Professional Documents
Culture Documents
(DK0+44 ~ DK26+461)
MS-53 B
Rev. B
Ref. Letter No :
1
Contents
5.0 Details and Procedure of carry out method statement activities. ............................... 4
5.2 Equipment............................................................................................................................................... 4
5.3 Detail procedure for carry out ctivities of the method statement. .......................................................... 6
2
1.0 Purpose of the Method Statement
This method statement provides the details of the materials, the equipment, the procedure and
relevant documents related to the post tensioning, grouting and anchor sealing of T girders.
Construction Manager, QAQC Manager, Structural Engineer, site Engineer and other relevant
personnel within whose scope of works shall be responsible for referred construction activities in related
to post tensioning and grouting of T girder precast shall carry out according to the stipulated method
statement unless otherwise changed by the Engineer. Experienced engineer who will be in charge,
Technical staff and Supervisors are assigned to the precast yard with responsibility and authority.
3
5.0 Details and Procedure of carry out the method statement activities.
5.1 Materials
The main materials engage in the post tensioning, grouting and recess concrete for PC-T girder
construction are follows but are not limited to.
5.1.1 Pre-stressed tendon (Strand)
Pre-stressed tendon used for T girder precast shall comply with the requirements given in the
section of the Approved Design drawings for 20m, 25m and 32m concrete T girders. (strand
Wires - Comply with BS 5896). PC tendons delivered to the site are stored indoor with safely
covered with numbered identity according to suppliers document and company store procedure.
Steel ducts of different diameter which use for precast T girder fabrication shall comply with the
requirements given in the section of the approved design drawings and specification for 20m,
25m and 32m span concrete T girders and are stored same as above.
Anchorages, spiral reinforcement, bearing plates and wedges used for T girder precast shall
comply with the requirements given in the section of the Approved design drawings as specified
for 20m, 25m and 32m T girders and those items will be supplied store safe indoor and deliver to
site at the time of use.
5.1.4 Grout
Grout which is of same strength as of girder concrete, the material and mixed product approved
by the Engineer is used for precast T girder tendon pipe infill shall comply with the requirements
given in the section of the Approved design drawings for 20m, 25m and 32m T- girder
fabrication.
5.1.5 Water proof and anticorrosive paint
Water proof material and anticorrosive paint use for T girder fabrication shall comply with the
requirements of the Approved Design drawings for 20m, 25m and 32m concrete T girders.
5.2 Equipment
The main equipments used for T girder post tensioning and grouting are as follows and are not
Limited to,
Gantry crane
Stressing Jack and assembly (Hydraulic Pumps & Jacks, dial gauges use for Post
tension)
Grout Mixers and Pumps
Air compressor Power source (Generators)
4
Electrical Hydraulic pump Hydraulic Jack Dial Gauge
5
5.3 Detail procedure for carry out activities the method statement.
b. Tendon materials will be randomly sampled for each batch delivered as specified in the
Laboratory inspection and test plan.
c. Design control tensioning stress shall always within the safe characteristics limit which is
(1416 MPa and is equal to 0.8Fpk = 0.8 X 1770 MPa.) (Refer the attached annexure 01-
Allowable tolerance given in the design for control stress of tensioning (SDA-CMC-283) the
jacking force shall be increased to 80% of characteristic strength and additional safety
precautions should take. in according to the BS 5400 P4 Cl:6.7.1.
When the tensioning stress approaches critical limit (75% of the characteristic strength), the
site working crew is given an alert about the risk.
Vacate the working crew from the line of load application axis.
d. However control stress during tensioning shall strictly adhere to be kept on 0.75Fpk. In such case
the final force is to be increased beyond the above limit in a well verified situation that is
necessary the maximum force shall slightly increase but fairly below 0.8 Fpk limit under all
necessary safe precautions are taken at site safety and stability of the girder.
e. Calculations and site records sheets which includes applying forces (Po), effective force (Pe), and
elongation (e0) etc are,
Annexure 04: Tendon stressing site calculations sheets and record sheets
6
5.3.2 Cutting and insert tendons.
Total working length of tendon is equal to sum of the design profile in the length drawing, grip anchor
length, length of tendon within the jack and other spacer assembly plus reserved working length.
Pre-stressed tendon shall cut at site to the length as above relevant to each tendon with a electrical disc
cutter or blade and separate strands which are numbered at both ends are stacked in bundle for each
tendon above the ground prior to install. Weld or Arc shall not be allowed for cut strands to avoid heat or
melt any tendon.
c. The tendon shall be coded and numbered for duct accordance to design drawing.
d. Each strand within a tendon shall number with marking tag before install at both ends.
e. Tendon which was cut shall install in bundles at earliest; otherwise it will be numbered and stock
above the ground to avoid coat dust or mud and covered against rust.
f. Pre-stress tendon will be stocked in rolls and covered by plastic sheet and keep under shade
against corrosion.
g. Tendons insert through the corrugate duct manually prior to the concrete and ensured unblocked
access. Aligned and fixed corrugated duct which were positioned at designed profile as in the
drawing.
h. The duct shall clean with high-pressure air before insert the tendons.
