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Matara-Kataragama Railway Extension Project

Matara-Beliatta Sector (Phase 1)

(DK0+44 ~ DK26+461)

Method Statement for Post Tensioning, Grouting and Anchor Sealing of

Precast T Girders Construction

MS-53 B

Rev. B

Contractor: China National Machinery Imp. & Exp. Corp.

No Date Prepared Checked Approved Remark

REV.A 2015.08.19 Darshaka B. Zhongxiang He Peizhi

REV.B 2015.08.26 Darshaka B. Zhongxiang He Peizhi

Ref. Letter No :

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Contents

1.0 Purpose of the Method Statement .............................................................................. 3

2.0 Scope of method statement ........................................................................................ 3

3.0 Documents to be referred with this Method Statement .............................................. 3

4.0 Responsibilities of relevant personal with respect to the activities ............................ 3

5.0 Details and Procedure of carry out method statement activities. ............................... 4

5.1 Materials ................................................................................................................................................. 4

5.1.1 Pre-stressed tendon (Strand) ................................................................................................... 4

5.1.2 Corrugated Duct, ...................................................................................................................... 4

5.1.3 Anchorage, spiral reinforcement, bearing plates and wedges .............................................. 4

5.1.4 Grout .......................................................................................................................................... 4

5.1.5 Water proof and anticorrosive paint ........................................................................................ 4

5.2 Equipment............................................................................................................................................... 4

5.3 Detail procedure for carry out ctivities of the method statement. .......................................................... 6

5.3.1 T- Girder Post tensioning .......................................................................................................... 6

5.3.2 Cut and insert tendons. ............................................................................................................ 7

5.3.3 Site Preparation and stressing operation. .............................................................................. 8

5.3.4 Tensioning: .............................................................................................................................. 10

5.3.5 Tendon Ducts Grouting and recess concrete........................................................................ 13

5.3.6 Quality assurance and quality control measurements. ....................................................... 16

5.3.7 HSE measures ......................................................................................................................... 17

5.3.8 Annexure ................................................................................................................................. 17

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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.

2.0 Scope of method statement


This method statement apply for main three scopes in the process which are,
1. Preparation of casting yard, fabrication of Girders and concreting.
2. Post tensioning and grouting of tendons.
3. Lifting and stack in the stock yard.
4. Grouting of Duct
5. Recess concrete
In this document explained activities in detail relevant to post tensioning, grouting and recess
concreting out of above five.

3.0 Documents to be referred with this Method Statement

Quality Assurance Plan


Project Safety and Environmental Plan
Design drawings of T girder, (Pre-stressed Concrete)

4.0 Personal and responsibilities relevant to the activity

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.

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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.

5.1.2 Corrugated Duct,

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.

5.1.3 Anchorage, spiral reinforcement, bearing plates and wedges

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)
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Electrical Hydraulic pump Hydraulic Jack Dial Gauge

Corrugated Duct Anchorage, spiral reinforcement, bearing plates and wedges

Pre-stressed tendon (Strand) Grout Mixer Grout pump

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5.3 Detail procedure for carry out activities the method statement.

5.3.1 T- Girder Post tensioning


a. 15.7mm of tendons are used for longitudinal and transverse stressing whose ultimate tensile
stress (UTS) is 1770MPa, Modulus of Elasticity 1.95105Mpa. Theoretical elongation shall
calculate with respect to actual cross-sectional area of the strand (A) and Modulus of Elasticity
(E) values which are obtained from the mill certificate delivered by the supplier for each coil and
proof document for each delivery will be submitted to the Engineer.

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.

Additional Safety Precautions

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,

Refer the attached annexure

Annexure 02: Tensioning Force for 20, 25 and 32m Girders

Annexure 03: Calculation of theoretical Elongation (SDA 269)

Annexure 04: Tendon stressing site calculations sheets and record sheets

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5.3.2 Cutting and insert tendons.

a. Working length of the tendon shall calculate as follows,

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.

b. Determination of tendon Length

Length calculation formula: L+2a+b+c+d+e

Ldistance between inward ends of two anchors (Profile length)

a- Thickness of front tool anchor

b- Limit plate thickness

c- Length of tensioning jack

d- Thickness of back tool anchor

e- Reserved redundancies 10cm(varied)

Working length of tendon as in the drawing: L+1400mm, only for reference.

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.

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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.

5.3.3 Site Preparation and stressing operation.

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.

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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.

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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:

Illustration of measuring elongation

Measuring steel rule stream edge which facing the jack can directly Zero.

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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.

Vertical deflection of the girder

Horizontal deflection of the girder

Elastic shortening of the girder

Any signs of cracks, crushing on girder surface

f. All the records and calculation relevant to each tendon stressed shall submit for engineer review
and approval within 24 hours.

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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.

The Tensioning order of PC T Girder will be as following.

