= i WPM an ap | | i} Zocor UN Statement for Consti ction of PSC Bo Letter No. FC/PD01/GO0/CEC/PMOF/15/1080 Date: 01.09.2015 | The Executive Engineer [Flyover Project Division F-133 | Public works Department, Govt. of Neth Mukarba Chowk, G.T. Kamal Road, Delhi-110033 |_ Name of Project: Comprehensive Development of Corridor (Outer Ring Road) between Mukarba Chowk to Wazirabad Chowk SH: - C/o Flyovers, Loops, Bridges across supplementary drain, FOBs, footpath, Cycle Track, Widening of road on | embankment, Rainwater Harvesting scheme, Electrical Works and other allied | works. - Submission of Method Statement for Construction of PSC Box Girder for Span PL10 - PL13 of Jagatpur Flyover ~ Reg. Ref: 1. Our Letter No. FC/PD01/GO0/CEC/PMOF/15/885 dated 04.05.2015 2. Your Letter No. 54(102)/F-133/PWD/2015/408 dated 29.07.2015 |Dear sir, |With reference to Letter cited at sr. no. 2, please find enclosed herewith the construction | methodology for construction of PSC Box Girder for Span PL10 to PL13 of Jagatpur Flyover after |incorporating comments. ‘Sno ~~ Comments Corrections — 1 The drawings are not supported with any | Design Note enclosed | calculation and capacity of members & cribs _| Refer Annexure-2 2 |The methodology need to be elaborated for | Incorporated as suggested - the complete erections and also concreting of the structure 7 | 3 No. of pours for the box girder is 2 as shown | Incorporated as suggested | in your document on page. 8 while it should be 3 CONTINENTAL ENGINEERING CORP Tetaoi-i6-so ‘aaweusen oF connnanra ouomce ‘ower 7hFloo Signature Toner Sector 28, NH 8, Gurgaon 12200 (HH, F926 9809 eg Ofc 71, ak A, Sector? hin New Deli 0065 Web stesemelcain| Two stages of post tensioning are mentioned | Earlier. method statement was in Box Girder construction of design document | submitted based on GFC Dwg. No. DD on the page 6" while itis single stage stressing | 1739 Rev. D issued on 25.03.2016. Now, Single Stage —Stressing | incorporated based on Revised GFC Dwg no. DD1739 Rev E issued on - _ | 25.05.15 The connection details of crib with PCC are | Details are provi missing drawings page no.7 Kindly accord your approval for the same at the earliest, | Assuring you of our best services at all the time, ing Corporation (Saure Project Manager Encl: PSC Box Girder Method Statement (PL10 — PL13)in 2 Setseae Construction of Signal free corridor {rom Mukarba Chowk to Wazirabad TABLE OF CONTENTS INTRODUCTION PURPOSE RESPONSIBILITY MANPOWER: EQUIPMENTS REQUIRED: BRIEF METHOD OF CONSTRUCTION JOB BREAKDOWN... 1. Reinforcement: Cutting and bending of reinforcement: Erection of shuttering arrangement: Placing of Reinforcemont:..... 2 3 4 5, Sheathing and Guide Cone Fixing: 6. Stage wise concreting of Box-Girder:. 7. Post Tensioning (Stressing of tendons) :. 8. Grouting 9. Removal of shuttoring:... 10. Installation of Expansion joints: RISK INVOLVED........ SAFETY PRECAUTIONS. ANNEXURE bbb bw a ib ob bo me VN ad 10 10 Method Statement for Cast In-Situ PSC Box Girder "Page 2 of 10SFovcmtoag Consinetionot signa ee contectom — (oon Se Mukarba Chowk to Wazirabad INTRODUCTION This method statement describes methodology for construction of Cast In-sity PSC Box Girder at Jagatpur in project "Comprehensive development of Signal Free Corridor from Mukarba Chowk to Wavirabad’. The objective of this method statement is to clearly understand the methodology for execution of Box Girder casting work, the step-by-step procedures of execution by considering time effectiveness & controlling the time wastage along with all safety precautions, and to achieve the desired target of project. Considering all the safety precautions are necessary to avoid any kind of injuries / accidents to personnel or any damage to any equipment or property. PURPOSE The purpose of this method statement is to describe the construction procedure to be followed at the site and is in the line of technical specifications of contract document ORGANIZATION CHART Project Manager DPM-1 Structure Works Sr. Engineer (-—) Sr. Engineer Engineer | Engineer Engineer Method Statement for Cast In-Situ PSC Box Girder DPM -2 Road Works Page 3 of 10,peeasas Construction of Signal free corridor from. Mukarba Chowk to Wazirabad RESPONSIBILITY a) The supervisor shall be responsible for managing all plant, machinery and labourers for Staging & Box Girder construction. 