7
i. Numbered strands in a tendon are threaded in respective slots reserved for each in the anchor
block at both ends. Projected tendon out of the girder shall rap cover and insert through pipe or
peace of duct.
a. Construction joint preparation and chipping for second stage concrete after sufficient curing on the
girder shall carry out as prescribed in design notes. Further, defective surface if any shall attend for
necessary repair by approved method to have homogeneous aesthetic finish and cure prior to stress
the girder.
b. Strong and stable safety buffers are hold behind the both stressing ends. (Refer the annexure 05 for
the tensioning safe plate drawing). Following photos shows the manufactured safety buffer for this
purpose. During the tensioning work, the pumping equipments are place behind this safety buffer
wall to prevent from the possible flying objects come out from the stressing ends. The barricade and
sign boards Tensioning work. Off limit are displayed around the working area. While doing the
tensioning, the safety officer should stay at the site and avoid the unofficial persons entering the
tensioning areas.
c. Gantry held crane or chain block and lifting frame assembly shall arrange to keep the jack in straight
with the tendons as the axis of stressing tendon and the axis of jack should coincide.
8
d. Effective communication by means of walky-talky shall arrange to coordinate among both working
groups at ends during simultaneous stressing operation.
e. Projected tendon part beyond the anchor head which will pass through the jack shall well clean by
mop and applying cleaning agent (WD-40) if necessary to free of rust, dust or lubricant coated if any
to have proper grip to avoid slip while tensioning.
f. Then permanent wedges are inserted to each strand and clip and tight by manual for which G I pipe
shall pass from end of the strand and push the wedge to tight the strand with the wedge anchor head
significantly.
g. Additional spacer and stretching tube shall insert first up to anchor block which help the jack to hold
out of the girder recess.
h. Since the jack is heavy equipment, it is hung on a specially prepared steel frame through a chain
block as shown in the following figure. In this set up, slight vertical and horizontal movement are
possible to position the jack axis with the duct centerline. The jack with tool anchor ring after spaces
shall lift and position to interface with tendon strands to the jack face by slight vertical and lateral
movements with the aid of mechanism provided for the jack and holding frame assembly. (Refer the
Annexure 06 for Jack holding frame work )
i. Jack, pressure gauge and pump are assembled properly to complete it as unit.
9
j. The equipment arrangement shall be checked by Site Engineer before start tensioning to confirm the
jack and pressure gauge combination to make sure they match each other according to calibration
reports available at site for same. Each can identify with serial numbers labeled on it.
k. A movable shade will be put up over tensioning ends to have cover for hot and rainy weather.
l. Tensioning equipment (Jack) shall calibrate before use combine with pressure gauge for co-relate
each other. Jack and pressure gauge combination is calibrated to determine the co-relation curve
between forces against pressure gauge dial reading. This relation of jack calibration always use for
stressing measurements check to have maximum accuracy of the job. Once calibrated equipment
calibration data shall re-verify after 12 months for use again. Refer the annexure 16 for Table of
force (kN) Vs Gauge pressure details)
m. Girder stressing is done in two stages which are initial and final stressing, at first stage tendons N2,
N4 and N5 only are tensioned for limited stress on cast bed as directed in the design then shift the
girder to stock yard and stack with safe support at the sides. Refer the attached details with drawings.
Annexure 07
n. Separate Method Statement will be submitted for the T girder lifting the shifting.
5.3.4 Tensioning:
Measuring steel rule stream edge which facing the jack can directly Zero.
10
a. Compressive strength of test samples of concrete, the test cubes which were match cured as the
girder should reach at least 30Mpa to apply initial stress. Behavior of vertical deflection,
Horizontal deflection and elastic shortening of the girder after the initial stress shall monitor at
this stage and that shall be done reference to pre-marked positions on girder bottom face at ends
and middle span with respect to pedestal top and the monitoring shall continue after final
stressing also at the stock yard for same reference points with the leveling instrument by which
elevation difference shall obtain at the mid span with respect end points. Also horizontal sag if
any shall check referred fixed offset line from the girder axis. Tensioning is done step by step in
20% equal increments to the force. Force relevant for each tendon shall determine from final
stress applicable for them given in the design at each stage. The mode of stressing from the both
ends of the tendon at simultaneous operation. Minimum pressure readable in the dial gauge shall
0.5MPa.
b. Once the stressing starts 20% of the load shall apply initially to stretch the tendon by this strands
are tightened with wedges and anchor head on the bearing plate without slack within tendon
inside the girder. Initial jack piston extension shall measure and record and the tendon elongation
is measured from this stage onward. Hold applied pressure for about one minute at each step
before measure and record the elongation. After apply final pressure on each tendon the applied
load shall hold for two minutes prior to measure and record final elongation to have the
maximum accuracy and precision of the final elongation result.
c. The tensioning shall carryout in initial and final stages following the approved sequence and
gross elongation is measured and record in each step of 20% increment other than limited stress
which should apply for selected tendons only at the initial stage as prescribed in the design. Final
stress shall apply after concrete has reached design strength and Modulus of Elasticity 50MPa
and 34MPa respectively to satisfy the requirements of BS5400 Standard Specification.
d. Step by step tensioning, measuring and recording procedure would follow as prepared data
record and calculation sheets attached. In that calculation shall prove final net elongation of the
tendon is remained within the allowable design limit of 6% with respect to anticipated
theoretical value against the proofed stress prior conclude entire operation of each tendon.
e. On the stressing record sheets, in addition to stressing details, following are to be mentioned.
f. All the records and calculation relevant to each tendon stressed shall submit for engineer review
and approval within 24 hours.