For 20m T Girder

(Initial Tensioning) 58.82%conN2 58.82%conN2 58.82%conN

4 (Final Tensioning)100%conN4 100%conN3 100%conN1 100%conN1


100%conN2 100%conN2

For 25m T Girder

(Initial Tensioning) 53.3%conN2 53.3%conN2 53.3%conN4 53.3conN5


(Final Tensioning)100%conN3 100%conN1 100%conN1 100%conN4
100%conN5 100%conN2 100%conN2

For 32m T Girder

(Initial Tensioning) 63.5%conN2 63.5%conN2 63.5%conN5 63.5conN6


63.5conN7 (Final Tensioning)100%conN3 100%conN6 100%conN1
100%conN1 100%conN4 100%conN5 100%conN7 100%conN2
100%conN2

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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.

Determination of basic requirements for grout (BS EN 445:2007)

Frequency of
Test Item Test Method Specified Limits(BS EN 447:2007)
testing

Fluidity (Cone) EN 445:2007 t0 25 Second Each Site Mixing

Bleeding Ratio EN 445:2007 < 0.3 % Each Material Delivery

Volume Change
EN 445:2007 -1 % to +5 % Each Material Delivery
Ratio

EN196-3 Initial set of the Grout3h Each Material Delivery


Setting time
EN196-3 Final set of the Grout24h Each Material Delivery

Density(Mud balance) EN 445:2007 Each Material Delivery

Compressive > 55 N/mm, 28days (Design


EN196-1 Each site Mixing
Strength(N/mm2) Req.)
Proportion - for Site 0
Water Grout W/P Temperature( C)
Mix
kg kg %
LANKO Water to
Type Ambient Grout
CG60 Powder

per one Grout bag 7 20 35% <32

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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.

Mix proportion (water added ratio).

Temperature of the grout mix

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

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Layout of pumping inlet and outlet

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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.

Roughening, water proofing and apply anticorrosive coating

Jointly Inspection
Re-bar tying
Jointly Inspection

Installation of end form


Jointly Inspection

Concrete work
Jointly Inspection

Curing

Jointly Inspection
Removal of form

Jointly inspection

Flow chart for recess concrete

5.3.6 Quality assurance and quality control measures.

Site layout should be strictly according to the design drawing.

Material for concrete will be from approved sources, in compliance with the requirements.

Reinforcement fabrication is strictly in accordance with design drawing.

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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.

5.3.7 HSE measures

Site staff only be allowed surround construction site and only wearing necessary HSE items.

All the equipments should be maintained regularly.

Special staff shall be arranged to direct the lifting & loading, Construction workers shall stay in

Safety area and alert other workers.

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
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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%

1 N2-1 9 80 0.00 324.97 649.94 955.80

Initial
stressing 2 N2-2 9 80 0.00 324.97 649.94 955.80
(708Mpa.)

3 N4 7 70 0.00 252.76 505.51 743.40

1 N4 7 70 0.00 743.40 758.27 1011.02 1263.78 1486.8 1326.969 159.831

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

5 N2-1 9 80 0.00 955.80 974.92 1299.89 1624.86 1911.6 1706.103 205.497

6 N2-2 9 80 0.00 955.80 974.92 1299.89 1624.86 1911.6 1706.103 205.497

NoteN1 & N2 Tensioning Force 1624.86 N3&N4 Tensioning Force 1263.78 KN

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%

1 N2-1 10 90 0.00 361.08 722.16 1062.00

Initial
stressing 2 N2-2 10 90 0.00 361.08 722.16 1062.00
(708Mpa.)

3 N4 6 70 0.00 216.65 433.30 637.20

1 N4 6 70 0.00 637.20 649.94 866.59 1083.24 1274.4 1137.402 136.998

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

5 N2-1 10 90 0.00 1062.00 1083.24 1444.32 1805.40 2124 1895.67 228.33

6 N2-2 10 90 0.00 1062.00 1083.24 1444.32 1805.40 2124 1895.67 228.33

NoteN1 & N2 Tensioning Force 1805.40 N3&N4 Tensioning Force 1083.24 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.

25m T-girder Stressing sequence and Tensioning Force

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

4 N5 7 70 0.00 278.78 557.55 743.40

1 N3 7 70 0.00 278.78 557.55 836.33 1115.10 1393.88 1486.80 1463.57 23.23


25m
Straight 2 N1-1 9 80 0.00 358.43 716.85 1075.28 1433.70 1792.13 1911.60 1881.73 29.87
Girder
final 3 N1-2 9 80 0.00 358.43 716.85 1075.28 1433.70 1792.13 1911.60 1881.73 29.87
stressing
4 N4 7 70 0.00 743.40 836.33 1115.10 1393.88 1486.80 1463.57 23.23
(1327.5Mp
a.) 5 N5 7 70 0.00 743.40 836.33 1115.10 1393.88 1486.80 1463.57 23.23
6 N2-1 8 80 0.00 849.60 955.80 1274.40 1593.00 1699.20 1672.65 26.55
7 N2-2 8 80 0.00 849.60 955.80 1274.40 1593.00 1699.20 1672.65 26.55

