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TRANSCRIPT
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T.Ranjithhumar,Project Engineer,Special Project Management Unit,RDA,Batticaloa.
T.Ranjithhumar,Project Engineer,Special Project Management Unit,RDA,Batticaloa.
Post tensioning and LaunchingBeams in New Kallady BridgePost tensioning and LaunchingBeams in New Kallady Bridge
Project ProfileProject Profile
1) Project Name: Pro-Poor Eastern Infrastructure Development
2) Finance: Special Projects Management Unit (SPMU)
3) L/A : SL-P87, 28th March 2006
4) Employer: Road Development Authority, MOP& Highways5) Consultant: Oriental Consultants Co., Nippon Koei Co., ECL
6) Scope of the Work
: Construction of New Kallady Bridge : L= 288.35 m
7) Contractor: State Development & Construction Corporation
(MAGA and UTRACON)
8) Total Estimation Rs. 813,469,566 (Original Contract Amount)
Rs. 1,389,500,000 (Amended Contract Amount)
9) Date of Commencement 19thApri l 2010
10) Completion Date Original : 8th January 2012
Amended: 31st December 2012
Bridge Length 288.35 m
Span Arrangement 6 x 48.05 + 0.05 m
Bridge Width Carriageway : 3.70m x 2 = 7.40mCycle Lane: 1.50m x 2 = 3.00m
Side Walk: 1.80m x 2 = 3.60m
Total 14.00m
Superstructure 6 Spans Simple PC Box Beam
Substructure Abutments RC Reversed T Type
Piers RC T Type
Foundation Cast-in-situ RC pileD=1,200mm, (A1:D=1,500mm)
Approach Roads 196m (Kalmunai) + 95m (Batticaloa)
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General InformationGeneral Information
Bridge Type and DimensionsBridge Type and Dimensions
Bridge Length and WidthBridge Length and Width
6 x 48.05 + 0.50 = 288.35 m
C
SIDE
WALK
CYCLE
LANE
CYCLE
LANE
SIDE
WALK
CARRIAGEWAY CARRIAGEWAY
1800 1500 2@3700=7400 1500 1800
14000
6 x 1485 = 8910 16451645900 900
2050
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Sub-structure : R/C Bored Pile
Construction
y Rotary drilling and percussion type drilling machines used.
y During the boring time continuous boring record to be maintained
and level of finding hard rock to be noted.
y Socketing for the Piers and Abutment piles : 1.2 m (Similar to the
diameter of the piles)
y The sand concentration to be kept at minimum to avoid the intrusion
of bentonite or sand in the pile.
y Reinforcement cage is kept in the bore with careful attention, with the
bottom covers (150 mm preferred)
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Sub-Structure : R/C Bored Pile
Construction Contd.
y The slump of the concrete is kept in the range of 150 225 mm to
ensure the concrete is smoothly flowing for the construction of piles.
y The concrete is casted by using the tremie pipe.
y Casting records should consist the volume of concrete casted, the
theoretical height filled and actual height filled.
y The length of tremie to be removed should be decided accordingly.
y At the cut-off level, either additional concrete casted and flushed for
the removal of bentonite slurry mixed concrete or hacked for further
construction.
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IIustration for the comparison of
theoretical and actual concrete volume
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Methods to test the piles
y Pile Dynamic Analysis Test (PDA) : Load Bearing capacity of the pile
could be analyzed and the settlement also could be measured
Abutment -12200kN & Pier-9500kN (1m height)
y Pile Integrity Test (PIT): Consistency of the casted concrete could be
verified from the generated wave pattern
y Cross Sonic Log Test (CSL/SLT) : Consistency of the casted
concrete could be verified
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Super Structures Post Tensioning Beam
| 48m Box girder beam
| Length of the beam > 25 m, normally post tensioning is preferred
|Reinforcements provided to resist shear and torsion
|Why box beam?
A. I -girders is suitable for beam length around 35 m. Longerbeams are with higher self weight and bending moment. So, boxsection satisfies the section criteria.
B. Box beams are good torsion resistant sections. Launching is
easier and safer for less torsion structure.