11
g. After record final gross elongation the applied force shall gradually released not up to zero but to
leave minimum pressure readable in the gauge which would not exceed 1MPa. At this rest stage
remaining jack piston extension shall measure to obtain actual wedge set draw in value and
compare with the expected draw in considered for gross elongation and determine net final
permanent elongation.
h. Then Jack shall take out and visible marking on tendon with 10cm offset distance from anchor
head shall establish and that will be checked after 24 Hours to ensure slip if any in the tendon
complete stressed and projected strands shall crop with rolling disc cutter leaving 3cm from the
anchor after joint verification of slip if any. Flame cutting is not allowed.
i. The anchor head shall seal with cement sand mortar (mix.1:3) and mortar fills into a form fixed
around anchor head as temporary measure to hold grout pressure inside and avoid any leak
through tendon grip during pressure grouting of the duct. Temporary seal shall break and remove
after grout in the duct hardened.
12
5.3.5 Grouting Tendon Ducts and recess seal concrete
a. Free space of Tendon ducts are filled with neat cement grout which has same characteristic of
girder concrete strength 50MPa pre designed as per specific requirement, same has been
approved by the engineer.
b. Grout mixer and the pump which has sufficient capacity and pressure respectively are selected
for the purpose to make grouting process is consistent and continuous for each tendon from start
to the end.
c. The capacity of grout mixer is 180L, and the volume of each pc duct is about 35L ( X L;
Avg. Length = 25m and duct dia. = 75mm) hence each batch be sufficient for at least 4 tendon
ducts is to be grouted at one and same attempt.
d. Each duct shall well clean and flush with high pressure air to make free of dust or impurities
which may accommodate inside before pump the grout into the duct.
e. The quality of the process and production of grout shall maintain as per specific requirements
and controlled conditions. That shall look after and control by laboratory staff at site
independently during grouting.
f. The quality of the materials for grouting should be verified before its application. Specific
requirements and sample test results for grouting material are given in the following table.
Frequency of
Test Item Test Method Specified Limits(BS EN 447:2007)
testing
Volume Change
EN 445:2007 -1 % to +5 % Each Material Delivery
Ratio
13
g. Test mentioned in the table shall be carried out for each batch of material supply. As a quality
control measure, following tests are done at site during the tendon grouting.
Fluidity of the grout mix to be checked initially and from the tendon outlet.
Grout test cubes are made at site for compressive strength test.
h. Grouting equipments and material proportion system, scales and machines are to be checked and
confirmed by the Engineer prior to commencing the grout mixing and pump.
i. Grouting shall be attended in 24 hours of stressing after confirmed to the Engineer. End recesses
shall be sealed following day.
j. Pump is connected to grouting port via PVC stop valve of same diameter as hose near by the
port and the outlet port also shall fixed with PVC stop valve assembly and kept valve opened
during grouting. Initial grout should pump out through hose after sampling and test prior to
connect in to port via PCV valve. Then continuous pumping in to the duct with unique pressure
of about 2 to 4 bars till grout comes out from the outlet port and let flow out until sample
collected from outlet meet the specified quality requirements. Then close the outlet valve and let
pump pressure remain constant as pumped for about 30 seconds to minute and close inlet valve
and cut off pump pressure immediately. The actual quantity inflow shall compare with
theoretical volume of the duct for verification.
k. The tendons grouted from most bottom one to top in the order so that neat and tidy surround
may ensure by avoid overflow grout from the ports and spilling on below tendons which are yet
to be grouted. All the tendons shall grout on same day in one attempt.
l. If continuous grout pumping for a duct would be interrupted due to unforeseen situation or
equipment breakdown or consistency of the grout is differ from specific requirements for certain
time more than about 45 minutes the entire duct should be flushed and wash with fresh water
immediately and fresh grout to be produced and pumped.
m. A movable shade shall put up at site for grouting work for cover in case of rain and for hot
weather.
Grouting port
14
Layout of pumping inlet and outlet
15
n. Recess shall be filled with concrete at earliest, once the grouting operation is completed.
o. Approved Anti-corrosion paint is manually applied using a brush on the anchor head (Refer the
attached Annexure 08 for Anticorrosive paint material Data sheet)
p. After anchors are treated against corrosion, protruded r/f of recess shall bend and tie to complete
re-bar arrangement as detailed in the drawing. Recess surface should be thoroughly wet prior to
concreting. Formwork is made with plywood sheets with two parts (Bottom part and upper part).
The formwork is supported by using jacks. Initially the bottom part formwork is fixed and
concreted. Subsequently, the upper part of the formwork is fixed and concreted.
q. The recess concreting is done with approved same grade concrete with the girder. The
maximum aggregate size is 20mm. Poker vibrator (30mm) is used for the concrete compaction.
In the bottom part compaction, poker can be immersed from the top. In the upper part
compaction, one hole is cut on the formwork to immerse the poker vibrator.
Jointly Inspection
Re-bar tying
Jointly Inspection
Concrete work
Jointly Inspection
Curing
Jointly Inspection
Removal of form
Jointly inspection
Material for concrete will be from approved sources, in compliance with the requirements.
16
Reinforcements should be only from approved suppliers, brands, and with acceptable conditions,
free from dirt, corrosion, grease and oil.