Note N1 Tensioning Force 1792.13 KN


N2 Tensioning Force 1593.00 KN
N3 & N4 & N5 Tensioning Force 1393.88 KN

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

4 N5 7 70 0.00 278.78 557.55 743.40

1 N3 7 70 0.00 278.78 557.55 836.33 1115.10 1393.88 1486.80 1463.57 23.23


25m
Curve 2 N1-1 10 90 0.00 398.25 796.50 1194.75 1593.00 1991.25 2124.00 2090.81 33.19
Girder
final 3 N1-2 10 90 0.00 398.25 796.50 1194.75 1593.00 1991.25 2124.00 2090.81 33.19
stressing
4 N4 7 70 0.00 743.40 836.33 1115.10 1393.88 1486.80 1463.57 23.23
(1327.5Mp
a.) 5 N5 7 70 0.00 743.40 836.33 1115.10 1393.88 1486.80 1463.57 23.23
6 N2-1 8 80 0.00 849.60 955.80 1274.40 1593.00 1699.20 1672.65 26.55
7 N2-2 8 80 0.00 849.60 955.80 1274.40 1593.00 1699.20 1672.65 26.55

Note N1 Tensioning Force 1991.25 KN


N2 Tensioning Force 1593.00 KN
N3 & N4 & N5 Tensioning Force 1393.88 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.

32m T-girder Stressing sequence and Tensioning Force

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

2 N2-2 10 90 0.00 334.50 669.00 1003.50 1062.00


Initial
stressing 3 N5 7 70 0.00 234.15 468.30 702.45 743.40
(708Mpa.)
4 N6 7 70 0.00 234.15 468.30 702.45 743.40

5 N7 7 70 0.00 234.15 468.30 702.45 743.40

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.

32m T-girder Stressing sequence and Tensioning Force

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

2 N2-2 11 90 0.00 367.95 735.90 1103.85 1168.20


Initial
stressing 3 N5 7 70 0.00 234.15 468.30 702.45 743.40
(708Mpa.)
4 N6 7 70 0.00 234.15 468.30 702.45 743.40

5 N7 7 70 0.00 234.15 468.30 702.45 743.40

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

2 N2-2 13 90 0.00 434.85 869.70 1304.55 1380.60


Initial
stressing 3 N5 7 70 0.00 234.15 468.30 702.45 743.40
(708Mpa.)
4 N6 7 70 0.00 234.15 468.30 702.45 743.40

5 N7 7 70 0.00 234.15 468.30 702.45 743.40

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

For j15.7 strands, Ap =150mm2 and Eg= 195000MPa, the theoretical


elongation values, Li were calculated by using the following numerical
formula
Pp x
Li
Ap E g

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

Prestress force, Ps at each section that is being considered was calculated by


using the following numerical formula;
( kx
PS P e ,and

Pp = P when straight

The results of calculated elongation values as well as prestress forces of each


type of tendons for 20m, 25m and 32m-span T-Girders, including the
transverse tendons are presented in the attachment

1/5
20m-span T girder - Prestress force vs Elongation Calculation
Tendon Type N1

Sec ID k -(KL+ ) e-(KL+ )


1-e-(KL+ )
Eg(Mpa)
P(KN) x(m) (rad) Pp(KN) Ps(KN) Ap(mm2) L(mm)
1 180.54 1.147 0.0015 0 0.0000 0.250 -0.00172 0.99828 0.00172 180.38 180.23 195000 150 7.07
2 180.23 1.326 0.0015 3.8 0.0663 0.250 -0.01857 0.98160 0.01840 178.57 176.91 195000 150 8.10
3 176.91 7.700 0.0015 0 0.0000 0.250 -0.01155 0.98852 0.01148 175.90 174.88 195000 150 46.30
Half length (Total) 10.173 61.47
Full length (Total) 20.346 122.95
Tendon Type N2
1 180.54 0.988 0.0015 0 0.0000 0.250 -0.00148 0.99852 0.00148 180.41 180.27 195000 150 6.09
2 180.27 2.618 0.0015 7.5 0.1309 0.250 -0.03665 0.96401 0.03599 177.01 173.78 195000 150 15.84
3 173.78 6.590 0.0015 0 0.0000 0.250 -0.00989 0.99016 0.00984 172.93 172.08 195000 150 38.96
Half length (Total) 10.196 60.90
Full length (Total) 20.392 121.79
Tendon Type N3
1 180.54 3.592 0.0015 0 0.0000 0.250 -0.00539 0.99463 0.00537 180.05 179.57 195000 150 22.11
2 179.57 2.618 0.0015 7.5 0.1309 0.250 -0.03665 0.96401 0.03599 176.32 173.11 195000 150 15.78
3 173.11 3.998 0.0015 0 0.0000 0.250 -0.00600 0.99402 0.00598 172.59 172.07 195000 150 23.59
Half length (Total) 10.208 61.48
Full length (Total) 20.416 122.97
Tendon Type N4
1 180.54 4.205 0.0015 0 0.0000 0.250 -0.00631 0.99371 0.00629 179.97 179.40 195000 150 25.87
2 179.40 2.618 0.0015 7.5 0.1309 0.250 -0.03665 0.96401 0.03599 176.16 172.95 195000 150 15.77
3 172.95 3.390 0.0015 0 0.0000 0.250 -0.00509 0.99493 0.00507 172.51 172.07 195000 150 19.99
Half length (Total) 10.213 61.63
Full length (Total) 20.426 123.27