5) The section engineer / manager (Work Manager) shall be responsible for all the activities of superstructure construction c) The execution engineer shall be responsible for the construction of Superstructure as per the technical specifications & drawings. ) The QA/QC engineer shall be responsible for ensuring the quality of work as er the specifications ©) The Survey engineer shall be responsible for ensuring the correct alignment and elevation of structure as per the drawings. f) The Safety engineer shall be responsible to ensure the safety of workers during the progress of work. 9) _ The project in charge shall be responsible for the overall completion of Project, within the set time. MATERIALS: _S.N. Name Brand/Source | Conforms to Remarks | 1 Concrete M45, M60 Libaspur 1S-10262, Grade Batching Plant _|_ 7 a 2” [Water 1S:456-2000 oe 3” [HDPE Sheathing Rex Drawing no 1739-D & 1713-C 4° | Anchorage Sets Dynamic | |eaaeatecae ___| stressing : __5___| Reinforcement steel | TATA(Fe-500) | 1S -1963/1S-2502 — | 6 | Deboning Agent | _— = 7__| G1Binding Wire - 18Gauge | 8 | Structural Steel for - 1S- 2062-2011 Shuttering _ c 9 [HT Cables TATA 1814268 — E 10 | Expanding Agent Fosroc/Gebex- | MORTH IV REV- 7 _ | 100 : 2014, IRC-112-2014 ii | Retarder scarce 42 | Inhibitor a _ | MANPOWER: Nos/Required | Remarks Welders 6 Fitters | 20 Masons Helpers Riggers Curing Labor Khalasi Method Statement for Cast In-Situ PSC Box Girder Page 4 of 10Construction of Signal free corridor team Pw! ‘Mukarba Chowk to Waziabad JOB BREAKDOWN Box Girder Construction Cutting and bending of reinforcement Erection of shuttering arrangements. Placing of Reinforcement. Sheathing and Guide Cone Fixing. Conereting in 3 pours. Post Tensioning Grouting & Mounting of Cable ducts. Shuttering & staging Removing Installation of Expansion joint. ©ONOTRYNA 1. Reinforcement: + TMT Fe 500 sce! bars of approved vendor shall be used. ‘+ Reinforcement stee! shall be supplied to steel bending yard directly from manufacturer. * Reinforcement shail be stacked on sleepers / Concrete blocks to avoid direct contact with local earth. The sleepers/concrete blocks shall be of 200 mm height. * Reinforcement shall be marked batch wise and tested as per Inspection and test Plan. * Reinforcement which confirms to the requirements shall be used for cutting and bending. + Approved BBS shall be used for cutting and bending ‘+ Reinforcement shall be protected from rusting, mortars, mills scale, grease oll or paints by covering with tarpaulin sheets as per the requirement in site. ‘+ Handling of reinforcement shall be in such a way so as to prevent damage or unwanted bending * Bars bent during transport or handling shall be straightened. Straightening by heating shall not be permitted. ‘+ Reinforcement left projecting from newly placed concrete shall be supported in such a way that there is no sag or risk of damage to the newly placed concrete 2, Cutting and bending of reinforcement: * Reintorcing steel shall conform to the dimensions and shapes given in the approved Bar Bending Schedules. + Reinforcement steel shall be fabricated through automatically operated machines and mandrels confirming to 1S1786:2008. * Quantity of Reinforcement steel fabrication shall be as per the Production schedule, * Cut and bent reinforcement shall be stacked on sleepers and protected to prevent rusting by covering with tarpaulin sheets. * The acceptable tolerances for placing the reinforcement are © Overall depth - 10mm for depth <200mm and 15mm for depth >200mm. * Cover to the reinforcement — Least of i) 1/3rd of specified cover ii) 5mm ‘Method