Before pouring concrete, Slump of the concrete should be comply with the mix design
requirements
During the concrete pouring, poker vibrators and shutter vibrator should be use adequately.
The pouring work will be carried out in an approved manner, the layer thickness and time
duration between two pouring will be strictly controlled.
The tendons shall be stored in the shed built in site and laid on square timber to prevent damp.
Site staff only be allowed surround construction site and only wearing necessary HSE items.
Special staff shall be arranged to direct the lifting & loading, Construction workers shall stay in
Staying in the front of jack is not permitted while tensioning. After the pause of tensioning, the
Operator can stand aside of jack and measure the elongation of tendons. The tensioning safe
plate shall be erected behind jack while tensioning (Refer the attached Annexure 15: tensioning
safe plate)
The connection condition of pipes shall be checked to assure safety. The pipes only can be
removed if there is no pressure.
Furtherer details please refer the attached risk assessment (Annexure 09)
5.3.8 Annexure
Annexure 01 - SDA-CMC-283
Annexure 02 -T-girder Tensioning Force
Annexure 03 -SDA-CMC-269
Annexure 04- Calculation and recorded sheet
Annexure 05 -The Tensioning Safe Plate
Annexure 06 - Girder Supporting Details at Stock yard
Annexure 07 Jack holding frame
Annexure 08 for Anticorrosive paint material Data sheet
Annexure 09 Rick Assessment
17
18
Annexure 01 - SDA / CMC / 283
Annexure 02 -T-girder Tensioning Force
MATARA-KATARAGAMA RAILWAY EXTENSION PROJECT (MATARA-BELIATTA SECTOR-PHASE-01)
Employer: Ministry of Transport.
Engineer: Central Engineering Consultancy Bureau.(CECB)
Contractor: China National Machinery Imp.& Exp.Corporation.
20mTgirderStressingsequenceandTensioningForce
Ns*As/1000
75% *1770
Tendon NO Tensioning Force(KN)
T-girder stressing stressing and No of 105% for 105% for
Duct dia Difference
Type procedure sequence Stressing Strands N7 N9
sequence 0% 20% 40% 58.82% 60% 80% 100%
Initial
stressing 2 N2-2 9 80 0.00 324.97 649.94 955.80
(708Mpa.)
20m
Straight 2 N3 7 70 0.00 252.76 505.51 758.27 1011.02 1263.78 1486.8 1326.969 159.831
Girder
final 3 N1-1 9 80 0.00 324.97 649.94 974.92 1299.89 1624.86 1911.6 1706.103 205.497
stressing
(1203.6Mpa
.) 4 N1-2 9 80 0.00 324.97 649.94 974.92 1299.89 1624.86 1911.6 1706.103 205.497
Ns*As/1000
75% *1770
Tendon NO Tensioning Force(KN)
T-girder stressing stressing and No of 105% for 105% for
Duct dia Difference
Type procedure sequence Stressing Strands N6 N10
sequence 0% 20% 40% 58.82% 60% 80% 100%
Initial
stressing 2 N2-2 10 90 0.00 361.08 722.16 1062.00
(708Mpa.)
20m
Curve 2 N3 6 70 0.00 216.65 433.30 649.94 866.59 1083.24 1274.4 1137.402 136.998
Girder
final 3 N1-1 10 90 0.00 361.08 722.16 1083.24 1444.32 1805.40 2124 1895.67 228.33
stressing
(1203.6Mpa
.) 4 N1-2 10 90 0.00 361.08 722.16 1083.24 1444.32 1805.40 2124 1895.67 228.33
Ns*As/1
Tendon Tensioning Force(KN)
*1770
T-girder stressing stressing No of 105% for 105% for 105% for
75%
000
NO and Duct dia Difference
Type procedure sequence Strands 0% 20% 40% 53.33% 60% 80% 100% N7 N8 N9
Stressing
1 N2-1 8 80 0.00 318.60 637.20 849.60
Initial 2 N2-2 8 80 0.00 318.60 637.20 849.60
stressing
(708Mpa.) 3 N4 7 70 0.00 278.78 557.55 743.40
Ns*As/1
Tendon Tensioning Force(KN)
*1770
T-girder stressing stressing No of 105% for 105% for 105% for
75%
000
NO and Duct dia Difference
Type procedure sequence Strands 0% 20% 40% 53.33% 60% 80% 100% N7 N8 N10
Stressing
1 N2-1 8 80 0.00 318.60 637.20 849.60
Initial 2 N2-2 8 80 0.00 318.60 637.20 849.60
stressing
(708Mpa.) 3 N4 7 70 0.00 278.78 557.55 743.40
Ns*As/1
Tendon NO Tensioning Force(KN)
*1770
T-girder stressing stressing No of Duct 105% for 105% for
75%
000
and Stressing Difference
Type procedure sequence Strands dia 0% 20% 40% 60% 63.50% 80% 100% N7 N10
sequence
1 N2-1 10 90 0.00 334.50 669.00 1003.50 1062.00
1 N3 7 70 0.00 234.15 468.30 702.45 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
32m 2 N6 7 70 0.00 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
Turnout
Girder 3 N1-1 10 90 0.00 334.50 669.00 1003.50 1338.00 1672.50 2124 1756.125 367.875
final 4 N1-2 10 90 0.00 334.50 669.00 1003.50 1338.00 1672.50 2124 1756.125 367.875
stressing
5 N4 7 70 0.00 234.15 468.30 702.45 936.60 1170.75 1486.8 1229.2875 257.5125
(1115Mpa
.) 6 N5 7 70 0.00 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
7 N7 7 70 0.00 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
8 N2-1 10 90 0.00 1062.00 1338.00 1672.50 2124 1756.125 367.875
9 N2-2 10 90 0.00 1062.00 1338.00 1672.50 2124 1756.125 367.875
Note N1 & N2 Tensioning Force 1672.50 KN
N3 N7 Tensioning Force 1170.75 KN
MATARA-KATARAGAMA RAILWAY EXTENSION PROJECT (MATARA-BELIATTA SECTOR-PHASE-01)
Employer: Ministry of Transport.
