100
275
680
23.14

240
200
100
1330
180
1100
275
680
29.17

240
200
100
1080
180
1100
275
680
23.80

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 5 of 16

DETAILS OF PSC GIRDERS FOR

4 ROBS

DETAILS

ROB-1

ROB-2

ROB-3

ROB-4

Concrete
quantity (cum)
Span length
Grade of
concrete
Pre stressing
type
Dia of
sheathing pipe
Bearing type
Nos of girders
per span

42.2

18.25

31.30

20.60

40.50
M40

23.14
M40

29.17
M40

23.80
M40

19K13

12T13

12T13

12T13

85mm dia

75mm dia

75mm dia

75mm dia

POT cum PTFE

6nos.

Elastomeric
6nos.

Elastomeric
6nos.

Elastomeric
6nos.

DETAILS OF SUPPORTING ARRANGEMENT DETAILS

Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

12.

Description

ROB-1

ROB-4

Live wire top RL (max)

Supporting arrangement height
over capping beam
Rail Top RL
Bearing Pedestal Top RL (min)
Top of Bearing RL
Trestle Foundation RL
RL at which PSC Girders are to be
cast:
Height at which PSC Girders are to
be cast from rail track top [7-3]
Minimum clearance from soffit to
live wire
Trestle height
Clearance from live wire
&supporting arrangement bottom
(ISMB 600) [7-2-1]
Lowering height [7-5]

14.445m
980mm

32.410m
980mm

8.145m
14.837m
14.934m
7.845m
17.349m

26.26m
32.799 m
32.879 m
26.000 m
34.870 m

9.201m

8.61 m

480mm

600 mm

8.060m
1.92m

7.35 m
1.480 m

2.415m

1.99 m

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 6 of 16

PLANT/MACHINERY & MANPOWER:

PSC beam Shuttering Beam Bottom

Beam Side Shuttering
Crane T320
Transit Mixer
Shutter Vibrator/transformers
Immersion Vibrator & Needle (60mm )
Beam Lifting Jack 50T
Batching Plant installed at nearest to
the respective ROBs shall be used.
Pre stressing Jack & Pump
Grouting pump

02 Set
01Set
01 No
02 Nos
06&02Nos
03 Nos
04 Nos

02 each
01No

Manpower:
Project engineer
Junior engineer
Foreman
Supervisor
Surveyor
Skilled/ Unskilled Labor:

Carpenter
Fitter
Khalasis
Concrete pump operator
TM Driver
Male Coolie

01
01
01
01
01

35
35
50
02
04
15

CONSTRUCTION METHODOLOGY:
The procedure as described below is for ROB-1, PSC girders. For other ROBs
similar arrangements and methods shall be adopted during the time of
construction as per respective drawing.

Trestle Foundation
After doing survey, trestle foundations shall be marked and shall be constructed
as per attached drawing 8007/TS/516C.

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 7 of 16

Fabrication of Trestle, Supporting arrangements & Shuttering

Shuttering and supporting arrangements shall be fabricated as per the following
drawings

i.

PSC Girder Shuttering: 8007/TS/518 & 519

ii.

Trestle Fabrication: 8007/TS/540

iii.

Details of Supporting Arrangement: 8007/TS/517A.

Typical sketch of Testle & supporting arrangement in enclosed in

Annexure-1

Sequence for casting of PSC Girder

PSC girders shall be cast as per the sequence given in Drg No.TS/561 &
TS/562.

Erection & Dismantling of Supporting Arrangement

Trestles and supporting arrangements shall be fixed as per drg. No. TS/516C. For
erection of trestles, cross girders shall be placed at PRE BLOCK TIME.
Only erection and dismantling of ISMB 600 (1nos Girder) shall be carried out
during BLOCK TIME which will take approximately 8hrs per beam. Exact BLOCK
TIME shall be intimidated during construction of obligatory spans of respective
ROBs.
Tata-320 crane shall be used for erecting ISMB 600 girder. To make approach
upto track line, approach ramp shall be constructed for erection of trestle near
pier cap and as well as in between track line during BLOCK TIME.
Crane shall be positioned at track centerline while at operation and also during
idle time.