1 2/5 1
25m-span T girder - Prestress force vs Elongation Calculation
Tendon Type N1

Sec ID k -(KL+ ) e-(KL+ )


1-e-(KL+ )
Eg(Mpa)
P(KN) x(m) (rad) Pp(KN) Ps(KN) Ap(mm2) L(mm)
1 199.13 1.149 0.0015 0 0.0000 0.250 -0.00172 0.99828 0.00172 198.95 198.78 195000 150 7.82
2 198.78 1.326 0.0015 3.8 0.0663 0.250 -0.01857 0.98160 0.01840 196.95 195.12 195000 150 8.93
3 195.12 10.199 0.0015 0 0.0000 0.250 -0.01530 0.98482 0.01518 193.64 192.16 195000 150 67.52
Half length (Total) 12.674 84.26
Full length (Total) 25.348 168.53
Tendon Type N2
1 199.13 3.713 0.0015 0 0.0000 0.250 -0.00557 0.99445 0.00555 198.57 198.02 195000 150 25.21
2 198.02 1.326 0.0015 3.8 0.0663 0.250 -0.01857 0.98160 0.01840 196.19 194.38 195000 150 8.89
3 194.38 7.640 0.0015 0 0.0000 0.250 -0.01146 0.98861 0.01139 193.27 192.16 195000 150 50.48
Half length (Total) 12.679 84.58
Full length (Total) 25.358 169.16
Tendon Type N3
1 199.13 4.664 0.0015 0 0.0000 0.250 -0.00700 0.99303 0.00697 198.43 197.74 195000 150 31.64
2 197.74 2.618 0.0015 7.5 0.1309 0.250 -0.03665 0.96401 0.03599 194.16 190.62 195000 150 17.38
3 190.62 5.435 0.0015 0 0.0000 0.250 -0.00815 0.99188 0.00812 189.85 189.07 195000 150 35.28
Half length (Total) 12.717 84.29
Full length (Total) 25.434 168.59
Tendon Type N4
1 199.13 5.966 0.0015 0 0.0000 0.250 -0.00895 0.99109 0.00891 198.24 197.35 195000 150 40.43
2 197.35 2.618 0.0015 7.5 0.1309 0.250 -0.03665 0.96401 0.03599 193.78 190.25 195000 150 17.34
3 190.25 4.144 0.0015 0 0.0000 0.250 -0.00622 0.99380 0.00620 189.66 189.07 195000 150 26.87
Half length (Total) 12.728 84.65
Full length (Total) 25.456 169.29
Tendon Type N5
1 199.13 6.503 0.0015 0 0.0000 0.250 -0.00975 0.99029 0.00971 198.16 197.19 195000 150 44.06
2 197.19 2.618 0.0015 7.5 0.1309 0.250 -0.03665 0.96401 0.03599 193.62 190.10 195000 150 17.33
3 190.10 3.612 0.0015 0 0.0000 0.250 -0.00542 0.99460 0.00540 189.58 189.07 195000 150 23.41
Half length (Total) 12.733 84.80
Full length (Total) 25.466 169.59

3/5
1 1
32m-span T girder - Prestress force vs Elongation Calculation
Tendon Type N1

Sec ID k -(KL+ ) e-(KL+ )