Engineer: Central Engineering Consultancy Bureau.(CECB)
Contractor: China National Machinery Imp.& Exp.Corporation.
Ns*As/1
Tendon NO Tensioning Force(KN)
*1770
T-girder stressing stressing No of Duct 105% for 105% for
75%
000
and Stressing Difference
Type procedure sequence Strands dia 0% 20% 40% 60% 63.50% 80% 100% N7 N11
sequence
1 N2-1 11 90 0.00 367.95 735.90 1103.85 1168.20
1 N3 7 70 0.00 234.15 468.30 702.45 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
32m 2 N6 7 70 0.00 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
Straight
Girder 3 N1-1 11 90 0.00 367.95 735.90 1103.85 1471.80 1839.75 2336.4 1931.7375 404.6625
final 4 N1-2 11 90 0.00 367.95 735.90 1103.85 1471.80 1839.75 2336.4 1931.7375 404.6625
stressing
5 N4 7 70 0.00 234.15 468.30 702.45 936.60 1170.75 1486.8 1229.2875 257.5125
(1115Mpa
.) 6 N5 7 70 0.00 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
7 N7 7 70 0.00 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
8 N2-1 11 90 0.00 1168.20 1471.80 1839.75 2336.4 1931.7375 404.6625
9 N2-2 11 90 0.00 1168.20 1471.80 1839.75 2336.4 1931.7375 404.6625
Note N1 & N2 Tensioning Force 1839.75 KN
N3 N7 Tensioning Force 1170.75 KN
Ns*As//
T-girder stressing stressing Tendon
d NO O No of
*1770
Tensioning Force(KN)
1000
Duct 105% for 105% for
75%
and Stressing Difference
Type procedure sequence Strands dia 0% 20% 40% 60% 63.50% 80% 100% N7 N11
sequence
1 N2-1 13 90 0.00 434.85 869.70 1304.55 1380.60
1 N3 7 70 0.00 234.15 468.30 702.45 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
32m 2 N6 7 70 0.00 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
Curve
Girder 3 N1-1 13 90 0.00 434.85 869.70 1304.55 1739.40 2174.25 2761.2 2282.9625 478.2375
final 4 N1-2 13 90 0.00 434.85 869.70 1304.55 1739.40 2174.25 2761.2 2282.9625 478.2375
stressing
5 N4 7 70 0.00 234.15 468.30 702.45 936.60 1170.75 1486.8 1229.2875 257.5125
(1115Mpa
.) 6 N5 7 70 0.00 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
7 N7 7 70 0.00 743.40 936.60 1170.75 1486.8 1229.2875 257.5125
8 N2-1 13 90 0.00 1380.60 1739.40 2174.25 2761.2 2282.9625 478.2375
9 N2-2 13 90 0.00 1380.60 1739.40 2174.25 2761.2 2282.9625 478.2375
Note N1 & N2 Tensioning Force 2174.25 KN
N3 N7 Tensioning Force 1170.75 KN
Annexure 03 -SDA-CMC-269
Considerations made
When calculating theoretical elongation values of strands against
prestress force
Where,
( kx
P(1 e )
Average prestress force, PP ,
kx
P- Prestress force (without loss),
X- Sectional length of tendon at each section being considered
-Tangent difference at each end of the section being considered
, k- Friction Coefficients (From OVM product data catalog, =0.25
and k=0.0015), and
Pp = P when straight
1/5
20m-span T girder - Prestress force vs Elongation Calculation
Tendon Type N1
1 2/5 1
25m-span T girder - Prestress force vs Elongation Calculation
Tendon Type N1
3/5
1 1
32m-span T girder - Prestress force vs Elongation Calculation
Tendon Type N1
4/5
1 1
T girder - Transverse Tendons- Prestress force vs Elongation
Calculation
T girder -
x(m) P(KN) Eg(Mpa) Ap(mm2) L(mm)
Type
2.86 194.00 195000 150 18.97
20m
2.42 194.00 195000 150 16.05
5/5
1 1
Annexure 04- Calculation and recorded sheet
MATARA-KATARAGAMA RAILWAY EXTENSION PROJECT (MATARA-BELIATTA SECTOR-PHASE-01)
Employer: Ministry of Transport.
Engineer: Central Engineering Consultancy Bureau.(CECB)
Contractor: China National Machinery Imp.& Exp.Corporation.
I GIRDER - TENDON STRESSING SITE RECORDS ( Gx~ Gx )
Structure Name: Nilwala No 02 Bridge Element ID: A2P40/R
Date of Casting: 14 th July 2015 Date of Stressing: 28th July 2015 Tensioning Starting Time: 10.00 A.M.