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Box Girder Section Detail
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Data for Post-Tensioning
(General Data-Kallady Bridge)
For 48 m Box beams.(Grade-50 concrete)
y Initial Pre-Stressing force per strand is 205 kN (79% of Breaking Load)
y Tentative average pre-stress elongation of the cable is 350 mm
y Cube strength for transfer condition is 36 N/mm2 (After 3 days)
y Expected pre-camber after stressing is 21 mm upwards
y Strength of cement grout to be 30 N/mm2 at 7 days
y Stressing sequence C-C,B-B,D-D,A-A and E-50%,E-100% &E-Balance 50%.
Strands Wires Details
y Nominal tensile strength 1860 N/mm2
y
Modulus of Elasticity 200 kN/mm2y Nominal steel area 139 mm2
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Losses
All allowable loss - 25% for Post tension
- 20% for Pretension
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Mix Design Details and Strength Details
Grade 50 for 1cum.
Cement-460kg
Aggregate-1133 kg Sand -719kg
GleniumAdmix B233-3220ml
Water-147 kg (W/C 0.32)
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From Lab records
3-days - 52 N/mm2
7-days - 57 N/mm2
28-days 58 N/mm2
Elongation = FL/AE
Elongation Stress
Data Sheet for Post Tensioning
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Grouting
Tests to be performed
1. Fluidity test < 25 sec
2. Expansion test - (-1) to 5%
3. Bleeding test < 2% (3-Hours)
4. Casting cubes (4 4) to determine the strength as per desired to
suit the construction. Normally for this kind of work 30N/mm2 in 28
days is desired.
Admixtures used
y
Old Beams- Glenium B233 & Flow cabley New Beams - STROAEG
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Grouting test sample sheet
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Grouting Test Sample Sheet
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Current Status of Beams and Launched Beams
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Yard Total NotStarted
In
Progress
Re-bar
Concreted Stressed Grout ed
Make Up
(Edge)Concrete
Launched
A1 48 3 2 0 2 3 7 31
A2 6 - 0 2 0 4 0 0
Total 54 2 3 2 2 7 7 31
Only 5 Nos. Beams to be casted (3 Nos. in Progress ou t of 5 Nos.)
Total Number of Beams : 54
Total number of beams launched from A1 side: 48
Total number of beams launched from A2 side: 6
General View (From Left Side)General View (From Left Side)General View (From Left Side)
Batticaloa Side
(A2 Side)
Kallady Side
(A1 Side)
P4 A1P1A2 P5 P2P3
PhotographsPhotographs
KalladyKallady Side (A1 Side)Side (A1 Side)
P2P3
P1
Batticaloa Side (A2 Side)Batticaloa Side (A2 Side)
A2
P5
P4
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Approach RoadApproach RoadApproach Road
a.a. KalladyKallady Side (A1 Side)Side (A1 Side)
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b. Batticaloa Side (A2 Side)b. Batticaloa Side (A2 Side)
SubstructureSubstructureSubstructure
Capping Beam
Stem
Pile Cap
AbutmentAbutment
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Beam Casting WorksBeam Casting WorksBeam Casting Works
a. Rebar Fabrication Worksa. Rebar Fabrication Worksb. Inner Shutter Fixingb. Inner Shutter Fixing
20 Nov 201220 Nov 2012
c. Duct Sheathes Fixingc. Duct Sheathes Fixing d. Outer Shutter Fixingd. Outer Shutter Fixing
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e. Beam Concretinge. Beam Concreting f. Stressing Workf. Stressing Work
g. Grouting Workg. Grouting Work h. After End makeup competed (Ready for Launching)h. After End makeup competed (Ready for Launching)
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Beam Launching WorksBeam Launching WorksBeam Launching Works
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DURING ASSEMBLING OF LUANCHING GIRDERDURING ASSEMBLING OF LUANCHING GIRDER
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DURING ASSEMBLING OF LUANCHING GIRDER contd.DURING ASSEMBLING OF LUANCHING GIRDER contd.