1-e-(KL+ )
Eg(Mpa)
P(KN) x(m) (rad) Pp(KN) Ps(KN) Ap(mm2) L(mm)
1 167.25 1.591 0.0015 0 0.0000 0.250 -0.00239 0.99762 0.00238 167.05 166.85 195000 150 9.09
2 166.85 1.194 0.0015 3.8 0.0663 0.250 -0.01837 0.98180 0.01820 165.33 163.81 195000 150 6.75
3 163.81 13.380 0.0015 0 0.0000 0.250 -0.02007 0.98013 0.01987 162.18 160.56 195000 150 74.19
Half length (Total) 16.165 90.02
Full length (Total) 32.330 180.05
Tendon Type N2
1 167.25 3.921 0.0015 0 0.0000 0.250 -0.00588 0.99414 0.00586 166.76 166.27 195000 150 22.35
2 166.27 2.387 0.0015 3.8 0.0663 0.250 -0.02016 0.98004 0.01996 164.60 162.95 195000 150 13.43
3 162.95 9.860 0.0015 0 0.0000 0.250 -0.01479 0.98532 0.01468 161.75 160.56 195000 150 54.53
Half length (Total) 16.168 90.31
Full length (Total) 32.336 180.63
Tendon Type N3
1 167.25 3.507 0.0015 0 0.0000 0.250 -0.00526 0.99475 0.00525 166.81 166.37 195000 150 20.00
2 166.37 5.236 0.0015 7.5 0.1309 0.250 -0.04058 0.96023 0.03977 163.04 159.76 195000 150 29.19
3 159.76 7.472 0.0015 0 0.0000 0.250 -0.01121 0.98885 0.01115 158.86 157.98 195000 150 40.58
Half length (Total) 16.215 89.77
Full length (Total) 32.430 179.54
Tendon Type N4
1 167.25 4.542 0.0015 0 0.0000 0.250 -0.00681 0.99321 0.00679 166.68 166.11 195000 150 25.88
2 166.11 5.236 0.0015 7.5 0.1309 0.250 -0.04058 0.96023 0.03977 162.79 159.51 195000 150 29.14
3 159.51 6.446 0.0015 0 0.0000 0.250 -0.00967 0.99038 0.00962 158.74 157.97 195000 150 34.98
Half length (Total) 16.224 90.01
Full length (Total) 32.448 180.01
Tendon Type N5
1 167.25 4.618 0.0015 0 0.0000 0.250 -0.00693 0.99310 0.00690 166.67 166.10 195000 150 26.31
2 166.10 5.236 0.0015 7.5 0.1309 0.250 -0.04058 0.96023 0.03977 162.77 159.49 195000 150 29.14
3 159.49 6.370 0.0015 0 0.0000 0.250 -0.00956 0.99049 0.00951 158.73 157.97 195000 150 34.57
Half length (Total) 16.224 90.02
Full length (Total) 32.448 180.04
Tendon Type N6
1 167.25 5.652 0.0015 0 0.0000 0.250 -0.00848 0.99156 0.00844 166.54 165.84 195000 150 32.18
2 165.84 5.236 0.0015 7.5 0.1309 0.250 -0.04058 0.96023 0.03977 162.52 159.24 195000 150 29.09
3 159.24 5.345 0.0015 0 0.0000 0.250 -0.00802 0.99201 0.00799 158.61 157.97 195000 150 28.98
Half length (Total) 16.233 90.26
Full length (Total) 32.466 180.51
Tendon Type N7
1 167.25 6.725 0.0015 0 0.0000 0.250 -0.01009 0.98996 0.01004 166.41 165.57 195000 150 38.26
2 165.57 5.236 0.0015 7.5 0.1309 0.250 -0.04058 0.96023 0.03977 162.26 158.99 195000 150 29.05
3 158.99 4.281 0.0015 0 0.0000 0.250 -0.00642 0.99360 0.00640 158.48 157.97 195000 150 23.19
Half length (Total) 16.242 90.50
Full length (Total) 32.484 181.00

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

2.86 194.00 195000 150 18.97


25m
2.42 194.00 195000 150 16.05

2.86 194.00 195000 150 18.97


32m
2.42 194.00 195000 150 16.05

Kekanadura 4.66 194.00 195000 150 30.91


Bridge 4.22 194.00 195000 150 27.99

Wewrukannala 10.56 194.00 195000 150 70.04


Bridge 10.12 194.00 195000 150 67.12

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:

Any signs of cracks, crushing on Girder surface

Checked by Position Name Signature Date


Contractor :
Consultant Engineer
Accepted by contractor Reviewed by Engineer
Name,Signature & Date Name,Signature & Date
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.
2
Concrete Grade (N/mm ) : 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 B
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 1,417 Dial Gauge No: G 1.5 2014.11.4993 Calibration Report No. OVM 2014 12 17921-13
20% 40% 53% 60% 80% 100% Releasing to 10%
NO. Piston Piston Piston Piston Piston Piston
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 0.00 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
N4,N5 N2-53.33%
53 33% N4 N5 & N2
N4,N5 N2-100%
100%
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:

Any signs of cracks, crushing on Girder surface

Checked by Position Name Signature Date


Contractor :
Consultant Engineer
Accepted by contractor Reviewed by Engineer
Name,Signature & Date Name,Signature & Date
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.
TENDON STRESSING REPORT OF 25M T GIRDER
Structure Name: Nilwala No 02 Bridge Element ID: A2P40/R
Tensioning Starting
Date of Casting: 14 th July 2015 Date of Stressing: 28th July 2015 10.00 A.M.
Time:
Elastic Modulus of Conc. Tensioning Finishing
Concrete Grade : C50/20 34 12.00 A.M.
(Ec- Mpa): Time:
Tendon Identification No: N1 L Initial Tensioning (Mpa): 708 Final Tensioning (Mpa) : 1327.5