Concrete Grade (N/mm2) : C50/20 Elastic Modulus of Conc.(E - kN/mm2) : 34 Tensioning Finishing Time: 12.00 A.M.
Tendon Identification No: N1 L Initial Tensioning (Mpa): 708 Final Tensioning (Mpa) : 1327.50
END A
Nominal Dia of Tendons (mm): 15 76
15.76 Initial Concrete Strength (N/mm2): 30 Final Concrete Strength (N/mm2): 50
Strand from Reel No: 3915/ 3914 - 4F1-10934 MATARA
Number of Strand per Reel (Nr.) : 9 Actual Strand Area per Reel, Ar (mm): 150.10 Actual Modulus per Reel, Er (GPa): 196.00
Equipment Identifiers, End A
Jack No: YCW 300 B 1,430 Dial Gauge No: G 1.5 2014.11.4991 Calibration Report No. OVM 2014 12 17921-18
20% 40% 53% 60% 80% 100% Releasing to 10%
NO. Piston
Pi t Piston
Pi t Piston
Pi t Piston
Pi t Piston
Pi t Piston
Pi t
Pressure Elongation Pressure Elongation Pressure Elongation Pressure Elongation Pressure Elongation Pressure Elongation
(Mpa)
Extension
(mm) (Mpa)
Extension
(mm) (Mpa)
Extension
(mm) (Mpa)
Extension
(mm) (Mpa)
Extension
(mm) (Mpa)
Extension
(mm) Pressure After
(mm) (mm) (mm) (mm) (mm) (mm) (Mpa) lock-off
N2 , N4 & N5-53.33%
N2/L A side 17.00 17.00 34.00 34.00 48.00 48.00
N2/R A side 18.00 18.00 34.00 34.00 49.00 49.00
6.02 12.04 16.05
N4 A side 19.00 19.00 36.00 36.00 47.00 47.00
N5 A side 16.00 16.00 33.00 33.00 49.00 49.00
N3 & N1-100%
N3 A side 17.00 17.00 34.00 34.00 54.00 54.00 66.00 85.00 75.00
N1/L A side 6.02 18.00 18.00 12.04 37.00 37.00 18.06 53.00 53.00 24.09 68.00 68.00 30.11 84.00 84.00 3.01 74.00
N1/R A side 19.00 19.00 36.00 36.00 55.00 55.00 66.00 66.00 85.00 85.00 76.00
N4 N5 & N2-53
N4,N5 N2-53.33%
33% N4 N5 & N2-100%
N4,N5
N4 A side 53.00 53.00 53.00 53.00 65.00 65.00 86.00 86.00 75.00
N5 A side 55.00 55.00 55.00 55.00 67.00 67.00 86.00 86.00 76.00
16.05 18.06 24.09 30.11
N2/L A side 56.00 56.00 56.00 56.00 66.00 66.00 88.00 88.00 77.00
N2/R A side 54.00 54.00 54.00 54.00 68.00 68.00 87.00 87.00 78.00
Initial stage
g Mid Initial stage
g Mid
After Completed the Tensioning Initial stage END A Initial stage END B Initial stage END A Initial stage END B Remarks
Point Point
Vertical Deflection of the Girder
Horizontal Deflection of the Girder
Elastic Shortening of the Girder Girder Center : LHS: RHS: Avg:
Concrete Strength 50
Nominal Dia of Tendons: 15.76 Concrete Strength: 30
(N/mm2):
Actual Values Delivered per Coil of Strands
Assumed for Calculations Actual Values Delivered per Pack or Reel of Strand
Assumed Strand Area, As (mm2) 150 Actual Strand Area per Reel, Ar (mm) 150.1
Assumed Modulus, Es (Gpa) 195 Actual Modulus per Reel, Er (GPa) 196
First Stage Stressing from End A Second Stage Stressing from End B
Jack Force Gauge Jack Force Gauge
(kN) (Mpa) (kN) (Mpa)
Required force before wedge set 1792.13 30.11 Required force before wedge set 1792.13 30.11
Maximum force at 80% UTS 1911.60 32.12 Maximum force at 80% UTS 1911.60 32.12
Theoretical elongation, A (mm) 84.26 Theoretical elongation, B (mm) 84.26
Stressing Mode
One End only No Both A then B No Both Simultaneous (A and B with 2 sets of equipment) Yes
80% 24.09 1433.70 17.6 Final wedge set at A, 24.16 1433.70 17.6 Final wedge set at B,
Wa=6mm Wa=6mm
Final 100% 30.11 1792.13 17.6 30.15 1792.13 17.6
A = (Sum) = Elongation before set at B,
Elongation before set at A, 88 B = (Sum) = 88
End A End B
First Stage Tensioning Relevant Piston Elongation Average Relevant Piston Elongation Average Total Cumulati
Stressing Force (KN) Gauge Extension per Elongation for Gauge Extension per Elongation for Elongation ve
Pressure (mm) increment 20% Pressure (mm) increment 20% at both Elongati
(Mpa) (mm) increment (Mpa) (mm) increment ends(mm) on at
Initial 20% 358.43 6.02 18.00 6.19 18.00 26.40 26.40
40% 716.85 12.04 37.00 19.00 12.18 37.00 19.00 38.00 64.40
53% 955.74 16.05 53.00 16.00 13.20 16.17 53.00 16.00 13.20 32.00 96.40
80% 1433.70 24.09 68.00 15.00 24.16 68.00 15.00 30.00 126.40
Final 100% 1792.13 30.11 84.00 16.00 30.15 84.00 16.00 32.00 158.40
Elongation Calculation
Elongation At A from 20 to 100% = 66.00 At B from 20 to 100% = 66.00
mm mm
Add for initial 20% load = 13.20 mm Add for initial 20% load 13.20 mm
Observations: No popping noises of broken wires O.K over elongations is within tolerance, O.K
140
126
120
100
96 96
80
64
60
40
26
20
0 0
1,000
1,250
1,500
1,750
2,000
2,250
2,500
0
250
500
750
Tensioning
Forces (kN)
Annexure 05 -The Tensioning Safe Plate
Annexure 06 - Girder Supporting Details at Stock yard
Technical Data Sheet
X-Roc GalZinc
Single component zinc rich anti corrosion primer 10280507
Uses Clean up
As an anti-corrosion primer for reinforcing steel to Clean hands and skin immediately with soap and water
extend the life of repairs made to reinforced concrete. or industrial hand cleaner, not solvents. Remove X-Roc
GalZinc from tools, equipment and mixers with xylene
Advantages immediately after use.