Statement for Cast In-Situ PSC Box Girder Page 6 of 10Construction of Signal free corridor from, Pw Mukarba Chowk to Wazirabad Description Quantity | Remarks 1__ | Batching Plant [02 Transit Mixer 11 | Tipper___ —| | Conerete Pump | ‘Shutter Vibrator | Needle Vibrator —[ Welding Machine "Gas Cutting Set iE 11 [Auto Level 12 | Total Station with __| Accessories Dewatering Pump (G_ = Hydraulic Jack Grouting Pump Motor Mixing Drum: BRIEF METHOD OF CONSTRUCTION After completion of pier cap construction the pedestal for bearing is to be cast as per the drawings and specification. After gaining required strength by the pedestal, spherical bearing shall be placed along with Box Girder bottom shuttering. For soffit slab shuttering, the staging arrangement is done as per the drawings attached in Annexure. For staging, cribs are placed in line on PCC Cover blocks at proper interval as provided in drawings. Upon which primary beam and secondary beam are provided by maintaining level and camber Bottom Shutter will be placed as per the survey setouts and level shall be maintained as per drawings. Upon approval of Rottom shuttering Side curved shutters / cantilever portion shall be placed which are supported by angle frames at regular intervals. Reinforcement shall be placed after approval of shuttering by Engineer-In Charge / PWD officials, Method Statement for Cast In-Situ PSC Box Girder Page 5 of 10,cumsumansny Construction of Signal free corridor {rom F Mukarba Chowk to Wazirabad + Centre-to-Centre distance - +10mm. * Transportation of Reinforcement © Cut and bent reinforcement shall be transported to place of work on trucks /trailers, * Reinforcement shall be stacked on elevated blocks in clean and dry condition, 3. Erection of shuttering arrangement: The staging will be erected on a level platform. Bottom Shutters of Box Girder will be placed with the supporting arrangements as per the scheme drawings attached in Annexure. Service cranes will be utilized for shifting / erecting of the staging & shuttering arrangements. The inside surface of shutters shall be cleaned perfectly with wire brush; emery paper etc. and any undulation if noticed will be flushed with ‘metal putty to provide the smooth concrete surface All dimensions are in mm. Fig. 1 - CRIB FOUNDATION DETAIL 4, Placing of Reinforcement: * Reinforcement shall be tied together at every intersection with MS Binding wire (18 gauge). + Lap length shall be as given in the GFC drawing and shall be staggered + Only cover block made of grout / concrete shall be placed at suitable locations to maintain clear cover. * Spacer bar shall be provided at 2m intervals in between reinforcement layers as equal to maximum diameter of steel Method Statement for Cast In-Situ PSC Box Girder Page 7 of 10masta Construction of Signal free corridor from Pw Mukarba Chowk to Wazirabad + Reinforcement (or the dowels left) shall be coated with inhibitor solution and cement slurry for protection against rusting. Inhibitor solution is a clear liquid Of pH value 10-14 and Specific gravity of 1.04 minimum. This inhibitor solution shall be stored in closed plastic containers 5. Sheathing and Guide Cone Fixing: + HDPE duct as per required technical specification shall be procured from supplier and shall be got approved from engineer before usage. * Profiling (layout of HDPE ducts) shall be carried out according to the co- ordinates given in the approved drawing * Steps in Duct profiling + HDPE duct shall be fixed as per the x, y, z co-ordinates given in the drawings. + Cone boxes shall be fixed at required locations as per the drawing in ‘Annexure B. These cone boxes shall be permanently welded to end block shutters and shall be approved from engineer prior to use. + Cable support / chairs shall be firmly tied to the secondary reinforcement and duct which shall be tied with the main reinforcement by binding wire, so as to avoid displacement of cable during concreting. Care shall be taken to make a smooth profile for the