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General Data for Launching
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Lunching Girder CapacityLunching Girder Capacity
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39 40
Beam Launching Sequences
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Progress of Launching Works
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Launching EquipmentsLaunching Equipments
Launching Beam
PSC Beam Casting Yard
PSC Beam
Front Support
A1 Abu tment
Rear Support
P1 Pier
Rear CraneFront Crane
Front Trolley
Rear Trolley
Platform
Platform
Gantry Crane
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Launching Beam
PSC Beam Casting Yard
PSC Beam
Front Support
A1 Abu tmen t
Rear Support
P1 Pier
Rear CraneFront CraneFront Trolley
Rear Trolley
Platform
Gantry Crane
1. Loading PSC Beam on Trolley using Gantry Crane
Gantry Crane
Platform
Trolley
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Launching Beam
PSC Beam Casting Yard
PSC Beam
Front Support
A1 Abu tment
Rear Support
P1 Pier
Rear Crane Front Crane
Front TrolleyRear Trolley
Platform
Gantry Crane
2. Moving PSC Beam to Front Crane using Trolley
PlatformTrolley
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Launching Beam
PSC Beam Casting Yard
PSC Beam
Front Support
A1 Abu tmen t
Rear Support
P1 Pier
Rear CraneFront Crane
Front TrolleyRear Trolley
Gantry Crane
3. Hanging PSC Beam by Front Crane from Trolley
Platform Trolley
PSC Beam
A1 Abu tment 46
Launching Beam
PSC Beam Casting Yard
PSC Beam
Front Support
A1 Abu tment
Rear Support
P1 Pier
Rear Crane
Front TrolleyRear TrolleyGantry Crane
4. Launching PSC Beam by Front Crane and Rear Trolley
PlatformTrolley
PSC Beam
A1 Abu tment
Front Crane
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Launching Beam
PSC Beam Casting Yard
PSC Beam
Front Support
A1 Abu tmen t
Rear Support
P1 Pier
Rear Crane
Front TrolleyRear Trolley
Gantry Crane
5. Hanging PSC Beam by Rear Crane from Rear Trolley
PlatformTrolley
PSC Beam
A1 Abu tmen t
Front Crane
Rear Trolley
Rear Crane
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Launching Beam
PSC Beam Casting Yard
PSC Beam
Front Support
A1 Abu tment
Rear Support
P1 Pier
Rear Crane
Front TrolleyRear Trolley
Gantry Crane
6. Moving PSC Beam by Front Crane & Rear Crane
Platform
PSC Beam
A1 Abu tmen t
Front Crane
P1 Pier
PSC Beam
Front Crane
Rear Crane
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Launching Beam
Front Support
A1 Abu tmen t P1 Pier
Rear Crane
Gantry Crane
7. Lateral Shift ing and Moving Down PSC Beam
by Front Crane & Rear Crane
Platform PSC BeamA1 Abu tmen t
Front Crane
P1 Pier
PSC Beam
Front CraneRear Crane
P1 Pier
Front Support
Front Support
v
50
v
PSC Beam Casting Yard
Front Support
A1 Abu tment
Rear Support
P1 Pier
Rear Crane
Front TrolleyRear TrolleyGantry Crane
8. Moving PSC Beam by Front Crane & Rear Crane
Platform
PSC Beam
A1 Abu tmen t
Front Crane
P2 Pier
Front Crane
Rear Crane
P2 Pier
P1 Pier
Launched Beams
Span-1
Platform
Rail Line
P3 Pier
Beam Lif ting Work on A1 SideBeam Lif ting Work on A1 Side Setting Beam on TrolleySetting Beam on Trolley
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Moving Beam by TrolleyMoving Beam by TrolleyHanging up Beam by Front Crane from FrontHanging up Beam by Front Crane from Front
TrolleyTrolley
Beam Launching WorksBeam Launching WorksBeam Launching Works Launching Beam by Front Crane and RearLaunching Beam by Front Crane and Rear
Trolley (1)Trolley (1)
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Launching Beam by Front Crane and RearLaunching Beam by Front Crane and Rear
Trolley (2)Trolley (2)
Hanging up Beam by Rear Crane from RearHanging up Beam by Rear Crane from Rear
TrolleyTrolley
Launching Beam by Front Crane and RearLaunching Beam by Front Crane and Rear
CraneCrane Moving Down and Lateral Shifting BeamMoving Down and Lateral Shift ing Beam
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Launched 9 Nos. of Beams 3rd SpanLaunched 9 Nos. of Beams 3rd Span Problems Faced at SiteProblems Faced at Site
After RectificationAfter RectificationAfter Rectification
1.1.1.
After RectificationAfter RectificationAfter Rectification
2.2.2.
After RectificationAfter RectificationAfter Rectification
3.3.3.
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After RectificationAfter RectificationAfter Rectification
4.4.4.
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Double Bailey Girder Arrangement for
Launching Beam by SD &CC
Double Bailey Girder Arrangement forDouble Bailey Girder Arrangement for
Launching Beam by SD &CCLaunching Beam by SD &CC5.5.5.