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PROJECT PRESENTATION ON PRESTRESS GIRDER 18.30M SPAN UNDER THE GUIDANCE OF Sh. RAJESH KUMAR PROF. T/I BY R.C.MANDAL, AXEN/C/SILAPATHAR K.K.KUTTY, AXEN/C/PANVEL H.K.DAS, ADEN/HQ/LUMDING INTREGRATED COURSE NO-813 FROM-14.07.08 TO 26.09.08

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PROJECT PRESENTATIONON

PRESTRESS GIRDER 18.30M SPAN

UNDER THE GUIDANCE OFSh. RAJESH KUMAR

PROF. T/IBY

R.C.MANDAL, AXEN/C/SILAPATHAR K.K.KUTTY, AXEN/C/PANVELH.K.DAS, ADEN/HQ/LUMDING

INTREGRATED COURSE NO-813FROM-14.07.08 TO 26.09.08

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The Br.No.63(3x18.3m span) in Construction,The Br.No.63(3x18.3m span) in Construction,under the project of Bogibeelunder the project of Bogibeel--railrail--cumcum--roadroadbridge over the river Brahmaputra has greatbridge over the river Brahmaputra has greatimportance in the socioimportance in the socio--economic matters ofeconomic matters ofUpper Assam . The people of Assam along Upper Assam . The people of Assam along with with Arunachal PradeshArunachal Pradesh will be benefited will be benefited with a better transport system and a better with a better transport system and a better railway communication. railway communication.

Contd.Contd.

The Bogibeel bridge is designed for road The Bogibeel bridge is designed for road way and broad gauge railway track. The way and broad gauge railway track. The length of the new railway line to be length of the new railway line to be constructed on the northern bank of the constructed on the northern bank of the river will be 18.6 km and the southern bank river will be 18.6 km and the southern bank will be 23.5 km. The length of Bogibeel will be 23.5 km. The length of Bogibeel bridge is 4.315 km.bridge is 4.315 km.

System Map N.F.RLY.System Map N.F.RLY.

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Two span completed*������ �������� �� �����

Drawings in connection with the BridgeDrawings in connection with the Bridge

The work is in progress as per Drg.No.1 .GAD-CE/CON/Bogi/B/162/2003.2.ASA/POST/18.3/1 –For Girder3. ASA/POST/18.3/2 –For Cable profile 4.ASA/POST/18.3/3 –For Reinforcement5. ASA/POST/18.3/4 –For Bearing

Hydraulic Data of BridgeHydraulic Data of BridgePrePre--stressed girder bridge on pile foundationstressed girder bridge on pile foundation--1.LWL1.LWL--103.915M103.915M2.HFL2.HFL--107.965M107.965M3.Silt Fector3.Silt Fector--0.8 0.8 4.Design Discharge 4.Design Discharge --130Cumec130Cumec5.LBL5.LBL--103.563M103.563M6.NSL6.NSL--100.496M100.496M7.Clearance Reqd.7.Clearance Reqd.--825mm(Provided)825mm(Provided)

8.Cut off level 8.Cut off level --104.121M (Pier)104.121M (Pier)9.Cut off level9.Cut off level-- 105.221M(Abutment)105.221M(Abutment)

Proposed constructionProposed construction

Super structureSuper structurePSC Girder bridge (IPSC Girder bridge (I-- section) section) ––Span Span -- 3x18.30m 3x18.30m

Sub structure:Sub structure:RCC abutment and pierRCC abutment and pier

Foundation :Foundation :�� Pile foundation Pile foundation �� 1200 mm 1200 mm diadia bored pile 6 bored pile 6 nosnos under pier andunder pier and

abutment each abutment each �� Depth of pile varies 25 m to 27m from cut off levelDepth of pile varies 25 m to 27m from cut off level

Bearing :Bearing :Elastomeric bearing 91 mm thick (630x450mm)Elastomeric bearing 91 mm thick (630x450mm)

FormworkFormworkForm work was designed for :Form work was designed for :1.Dead load of wet concrete and reinforcement1.Dead load of wet concrete and reinforcement2.Self weight of form work2.Self weight of form work3.Plant and equipment including impact 3.Plant and equipment including impact 4.Construction personal4.Construction personal5.Water proofing5.Water proofing��Formwork was fabricated with MS plate 8 MM Formwork was fabricated with MS plate 8 MM thick as per standard approved drawing of girder. thick as per standard approved drawing of girder. As per designed screw and jack type staging were As per designed screw and jack type staging were erected to support girder formwork. Shuttering oil erected to support girder formwork. Shuttering oil was applied before casting of girder. was applied before casting of girder.

Materials for construction:Materials for construction:Mix Design DataMix Design DataDone by Assam engineering college ,GuwahatiDone by Assam engineering college ,Guwahati

MM--30 ( For foundation and sub structure)30 ( For foundation and sub structure)TMSTMS--38.25MPA38.25MPAWater cement ratioWater cement ratio--0.400.40CementCement--450kg/cum450kg/cumWaterWater--176.58 kg/cum176.58 kg/cumSandSand-- 487.97kg/cum487.97kg/cumCourse Agg.Course Agg.--1224.02kg/cum1224.02kg/cum28 days cube strength 28 days cube strength –– 38.50 N/sq mm 38.50 N/sq mm

40.20N/ sq mm40.20N/ sq mm39.10 N/sq mm 39.10 N/sq mm

Mix Design DataMix Design DataMM--40 (For superstructure and girder)40 (For superstructure and girder)Done by Assam Engineering College ,Guwahati ASSAMDone by Assam Engineering College ,Guwahati ASSAM