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

Strand from Reel No: 3915/ 3914 - 4F1-10934

Number of Strands, Ns 9 Number of Strand per Reel (Nr.) 9

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

Product, Ns*As*Es = 263,250.00 Product, Nr*Ar*Er = 264,776.40

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

Total Theoretical Elongation (mm) A+B= 168.53


Expected Wedge Set, End A, Wa (mm) 6 Expected Final Wedge Set, End B, Wb (mm) 6

Jack Gauge Jack Gauge


Equipment Type, End A YCW 300 B G 1.5 Equipment Type, End B YCW 300 B G 1.5
Equipment Identifiers, Equipment Identifiers,
1430 2014.11.4991 1,417 2014.11.4993
End A End B
Calibration Report No. OVM 2014 12 17921-18 Calibration Report No. OVM 2014 12 17921-13

Stressing Mode
One End only No Both A then B No Both Simultaneous (A and B with 2 sets of equipment) Yes

Target Gauge Pressure and Elongations


End A End B
Gauge Elongation
Tensioning Wedge Set Pressure Tensioning Elongation
Pressure per Wedge Set
Force (KN) (mm) (Mpa) Force (KN) per increment
(Mpa) increment
Initial set at B
Initial 20% 6.02 358.43 17.6 6.19 358.43 17.6

40% 12.04 716.85 17.6 12.18 716.85 17.6

53.33% 16.05 955.74 11.7 16.17 955.74 11.7

60% 18.06 1075.28 5.9 18.17 1075.28 5.9

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

Net Elongation after wedge


(A-Wa) = 82 Net Elongation after wedge set at B, (B-Wb) = 82
set at A,
Overall anticipated elongation, =
Elongation Measurement

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

60% 1075.28 18.06 53.00 0.00 18.17 53 0.00 0.00 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

After releasing Design force to 10%


Releasing to
59.62 1.00 74.00 1.19 74.00
0.1%
Wedge Set at A (Wa mm) 10.00 Wedge Set at B (Wb mm) 10.00

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

Elongation before set, at End-A = 79.2 mm at End-B = 79.2 mm

Total Elongation before set, (A + B) = 158.40 mm


Deduction for elongation inside the Jack & Spacer
Length of tendon inside the jack+ Stretching Tube + at End-A =
564.00 mm at End-B = 564.00 mm
Spacer arrangement (mm)
Deduct for elongation inside the jack + Stretching at End-A =
3.84 mm at End-B = 3.84 mm
Tube + Spacer arrangement (mm)
Deduct for Total elongation inside the jack + Stretching Tube +
Spacer arrangement (mm) (A + B)
7.63 mm

Actual Draw In Value


Actual Draw In value
at End-A = 6.16 mm at End-B = 6.16 mm
(wedge set -ddt for elongation in extra length, mm)
Expected Wedge Set, (mm) at End-A = 6.00 mm at End-B = 6.00
Total Actual Draw in value, (mm)
12.32 mm
Final Wa + Final Wb only =

Final Elongation (mm) = 138.44 mm Ratio of (Final / Expected)


Theoretical Elongation = 168.53 mm 82.150%

Approved OK Not Approved Under or Over -17.850% <6% O.K

Observations: No popping noises of broken wires O.K over elongations is within tolerance, O.K

Checked by Position Name Signature Date


Contractor :
Consultant Engineer
Accepted by contractor Reviewed by Engineer
Tensioning Force (kN) Vs Cumulative Elongation
Cumulative at both side (mm)
Elongation (mm)
180
y = 0.089x
160 158

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

Product Description after initial application. Once priming is complete and


X-Roc GalZinc is a single component zinc rich epoxy has fully dried, it is essential that the repair mortar is
primer. applied as soon as possible.

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.

Coverage Store unmixed materials in a cool (preferably


Typically 8m2 per liter (86ft per quart) temperature controlled) environment, avoiding exposure
to direct sunlight. Keep equipment cool, arranging shade
Packaging protection if necessary. It is especially important to keep
1 and 5 liters cool those surfaces of the equipment which will come
1 quart and 1 gallon tins (USA) into direct contact with the material itself. Try to avoid
application during the hottest times of the day, arrange
Shelf Life temporary shading as necessary. Make sufficient
7 months when stored at below 25C (77oF) under material, plant and labour available to ensure that
shade in a dry environment. application is a continuous process.

Installation Guidelines Health and Safety


Surface Preparation This product is for industrial use only by trained
The reinforcing steel should be abrasion blasted operatives. It is potentially hazardous if not used
completely to bright metal to remove all scale and correctly. Please refer to the Material Safety Data
corrosion deposits. Sheet (MSDS) prior to the purchase and use of
this product. The MSDS can be obtained via our
Application website www.x-calibur.us
Apply within one hour of preparing the reinforcing steel.
The product should be applied by brushing, to ensure Authorized Technical Specialist
continuous coverage over the total surface Please note that only X-Calibur Authorized Technical
area of the exposed steel. It may be necessary to apply Specialists (ATSs) are permitted to change any of the
a second coat if it is felt that some holidays may exist in information in this data sheet or to provide written
the first coat. Allow the first coat to dry fully before recommendations concerning the use of this product.
application of the second coat. X-Roc GalZinc is Visit www.x-calibur.us for a full list of X-Calibur ATSs.
recoatable generally between 30 minutes and one hour