HDPE pipes + HDPE pipe shall be fixed over supports. At the end of the cable, HDPE duct shall be inserted in the guide collar provided to accommodate the HDPE duct and the joint sealed with tape to avoid ingress of slurry during the concreting, + Threads of guide bolts can be protected by M.S threaded sleeves / PVC sleeves. + Co-ordinates shall be checked once again since there is chance of disturbances due to shifting of prefabricated cage to the casting bed + For proper matching of centre line of duct for previously cast segment to be cast and to avoid ingress of slurry during concreting, a rubber cone shall be inserted inside the HDPE pipe of match cast segment. Joints shall be sealed by glass putty. + Layout of the duct shall be marked on the pre fabricated cage as per the drawing of respective segment + For Y-ordinate a 10 mm diameter tor steel bar shall be tied to the supporting arrangement at the required heights measured from top of the shutter to the top of the duct. + Z-ordinate shall be taken from the centre of segment to the centre of pipe. The pipe shall be tied securely over the support bar, so that it shall not be displaced during concreting. + The duct for prestressing shalll be fully checked for correct profile and is ready for concreting 6. Stage wise concreting of Box-Girder: After ensuring perfect supporting and shutter arrangement; formwork will be set for concerting. Concrete will be produced in the batching plant and it will be transported to the location by Transit mixer. Concreting shall be done in 3 pour as shown in Fig.1 below with the help of concrete pumps / boom placer. Curing will be carried out for 28 days. Method Statement for Cast In-Situ PSC Box Girder Page 8 of 10S fl sridor fi EE exe nn Construction of signal free corridor from few = ‘Mukarba Chowk to Wazirabad Coat 1 ee Pons SS Fig.2 - CONCRETE POUR DETAILS WS Fos 7. Post Tensioning (Stressing of tendons) : ‘Stressing of cables upto Jacking force/ elongation shall be carried out on 28 day or when the strength of concrete is 45Mpa whichever is later. Stressing of ‘Tendons shall be done in the following order 1b, 1a, 3b, 3a, 2b, 2a, 4b, 4a, 5b, 5a, 6b & 6a Refer Pre-stressing Method Statement in Annexure, 8. Grouting Aiter stressing, grouting of Tendons shall be cartied out as per IRC112-2010. Flushing the sheathing with water grouting shall be done with plain cement grout with water cement ratio not exceeding 0.45. A suitable Non-Aluminium based expanding agent shall be added to the grout. Detail methodology of stressing and grouting will be provided later on. 9. Removal of shuttering: Removal of shuttering of the Box-girder will be done after stressing. For removal, first bolting arrangements will be disconnected and then shutter will be removed by crane, which will be moved to the subsequent box-girder location 10.Installation of Expansion joints: Single Strip seal / Modular expansion joints will be installed over full width of deck, accordance with the detail shown on the drawings and the manufactures recommendations. Temperature during installation should be between 20°C to 30°C RISK INVOLVED 1. Working at height 2, Working with cranes & equipment’s movements 3. Falling of object 4, Work in heavy vehicular traffic area. Method Statement for Cast In-Situ PSC Box Girder Page 9 of 10,= eongn i Construction of Signal free corridor from Mukacba Chowk to Warirabad SAFETY PRECAUTIONS 1. For working at height all the necessary safety measures has to be considered. 2. The crane will be operated within safe working radius and all equipments will be Properly maintained and checked. No personnel will be allowed in the area of working/ swing radius of the crane and other equipment. 3. Checking and confirming of stability of all temporary supports are very essential 4. Trailer, truoks, Crane etc, are being moved and worked with in a constricted Space, so the movement of the equipments should be well planned. 