Shuttering, Reinforcement & Cable Profile

After erection of supporting arrangement, beam bottom shuttering shall be
placed.
Jacking stool, as per drg. No. 8007/TS/570, shall be placed at position before
casting of PSC Girders. Both shuttering shall be leveled accordingly.
One Side shuttering shall be fixed as per drg. No. 8007/TS/519 & then it shall be
ready for placing of reinforcement.

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 8 of 16

Reinforcement
Treated bars shall be fabricated in advance as per approved bar bending
schedule. After fixing and checking verticality of one side shuttering,
reinforcement fixing shall be completed.

Cable Profile
Fabricated sheathing pipe shall be brought to location and shall be placed over
marked cable profile as per drg. No.ROB-1/08(R1). After necessary checking by
the Engineer, cable profiling shall be completed.
After checking of cable profiling, closing of shuttering shall be carried out. Proper
alignment of the girder shall be carried out by the help of adjustable props and
then it shall be ready for final checking before concreting.

Concreting of PSC Beam:

DETAILS

ROB-1

ROB-2

ROB-3

ROB-4

Concrete quantity
Grade of Concrete
Time for completion
Location of Batching
Plant

42.2
M40
5 hrs
Existing
Haldipada
Batching plant

18.25
M40
2 hrs
ROB-2
Batching plant

31.30
M40
4 hrs
Existing Belda
Batching plant

20.60
M40
3 hrs
Existing Belda
Batching plant

(yet to be installed)

Proposed Plan for Concreting of PSC Beam:

Concrete pump/ Crane Bucket

Transit mixer (suitable numbers considering lead, Min is 2nos.)
Shutter Vibrator: 6nos.
Needle Vibrators: 2nos.

1. Concrete shall be produced at batching plant and will be transported by

transit mixers to the location.
2. Placing of concrete shall be done by concrete pump/crane bucket@ rate
of 8cum/hr

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 9 of 16

3. Concreting shall be done up to a depth of 400 mm and the same layer will
be continued till completion of the beam.
4. Compaction of concreting at bottom flange, web shall be done by using
shutter vibrator and also with immersion vibrator simultaneously.
5. Proper care shall be taken to ensure all the cables are free from concrete.
6. During concreting and up to 3 to 4hrs after completion of concreting, the
cables shall be checked manually for free movement.
7. Finally surface hacking shall be done at the beam top surface for proper
construction joint with deck slab.

CURING & DESHUTTERING

Normal curing shall be commenced after final setting of concrete i.e. 6hours
(approx) depending on cement.
For regions where safe access is not there due to overhead electric wires,
approved curing compound shall be used instead of ordinary curing. Curing shall
be continued till the concrete reaches strength 32N/mm2

PRE-STRESSING
1. 1ST Stage stressing will be done when the concrete achieves strength of
32 MPa and total 3nos. cables (i.e. cable no.1, 2&3) in each girder shall
be stressed in 1st stage by the help of K-350 FPCC make jack.
2. 2nd Stage stressing will be done after completion of diaphragms and
deck slabs and attains specified strength of 40MPa. 3nos. (i.e. cable no.4,
5&dummy) of cables shall be stressed in each beam in 2nd stage.
3. Extension at each end during stressing operation should be equal as far
as possible, max. Difference should not exceed 5% of the prescribed
extensions at each end. In case the required extensions are not obtained
at the specified pressure stressing should be continued till the required
extensions are obtained subjected to jack pressures not exceeding
585kg/cm2
4. difference between calculated and observed tension and elongations
during the pre-stressing operations shall be regulated as per MOST sec.
1807 under post tensioning head as per point a, b, c, d

Method of Stressing
1. During curing of pre-stressing beam, arrangements for pre-stressing shall
be started
2. Place the tripod on both end of PSC beam