Single component
High zinc content Limitations
Combats corrosion Do not leave the primed surface exposed to the
Compatible with all cementitious mortars elements for longer than 7 days before overcoating or
Protects adjacent areas of the repair applying repair mortar.
Easy to use
Fast drying Do not apply X-Roc GalZinc when the ambient or
substrate temperature is below 4C (40F) or if the
Application Properties temperature is within 3C (5F) of the dew point. When
Typical wet film thickness: 135 microns (5.4mils) the temperature is above 35C (95F) the following
Typical dry film thickness: 40 microns (2mils) guidelines are adopted as good working practice.
28
Datasheet Validity
X-Calibur makes modifications to its product datasheets
on a continuous basis. Please check the datasheet
update section on www.x-calibur.us to ensure you have
the latest version.
Warranties
X-Calibur supplies products that comply with the
properties shown on the current datasheets. In the
unlikely event that products supplied are proved not to
comply with these properties, then we will replace the
non-compliant product or refund the purchase price.
X-Calibur does not warrant or guarantee the installation
of the products as it does not have control over the
installation or end use of the products. Any suspected
defects must be reported to X-Calibur in writing within
five working days of being detected. X-Calibur
Construction Systems Inc. makes no warranty as to
merchantability or fitness for a particular purpose
and this warranty is in lieu of all other warranties
express or implied. X-Calibur Construction Systems
Inc. shall not be liable for damages of any sort including
remote or consequential damages, down time, or delay.
www.x-calibur.us
China National Machinery Import & Export corporation.
Doc. No : RA/CMC/09
Project : Matara-Kataragama Railway Extension Project Matara-Beliatta Sector Rev. No : 00
(Phase 1) Date : 21/07/2015
Employer: Ministry of Transport.(MOT) Page : 1 of 17
Engineer: Central Engineering Consultancy Bureau (CECB)
Contractor: China National Machinery Import & Export Corporation.(CMC)
Strand Transverse
Grouting post-stressing lifting and transporting
Reference sheet
Document number Description
CMC/GEN/009 Rev 00
Page 1 of 17
Revision history
CMC/GEN/009 Rev 00
Page 2 of 17
Project : Matara-Kataragama Railway Extension Project Matara-Beliatta Sector (Phase 1) HEALTH AND SAFETY RISK
Employer : Ministry of Transport. ASSESSMENT
Engineer : Central Engineering Consultancy Bureau (CECB) Strand Transverse concreting
Contractor : China National Machinery Import & Export Corporation Post-stressing lifting & transporting
Name of the activity: Strand Transverse concreting Method Statement
CMC/SRP/RA/09
post-stressing, lifting and transporting Reference No.
1. Site Engineer Mr. Samantha
Date of Assessment: 21st July 2015 Name of Risk Assessor(s) 2. Safety Engineer Mr.Nihal
3 Electrician Mr. Jing Jun
Original Risk Residual Risk
Classification Classification Mitigation Control
Unit
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
1. Site Engineer
Tensioning operations 4 4 16 Jack and pump assembly with high presser oil 1 4 4 Mr. Samantha
Lack of correct information on hose must be fully checked and free hold 2. Safety Engineer
CMC/GEN/009 Rev 00
Page 7 of 17
Project : Matara-Kataragama Railway Extension Project Matara-Beliatta Sector (Phase 1) HEALTH AND SAFETY RISK
Employer : Ministry of Transport. ASSESSMENT
Engineer : Central Engineering Consultancy Bureau (CECB) Strand Transverse concreting
Contractor : China National Machinery Import & Export Corporation Post-stressing lifting & transporting
Name of the activity: Strand Transverse concreting Method Statement
CMC/SRP/RA/09
post-stressing, lifting and transporting Reference No.
1. Site Engineer Mr. Samantha
Date of Assessment: 21st July 2015 Name of Risk Assessor(s) 2. Safety Engineer Mr.Nihal
3 Electrician Mr. Jing Jun
Original Risk Residual Risk
Classification Classification Mitigation Control
Unit
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
must be used.
Cable routing in proper manner avoiding
access ladders, water accumulation, drive
carriage ways etc.