5. Highly skilled crane operators, will be engaged for the work. They will be educated and trained as per guidelines of safety regulations, about the procedures of the Job and high degree of risks involved in the job. 6. Working area will be barricaded locally to prevent ingress of the other unauthorized workers 7. The work methodology of the activity will be explained to all the key personnel and workmen involved in that activity and standing instructions will be given. 8. All the workmen will follow the safety rules as per the contract. Availabilty of site first aid facility 9. Proper illumination shall be maintained during night work. REFERENCES GOOD FOR CONSTRUCTION Drawings used for the purpose are as follows: For SPAN PL13 to PL 10: 1. Numeration details of continuous PSC box-girder between piers (PL13 - PL10) (Sheet 1, sheet 2) DD-1735 Rev. H & DD-1736 Rev. G. 2. RC details of continuous PSC box-girder blw piers (PL13-PL10) (Sheett, sheet2, sheet3) DD-1740 Rev. E, DD-1741 Rev.E, DD-1742 Rev. F 3. Numeration and RC detail of end diaphragm of continuous PSC box-girder. PL10 DD-1743A Rev. D, and PL13 DD-1743. Rev.E 4. Numeration and RC detail of mid diaphragm of continuous PSC box-girder between Piers (PL13-PL10) DD-1744 Rev.D. 5. Prestressing details of continuous PSC box-girder between piers (PL13- PL10), (sheet, sheet2, sheet3), DD-1737 Rev. F, DN-1738 Rev. D, DD-1739 Rev. E. Technical Specifications of Contract Agreement. ANNEXURE Scheme drawings for Staging and Shuttering Arrangement- Prestressing Method Statement Cribs and Bracing design note Plan at Base Level — Dwg No. RDAICEC/JF/S-01 Elevation of Staging — Dwg No. RDA/CECIJF/S-01 Plan at Primary Beam Level Plan at Secondary Beam level Shuttering Arrangement of Soffit, Web and Deck slab NOGRONS ‘Method Statement for Cast In-Situ PSC Box Girder Page 10 of 10ANNEXURE-1 DYNAMIC PRESTRESS PROJECTS & SERVIC PRE ING WORK PROCEDUK NTINENTAL ENGINEERING CORPORATION : Comprehensive Development of Corridor (Outer Ring Road) between Mukarba Chowk to Wazirabad Chowk. PVT.LTD, | PROJEC METHODOLOGY FOR PRESTRESSING & GROUTING OF POST TENSIONED BOX - GIRDER (JAGATPUR FLYOVER} PROJECT DETAI OWNER | PWD - DELHI [| __ DESIGN .- y - ~ | consULTANTs | _{&T-RAMBOLL CONSUI TING ENGINEERS LIMITED CONTRACTOR | CONTINENTAL ENGINEERING CORPORATION. - DYNAMIC PRESTRESS PROJECTS & SERVICES. PRESTRESSING PVT. LTD. AGENCY — | ADD: 64, Mahavir Centre, Sector ~ 17, Vashi, Na _ Mumbai ~ 400 705, Maharashtra State, INDIA. _ SUMMARY OF GIRDERS PSC Box Girders - 06 Modules of 18 Spans cast in situ total 609mtr length REFERENCE DOCUMENTS/CODES/DRAWINGS. 1. 1S: 1343 Prestressed Concrete 2. 1S: 14268 Stress Relieved Low Relaxation 7 Ply Strands for Prestressed Concrete. 3. 1S: 210 Grey Iron Casting - specification 4. BS: 970 Specifications for Wrought Steels for Mechanical & Allied Engineering Purposes 5. IRC: 18-2000 Design Criteria of Prestressed Concrete Road Bridges (Post-tensioned Concrete) | 8. Relevant Prestressing Drawings (Latest Revisions). 7. Specifications Related to Prestressing Work. PRESTRESSING MATERIALS * High Tensile Strands Following are the properties of 15.2 mm @ Low Relaxation High Tensile Strands. Oiled strand shall be used — a Nominal Area of Strand = 140.0 mm? 2 Minimum Breaking Strength orUTS, - 260.7 KN @ Nominal Weight of Strand = 1.102 kg/mtr.ANNEXURE-1 8 PROJECTS & SERVIC ING WORK PROCEDURE. + SHEATHING PIPES 75 mm ID HDPE sheathing pipes for 7DP15 Sheathing duct shall be made up of HDPE of thickness (3,0 mm # 0.03) mm 85 mm ID HDPE sheathing pipes for 12DP15, Sheathing duct shall be made up of HDPE of thickness (3.0 mm + 0.03) mm 107 mm ID HDPE sheathing pipes for 19DP15. ‘Sheathing duct shall be made up of HDPE of thickness (3.0 mm + 0.03) mm. * Dynamic 7DP15, 12DP15 & 19DP15 Live end Anchorage System The cast-in-situ module of box-girder will be casted after reinforcement & sheathing placing along with cables, then as per latest drawing schedules stressing process will be started. “Tube Unit (Anchor Cone) The basic raw