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 10 of 16

3. HT Strands to be physically checked to ensure the strands are free from

any concrete blockage.
4. Keep all strand ends at particular point approx 450mm from the
anchorage cone.
5. Clean all projected HT strands by petrol and afterwards give a coating of
wax for smooth operation place the bearing plate on the outer face of
each of the anchorage cone of PSC Beam.
6. Fix the cir clip in each hole of bearing plates by means of a pipe.
7. Erect the pre-stressing jacks and place the jacks first in cable-1 of both
end and then fix the barrel and grip in pre-stressing jacks.
8. Initial force shall be applied for tightening of jacks, for gauge marking for
measuring extensions of cables.
9. Stressing to continue till it reaches its final extensions as per table i.
10. Afterwards all the other cables to be stressed in 1st stage as per
sequence as given above.
11. Slip of each cable shall be measured and recorded as per MOST.

Lowering of Girder
J Bolt shall be fixed over pier as per drg. No.TS/112 at the time of casting of
pier cap and then girder shal be lowered with the help of hydraulic jack and
pre-fabricated stool as per drg. No. TS/570 by removing the stools one by
one.

THE FOLLOWING SEQUENCE SHALL BE ADOPTED FOR FIXING OF POT

cum PTFE BEARINGS:
1. 90mm dia pockets along with PVC hose shall be provided at end
block portion of PSC Girder before casting of girder.
2. Pedestal shall be cast leaving pockets for grouting after bearing
sleeves are fixed in position
3. Positioning of bearing on pedestal shall be done matching project and
bearing centerline in both axes keeping preset line of bearing towards
next span. Pedestals shall be cast 10mm down or else 10mm
chipped. The products of sleeves shall be grouted using
Conbex/Cebex-100 @ 225 g per 50 Kg of Cement (w/c ratio 0.4) by

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 11 of 16

natural pouring to get a uniform thickness (i.e. 10mm) mortar in

between bearing and pedestal.
4. Erection and lowering of girders
5. Side shifting of girder & placing over bearings if required.
6. Fixing of bolt sleeves in top plates of bearing, ensuring bearing
sleeves are in vertical position
7. Lower the girder over grouted bearing after 48 hours when required
strength is attaining.
8. Grout the top pockets as in item no. 1 &2 for fixing bearing by
plasticized expanding grout admixture i.e. Conbex100 @ 225 g per
50 Kg of Cement with the help of Hand Grouting Pump through PVC
hose.

TESTING & SAMPLING PROCEDURES:

Slump Test:
Slump shall be taken continuously for each load and also slump shall be taken
periodically as per the direction of Engineer. The same shall be recorded in
Concrete Pouring Report.

Cube Test:
Cubes of size 150x150x150mm shall be taken. Number of cubes shall be taken
as per Table No.1700 in MOST specification.
The same shall be tested at the Q.C.lab for 2 to 3 days strength and 28 days
strength and it will be entered in the cube test register. 30% of concrete cube
shall be placed at top of PSC Beam for checking of periodical strength to ensure
minimum strength specifications for Pre-Stressing..

RECORDS:
Documents/Records

Format for checklist for reinforcement

Format for checklist of Staging and Formwork

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 12 of 16

concrete pour card

concrete pouring formats
Record of Pre-stressing operation along with elongations and
jack pressure data shall be maintained as per format 1800/ii of
MOST.

SAFETY MEASURES:
SAFETY ARRANGEMENTS FOR CASTING PSC GIRDER IN ROBs.

Insulation over live wire over obligatory span portion :

(NHAI/Railways to take action)
Maximum possible lowering of live wire to set maximum
clearance for permanent and temporary structures
Use of large quantity of water for curing shall be restricted
Restricting shifting and handling of materials during erection
and dismantling during Pre Block & Block time to avoid falling
of foreign objects over track
Barricading the work area by CGI sheets keeping one entry &
exit point
Providing a Flag man with whistle in the Balasore side

GENERAL:

Technical personnel and work men are engaged during

concreting operation both at batching plant and Site shall be
equipped with helmets.
Safety shoes shall be provided to masons and khalasis
engaged for vibrator operations.
There shall be safety signs painted on boards displayed and
also barricading / fencing shall be done.
There shall be security guards posted at suitable locations.
For night concreting, sufficient flood lighting shall be provided
with red light danger signs at vantage locations.
First Aid Counter shall be maintained separately in stores
throughout the working hours.