Earthling / grounding of the equipment must
be ensured
A stringent inspection regime must be
followed for the electrical installations.
Toolbox talks and correct instructions must
be delivered to the operatives.
Worker shall wear Shock proof PPE for the
activities
CMC/GEN/009 Rev 00
Page 9 of 17
Project : Matara-Kataragama Railway Extension Project Matara-Beliatta Sector (Phase 1) HEALTH AND SAFETY RISK
Employer : Ministry of Transport. ASSESSMENT
Engineer : Central Engineering Consultancy Bureau (CECB) Strand Transverse concreting
Contractor : China National Machinery Import & Export Corporation Post-stressing lifting & transporting
Name of the activity: Strand Transverse concreting Method Statement
CMC/SRP/RA/09
post-stressing, lifting and transporting Reference No.
1. Site Engineer Mr. Samantha
Date of Assessment: 21st July 2015 Name of Risk Assessor(s) 2. Safety Engineer Mr.Nihal
3 Electrician Mr. Jing Jun
Original Risk Residual Risk
Classification Classification Mitigation Control
Unit
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
CMC/GEN/009 Rev 00
Page 11 of 17
Project : Matara-Kataragama Railway Extension Project Matara-Beliatta Sector (Phase 1) HEALTH AND SAFETY RISK
Employer : Ministry of Transport. ASSESSMENT
Engineer : Central Engineering Consultancy Bureau (CECB) Strand Transverse concreting
Contractor : China National Machinery Import & Export Corporation Post-stressing lifting & transporting
Name of the activity: Strand Transverse concreting Method Statement
CMC/SRP/RA/09
post-stressing, lifting and transporting Reference No.
1. Site Engineer Mr. Samantha
Date of Assessment: 21st July 2015 Name of Risk Assessor(s) 2. Safety Engineer Mr.Nihal
3 Electrician Mr. Jing Jun
Original Risk Residual Risk
Classification Classification Mitigation Control
Unit
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
CMC/GEN/009 Rev 00
Page 13 of 17
Project : Matara-Kataragama Railway Extension Project Matara-Beliatta Sector (Phase 1) HEALTH AND SAFETY RISK
Employer : Ministry of Transport. ASSESSMENT
Engineer : Central Engineering Consultancy Bureau (CECB) Strand Transverse concreting
Contractor : China National Machinery Import & Export Corporation Post-stressing lifting & transporting
Name of the activity: Strand Transverse concreting Method Statement
CMC/SRP/RA/09
post-stressing, lifting and transporting Reference No.
1. Site Engineer Mr. Samantha
Date of Assessment: 21st July 2015 Name of Risk Assessor(s) 2. Safety Engineer Mr.Nihal
3 Electrician Mr. Jing Jun
Original Risk Residual Risk
Classification Classification Mitigation Control
Unit
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
1. Site Engineer
Lack of communication between Mr. Samantha
Communication system (Hand held radio or
construction site ground staff. 3 3 9 warning beacon system) shall be established 1 3 3 2. Safety Engineer
Difficulty to communicate in Mr.Nihal
between ground staff and site staff. 3 Electrician
emergency situation
1. Site Engineer
Mr. Samantha
Lack of First aid materials in 4 3 12 Basic first aid materials shall be provided in 1 3 3 2. Safety Engineer
construction site. site. Mr.Nihal
3 Electrician
CMC/GEN/009 Rev 00
Page 14 of 17
Project : Matara-Kataragama Railway Extension Project Matara-Beliatta Sector (Phase 1) HEALTH AND SAFETY RISK
Employer : Ministry of Transport. ASSESSMENT
Engineer : Central Engineering Consultancy Bureau (CECB) Strand Transverse concreting
Contractor : China National Machinery Import & Export Corporation Post-stressing lifting & transporting
Name of the activity: Strand Transverse concreting Method Statement
CMC/SRP/RA/09
post-stressing, lifting and transporting Reference No.
1. Site Engineer Mr. Samantha
Date of Assessment: 21st July 2015 Name of Risk Assessor(s) 2. Safety Engineer Mr.Nihal
3 Electrician Mr. Jing Jun
Original Risk Residual Risk
Classification Classification Mitigation Control
Unit
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
CMC/GEN/009 Rev 00
Page 15 of 17
Project : Matara-Kataragama Railway Extension Project Matara-Beliatta Sector (Phase 1) HEALTH AND SAFETY RISK
Employer : Ministry of Transport. ASSESSMENT
Engineer : Central Engineering Consultancy Bureau (CECB) Strand Transverse concreting
Contractor : China National Machinery Import & Export Corporation Post-stressing lifting & transporting
Name of the activity: Strand Transverse concreting Method Statement
CMC/SRP/RA/09
post-stressing, lifting and transporting Reference No.
1. Site Engineer Mr. Samantha
Date of Assessment: 21st July 2015 Name of Risk Assessor(s) 2. Safety Engineer Mr.Nihal
3 Electrician Mr. Jing Jun
Original Risk Residual Risk
Classification Classification Mitigation Control
Unit
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
Consequences
Consequences
Activity and hazard Proposed Mitigation Measures
(Who is
Likelihood
Likelihood
Risk Level
Risk Level
(consider the Worst Credible Scenarios)
(What Precautions you are going to implement?) responsible for
doing this?)
Item
CMC/GEN/009 Rev 00
Page 17 of 17