material for manufacture of tube unit is gray cast iron. It allows the transfer of prestressing force from the bearing plate to the concrete. The Tube Unit is embedded in concrete and can be easily fixed to the MS cone box by means of bolts and nuts. The design of Tube Unit allows uniform flaring of H. T. Strands while stressing and free access to the injection of grout. “Anchor Head (Bearing Plate) The basic raw material for manufacture of bearing plate is Steel casting / forged steel. The conical holes facilitate the seating of wedges and holding the strands in stressed condition. “Wedges The basic raw material for manufacture of wedges is alloy steel. The individual high tensile strands passing through the bearing plate is anchored by the wedges. The 3 ‘segments of the wedges are held together around the strand by means of special wire circlips for better functioning, easy placement and storage. Prestressing and Grouting is broadly divided into following activities, viz., 1. Layout & Profiling of the cables/sheathing 2. Fixing of tube unitiend block 3. Cable cutting and threading 4. Fixing of Bearing plate & Wedges. 5. Stressing. 6. Cutting and end Sealing, 7. GroutingANNEXURE-1 § PROJECTS & SERVIC ING WORK PROCEDURE, SPYT.LID. DYNAMIC PRE P 1. LAYOUT & PROFILING OF SHEATHING PIPES After completion of alignment of bottom shuttering & bottom reinforcement of girder, layout & Profiling of cables shall be carried out in following steps: ¥ Layout of cables is carried out as per given ordinates & related reference drawings. Y After all ordinates are plotted, tie bars of 10 mm, dia. shall be installed as per ordinates to place the sheathing pipe wherever required. Installation of sheathing pipe is carried out over the tie rods. ¥ Sheathing pipe shall be supported in the bottom by tie rods & shall be cross bound using double binding wire, It should be ensured that the sheathing Pipes are fixed firmly in position so as to prevent displacement during concreting by weight of concrete, vibration or by floatation. ¥ Connect the sheathing with the help of couplers provided at the end of each pipe. ¥ Sealing of sheathing joints will be done using PVC tapes. It will be ensured that no joints are remaining unsealed. ¥ Cable profile shall be checked. Vertical ordinates shall be check from soffit of the bottom shutters. Horizontal ordinates shall be check from the face of the side shutters, which has been already checked for verticality or as in drawing 2. FIXING OF TUBE UNIT % Fixing of tube unit shall be carried out after installation of end shuttering plate. % Fix tube unit to End plate with the help of 4 nos. of bolts. % Bursting reinforcement shall be fixed according to the drawing ‘ Connecting the tube unit to sheathing pipe. % Joint shall be sealed with the help of PVC tape. % The face of the tube unit shall be truly perpendicular to the axis of the cable and about 1.5m of cable before trumpet should be in straight alignment. * After the fixing of tube unit and cable layout, insert the HDPE pipes Or Dummy Ball along with rope inside all ducts to avoid the damage of sheathing Pipe & ingress of cement slurry inside the duct at the time of concreting, 3. CONCRETING » Although concreting is not a part of sessing, but it plays a vital role in successful stressing of structure. > It shall be noted that the needle vibrator is not placed directly on sheathing pipe, which may damage the sheathing pipe. >» HDPE pipe Or Dummy Ball along with rope in all the cables and should be Moved in both directions during the period of concreting. > Due care should be taken while concreting in the end block portion. Proper compaction of concrete should be ensured to avoid honeycombingDYNAMIC PRESTR & SERVICES PVT. LTD. PRESTRESSING WORK PROCEDURE. 