SAFETY DURING STRESSING:

Use hydraulic equipments supplied with a relief valve

Place safely valve in between jacks and connection high
pressure hose.
Use hose pipes in good conditions, avoid to use worn out hose
pipes.

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 13 of 16

Check the concrete around bearing plate and anchorage to

see whether there are any voids /honeycombing
Dont allow anybody behind stressing devices or in line with
tendon or in the vicinity of hydraulic hoses.
When the stressing works are in progress no other work
should continue in the vicinity
Health of safety systems incorporated in the stressing
equipment shall be ascertained once a week.
Provide safety barriers during stressing operations
Display clearly visible sign DANGER..PRESTRESSING
WORKS IN PROGRESS

GROUTING OF CABLES IN PRESTRESSED

CONCRETE
Grouting of cables shall be conducted preferably within 14days of stressing of
cable.

Materials:

Water: clean, potable water free from impurities will be used.

Cement: OPC as mentioned above
Sand: sand conforming to IS:383 will be used
Admixture: admixture if required conforming to IS:9102 will be
used.

Grout Mixer & Agitator: the grout shall be maintained in a

homogeneous state with uniform consistency to avoid any
separation of cement.
Grout Pump: Positive displacement type grout pumps capable
of ejecting grout in a continuous operation shall be used.
Grout Screen: grout should be passed through this screen,
having a mesh size of 106microns prior to introduction in to the
grout pump.
Connections & Air Vents: all the connections shall be of the
Quick Couple type and at change of diameters suitable
reducers will be provided.

Equipment:

Mixing of Grout:

Proportions of the required materials will be measured by

weight before starting of mixing operation.
Water shall be added to the mixer followed by cement, sand &
admixture/ readymade grout mixture.

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 14 of 16

Mixing shall be done for approximately 2 to 3 minutes until

uniform and thoroughly blended grout is achieved.
Adequate care shall be taken to prevent any addition of water
to mixed grout to increase fluidity.
Cubes of 100mm shall be taken for verification of Compressive
Strength

METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 15 of 16

Grouting Operations:

Injection of Grout

Grouting shall be carried out within 2 weeks of stressing of

cables.
Ducts shall be flushed with water for cleaning as well as for
wetting the surfaces of the duct walls. Water used for flushing
should be of same quality as used for grouting.
After cleaning all water shall be drained thoroughly by vent
pipe or by blowing compressed air through duct.
During and after 3 to 4 hours of grouting other non stressed
cables shall be checked manually for free movements.
All outlet points including vent openings should be kept open
before to commencement of grouting.

After mixing grout should be kept in continuous movement and

injection of grout must be continuous without any interruptions.
Grouting shall be commenced initially with a low pressure of
injection of up to 0.3MPa increasing it until the grout come out
through the other end with same consistency as that of the
grout @ injection end.
Full injection pressure (approx 0.5MPa) shall be maintained for
a minimum of 1 minute before closing the injection pipe.

Records

Grouting records shall be maintained as per format conforming

to MOST, Appendix 1800/IV

Annexure-1
METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 16
of 16
FIG: OBLIGATORY SPAN SUPPORTING ARRANGEMENTS AT ROB-1
17.349m

14.934 m
14.837 m

8.145m

7.845m

Annexure-2

B
A

LEGENDS:
A Overhead Railway Electrical Conductor.
B Aluminium profile both side covered with 25mm thick
Rubber sheet of adequate insulation grade.
C Adjustable Suspenders.
D - 33 KV Disc insulators.
E Overall length of the profile 4mtrs if the beams are cast
and shifted, 17mtrs if all six beams are cast simultaneously.