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)

HEALTH AND SAFETY RISK ASSESSMENT

Strand Transverse
Grouting post-stressing lifting and transporting

Reference sheet
Document number Description

CMC/GEN/009 Rev 00
Page 1 of 17
Revision history

00 21/07/2015 SM For approval CM CE CR


Revisio Prepared Checked Checked Accepted
Date Description
n by by by by
China National Machinery
Total number of pages (including attachments): 17
Import & Export Corporation

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

Area of operation to be barricaded and sign


posted
All activities must be performed within the
1. Site Engineer
barricaded. Mr. Samantha
Third party traffic in the near 3 3 09 Onlookers and other parties who are not 1 3 3 2. Safety Engineer
vicinity of the site involved in the activity to be advised to stay Mr.Nihal
away. 3 Electrician
All workers must wear prescribe PPE

All power tools must be checked for good


maintenance
All workers must wear safety goggles and 1. Site Engineer
Mr. Samantha
Unsafe power tools for concrete 4 3 12 ear plugs 1 3 3 2. Safety Engineer
chipping works Electrical cords used for the activity must be Mr.Nihal
in good insulation and not be repaired locally 3 Electrician
using insulation tapes.
All power tools to be routed through a proper
CMC/GEN/009 Rev 00
Page 3 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

distribution boards with RCCB.


All cables must be routed properly to avoid
tripping hazards.
Workers must be routinely changed / given
break.
All concrete debris must be frequently
disposed.
Connect the tool to the correct rated voltage
and power supply
Remove the electrical sockets when not in
use to avoid accidental operation.
Do not enter danger zone
Distance between nozzle & wall <1.5m 1. Site Engineer
Mr. Samantha
3 4 12 Wear shot Crete protective helmet 1 4 4
Concreting and grouting 2. Safety Engineer
Wear respiratory protection Mr.Nihal
3 Electrician
Wet mix with alkali free additive to reduce
dust & air pollution
CMC/GEN/009 Rev 00
Page 4 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

All workers must wear dust masks and other


PPEs at all times.
Works risk must be re assessed in case of
adverse weather.
Workers must be routinely changed to avoid
manual handling injuries and upper body
pain.
Conduct toolbox on the activity.
All electrical cables must be properly routed
and checked for sound insulation.
Ensure all cranes and lifting tackles are
thoroughly tested by an approved 3rd party
competence persons as per National 1. Site Engineer
regulations in factory ordinance No 42of Mr. Samantha
Lifting / Slinging and Hoisting 5 3 15 1 3 3 2. Safety Engineer
operations 1942 under section 27. Mr.Nihal
Ensure all operators are licensed, trained and 3 Electrician
competent as per National regulations
Ground support for the beam should be to
CMC/GEN/009 Rev 00
Page 5 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

loosened sequentially before lifting and after


well hung by the crane at stable
recommended points
Lifting height to be restricted as necessary
Swing at one direction only and two gantry
hold cranes operation should well
synchronized
Never swing load overhead people
Never exceed the marked safe working loads
(SWL)
Ensure competent and trained Rigger
Position the crane on a well compacted,
leveled ground
Outriggers must be fully extended and
adequately supported
If possible, the load must be visible to
operator
If visibility of the load and rigger is not
CMC/GEN/009 Rev 00
Page 6 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

feasible, proper communications facilities


must be provided
Fire extinguisher bottle must be in the cabin
of the operator
Ensure use of tag line to control the load
Proper training and refresher courses for
operatives
Use of proper PPE must be strictly enforced
All lifting operations must be controlled by a
competent person who will take overall
responsibility and possess a method statement
for the work activities
Load must be correctly slung and secured
Loosed materials must be carried in boxes /
containers

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

the machinery with enough length on the ground Mr.Nihal


Tools Safe standing barriers behind the jack should 3 Electrician
Lack of competence ensured
Inadequate inspections No workers should not be allowed behind the
tensioning jack while tensioning
No worker or operator shall stay directly
pressure nozzles and joints
Jack must be well hung to pre formed stable
and strong stand by means of crane on chain
block fitting with facility to move forward
and back word
All Electrical installation must be connected
through ELCBs / over voltage/ current
protection devices.
Local repairs shall not be carried out on the
electrical cables and bare wires shall not be
used for connecting to the sockets.
Industrial sockets and splash proof connections
CMC/GEN/009 Rev 00
Page 8 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

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

Pressurisation area must be barricaded and 1. Site Engineer


Mr. Samantha
Unsafe pressure pipes and hoses and 3 4 12 unauthorised entry of personal must be 1 4 4 2. Safety Engineer
pressure pumps. prohibited. Mr.Nihal
All equipment, pipelines and other 3 Electrician

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

accessories must be on sound construction.