4. CABLE CUTTING & THREADING After completion of concreting & removing end block shuttering, cable threading shall be done. +H. T. Strands shall be threaded manually. * For cutting strands, a portable grinding wheel shall be used. +H. T. Strands shall be cut as given in drawings, considering site conditions & gripping length of jack. 5. FIXING OF BEARING PLATES & WEDGES * Fixing of bearings plates & wedges is done before stressing. It is ensured that the tapered holes in bearing plates & wedges are froe of rust. * Insert the strands into the tapered holes provided in the bearing plate. + Install the wedges over the strands and push them with a pipe into the tapered holes of the bearing plate. > Tao Unit Bearing Coler ~ Caller Tigthening Bo Prestressing of the girder is done as required by the system of prestressing and design. Following points will be observed while carrying out the stressing operation. * The required strength of the girder concrete as mentioned in drawings/specitications shall be ensured by cube testing before starting the stressing work * Stressing of cables shall be done as per the sequence mentioned in the drawings/specifications * Elongation mentioned in the drawings must be modified for actual value of Modulus of elasticity ‘E’ and the area of c/s of strands ‘A’ of the cables as per the results unless otherwise mentioned in the drawings/specifications * Actual pressure shall be calculated after applying Jack efficiency factor. + Stressing shall be done using Multi-pull jacks only. * Stressing shail be done from both ends, care will be taken to achieve almost equal readings of elongation at both the ends in each step of increment of pressure.ANNEXURE-4 DYNAMIC PRESTRESS PROJECTS & SERVICES PVT. LID. PRESTRESSING WORK PROCEDURE. + Readings will be taken preferably at incremental steps of 50 kg/cm? up to the final pressure + After locking the wedges the pressure in the jack will be released very slowly to avoid transfer of prestressing force by impact. ‘+ In every cable instantaneous slip of anchorages must be recorded. It will be Within limits prescribed by the designer or by the prestressing agency. ¢ The pressure applied and elongation achieved will match within the prescribed limits. Normally, this limit is + 5% of pressure and elongations, + No person will be allowed to stand behind the anchorages in any circumstances during the process of tensioning 6.1 THE FOLLOWING STEPS SHOULD BE PREFERED FOR JACK MOUNTING: Fix the bearing plates at both the ends of the tensions. Insert the bearing collar & fix it on tube unit with the help of screws. Insert the lock-off plate as per the orientation the bearing plate. A rigid runaway beam (ISMC/ISMB) structure shall be made at the end of the bridge girder from where the Jack is to be suspended by means of a chain pulley block. The arrangement will give full flexibility of movement of Jack both transversely and longitudinally. => Push the Jack over the strands. The axis of the Jack must coincide with the tendon axis. Insert the strand in to the Jack. Apply ‘wax" inside the holes of pulling plate as well as outside of master grip. Install the 3-piece wedge (master grip) over the strand into the pulling plate inside the rear of the Jack. Push the grips with a piece of hollow hammering pipe to seat tightly inside the pulling plate holes. => Ensure all connection of Jack with pump is correct and flexibility of hose pipe for movement of the Jack at the time of stressing {t is important that the supporting chain or hook shall be slackened off ‘soon as the Jack starts to carry load, but they must be ready to support the Jack again when the pressure is released Yuu Uy Locking pressure should be maintained approximately 70-80 % of the stressing Pressure i.e, 78.3% of U.T.S, (i,e,) 204.13 KN per strand, 8. CUTTING AND END SEALING Culling should be carried out after checking the 24 hrs. slip loss, Strand should be cut approximately 40 mm. from the face of bearing plate. End sealing should be done with the help of GROUT CAP or Epoxy & Cement Mortar (Mounting the ends) 7.1 GROUT CAP: The advantages of using Dynamic Grout Cap are used for speedy grouting and saving of sealing material i.e. cement mortar.