All end connections must be fitted properly
and checked for leakages at low pressure.
Drip trays to be provided for the hydraulic
reservoirs / pumps to avoid accidental
spillage.
Ensure the carrier operator is licensed,
trained and competent as per National
regulations
Checked the carrier pre-operation test before
Transporting I girder loading 1. Site Engineer

Overturning and sliding 5 5 25 Carrier beds trollies should well stationed on 1 5 5


Mr. Samantha
2. Safety Engineer
Crossing the public road flat ground and well locked. Mr.Nihal
Risk of fire diesel or gasoline Toolbox meeting shall be conducted for all 3 Electrician
staff
Pilot road must be in good condition and
demarked.
If visibility of the load and rigger is not
CMC/GEN/009 Rev 00
Page 10 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

feasible, proper communications facilities


must be provided
When girder traveling on bed or trolley well
jacked supported and correctly slung and
secured
No workers allowed to travel on the bed
Warning signs shall be displayed along the
public rd
Travel route shall be on flat route and
controlled gradient of less than 1: 10
Flagman shall be posted for traffic control
Communication device shall be provide
Provided with 10kg form fire extinguishers
Pre- operational checks by operator or
engineer for potential fuel leaks

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

Active participation of site team


contractors weekly safety meetings 1. Site Engineer
Mr. Samantha
Communications 2 4 12 Safety & health a standing item in biweekly 1 4 4 2. Safety Engineer
co-ordination meeting. Mr.Nihal
Everybodys (training conducted by safety 3 Electrician
department )
1. Site Engineer
Adequate lighting shall be provided for all Mr. Samatha
Working in nights poor visibility 3 3 9 barges. (Safe voltage 12 volts) Min 50 lux 1 3 3 2. Safety Engineer
illumination Mr.Nihal
3 Electrician
Provide 8 hrs. Work schedules. Two shift
1. Site Engineer
Workmen exhausted due to operation. Mr. Samantha
exposure to direct sunlight and 4 3 12 Provide adequate drinking water to the 1 3 3 2. Safety Engineer
windy conditions for extended workers. Mr.Nihal
3 Electrician
working hours Provide Sunshades / shelters for resting
workers
CMC/GEN/009 Rev 00
Page 12 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

Job rotation shall be implementing.

Compactors shall be provided with 10 kg


1. Site Engineer
form fire extinguishers. Mr. Samantha
Risk of Fire. Diesel and Gasoline 3 4 12 Pre-operational checks by Operator or 1 4 4 2. Safety Engineer
operated engines or compactors. Mr.Nihal
Engineers for potential fuel leaks.
3 Electrician

Excessive noise from machines and 1. Site Engineer


compactors engine. (Over 85 dB). Mr. Samantha
Potential to expose to Noise induce 4 4 16 Operators and workmen in operate who shall 1 4 4 2. Safety Engineer
hearing loss wear ear protectors Mr.Nihal
3 Electrician

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

Emergency response procedure shall be


established and communicated to all
Lack of emergency response 1. Site Engineer
employees and subcontractors. Mr. Samantha
procedure for Occupational accident 4 4 16 Singes shall be posted including emergency 1 4 4 2. Safety Engineer
/ Occupational sickness or Fire Mr.Nihal
aids and contact numbers.
incident 3 Electrician
Vehicle shall be available (Day and night)
for emergency response.

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

Daily toolbox talks shall be conducted for all


1. Site Engineer
Human failures / Unsafe acts which workmen by safety officers to educate them Mr. Samantha
may lead to accidents 4 4 16 on hazards and preventive actions. 1 4 4 2. Safety Engineer
Regular inspections by safety Officers Mr.Nihal
3 Electrician

Expose running belts / Nip points. 1. Site Engineer


Mr. Samantha
Potential to cause trap or impact 4 3 12 Expose running belts shall be covered with 1 3 3 2. Safety Engineer
injuries Material transport Truck suitable guarding to avoid contact Mr.Nihal
and machine. 3 Electrician

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

Death, toxic release off- Death, toxic release off-site with


Almost Is expected to occur in most Extreme
5 Catastrophic site with detrimental 5 detrimental effect, huge financial 15 to 25
certain circumstances risk
effect, huge financial loss loss
Extensive injuries, loss of
Extensive injuries, loss of
Will probably occur in most production capability, off-
production capability, off-site
Likely circumstances 4 Major site release with no 4 5 to 12 High risk
release with no detrimental
detrimental effects, major
effects, major financial loss
financial loss
Medical treatment
required, on-site release Medical treatment required, on-
Might occur at some time Moderate
Possible 3 Moderate contained with outside 3 site release contained with outside 3 to 4
risk
assistance, high financial assistance, high financial loss
loss
First aid treatment, on-site
First aid treatment, on-site release
Could occur at some time release immediately
Unlikely 2 Minor 2 immediately contained, medium 1 to 2 Low risk
contained, medium
financial loss
financial loss
No injuries, low financial
May occur only in exceptional
Rare 1 Insignificant loss
circumstances 1
CMC/GEN/009 Rev 00
Page 16 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 17 of 17