TMSTMS--48.25MPA48.25MPAWater cement ratioWater cement ratio--0.380.38CementCement--473.68kg/cum473.68kg/cumWaterWater--180 kg/cum180 kg/cumSandSand-- 410.18kg/cum410.18kg/cumCoarse Agg.Coarse Agg.--1311.55kg/cum1311.55kg/cum28 days cube strength 28 days cube strength –– 52.15 N/ sq mm52.15 N/ sq mm

48.31 N/ sq mm48.31 N/ sq mm51.24 N/ sq mm51.24 N/ sq mm

ReinforcementReinforcement

a) Procure HYSD steel of IS a) Procure HYSD steel of IS –– 1786 1786 -- 19851985b) After receiving satisfactory test results fromb) After receiving satisfactory test results from

laboratory, steel was used for reinforcementlaboratory, steel was used for reinforcementpurpose.purpose.

Pre stressing steelPre stressing steelUncoated stress relieved low relaxationUncoated stress relieved low relaxationstrand IS 12468. strand IS 12468. Following test for strands was conductedFollowing test for strands was conducted1. Elongation percentage1. Elongation percentage2. Cross2. Cross--section areasection area3. Lay length3. Lay length4. Yield stress4. Yield stress5. Breaking load5. Breaking load

SheathingSheathingGalvanized sheathing were used for duct :Galvanized sheathing were used for duct :

Following test were conducted : Following test were conducted : 1. Load test1. Load test2. Bend test 2. Bend test 3. Ductility test 3. Ductility test 4. Water Leakage test4. Water Leakage test

AnchorageAnchorage�� The anchorage device shall be capable of holding The anchorage device shall be capable of holding

pre stressing tendon with out more than nominal pre stressing tendon with out more than nominal sleep . It should be strong enough to resist force sleep . It should be strong enough to resist force equal to equal to atleastatleast breaking strength of tendon. The breaking strength of tendon. The anchorage should be safe and secure both anchorage should be safe and secure both dynamic static load as well as against impact. dynamic static load as well as against impact.

�� The anchorage shall provision for the The anchorage shall provision for the introduction of neat cement grout for protection introduction of neat cement grout for protection of pre stressing tendon . Anchorage for 12T13 of pre stressing tendon . Anchorage for 12T13 were used in this girder. Three split wedge were were used in this girder. Three split wedge were used for locking the tendon.used for locking the tendon.

Sequence of constructionSequence of construction

�� Pile boring Pile boring �� Pile cape casting Pile cape casting �� Abutment and pier casting Abutment and pier casting �� Pedestal casting Pedestal casting �� Placing of bearing Placing of bearing �� Casting of PSC girderCasting of PSC girder

Casting of girderCasting of girderBed for Erecting StagingBed for Erecting Staging1. Bed for erecting pipe and jack for prop 1. Bed for erecting pipe and jack for prop

concreting was done earlier.concreting was done earlier.2. Care was taken no settlement took place.2. Care was taken no settlement took place.3. Horizontal bracing was provided.3. Horizontal bracing was provided.4. Bottom girder shuttering was done.4. Bottom girder shuttering was done.

Placing of BearingsPlacing of Bearings1. Bearing was placed truly horizontal 1. Bearing was placed truly horizontal 2. Bearing was fixed on specified surface with 2. Bearing was fixed on specified surface with

adhesive material.adhesive material.

Placing reinforcementPlacing reinforcement

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Placing of cable ductPlacing of cable duct

��. After completion of reinforcement cable duct . After completion of reinforcement cable duct was fixed as per design profile.was fixed as per design profile.

2. 75mm 2. 75mm diadia hole have been kept for cable.hole have been kept for cable.3. Care should be taken during concreting no 3. Care should be taken during concreting no

leakage took place.leakage took place.4. PVC pipe of 60 mm 4. PVC pipe of 60 mm diadia was inserted in to the was inserted in to the

ducts and moved to and fro to prevent ducts and moved to and fro to prevent setting of slurry leaked in to the duct if any setting of slurry leaked in to the duct if any during casting of girder. during casting of girder.

5. Side shuttering was done.5. Side shuttering was done.

Cable profileCable profileDistance of cable from bottom of girder Distance of cable from bottom of girder

Cable NoCable No. . Dist.(mm)Dist.(mm)

CenterCenter 2m2m 4m4m 6m6m 8m8m EndEnd1. 120 128.7 154.80 198.20 259.21. 120 128.7 154.80 198.20 259.20 3300 3302. 120 141.10 204.50 310.30 458.102. 120 141.10 204.50 310.30 458.10 6306303. 280 306.90 3876.70 522.40 711.10 3. 280 306.90 3876.70 522.40 711.10 9309304. 440 472.70 570.90 734.60 963.804. 440 472.70 570.90 734.60 963.80 123012305. 630 638.5 754.10 946.80 121.65. 630 638.5 754.10 946.80 121.60 15300 15306. 760 804.30 937.30 1159.00 1469.40 6. 760 804.30 937.30 1159.00 1469.40 18301830

Cable position

Cable position

Concreting of girderConcreting of girder

Mixing Mixing

Proper mixing of concrete was done to obtainProper mixing of concrete was done to obtainhomogenous mass and uniform homogenous mass and uniform colourcolour &&consistency . Mixing was done by machine mixconsistency . Mixing was done by machine mixwith weigh batchers. Mixing time was taken 2 min. with weigh batchers. Mixing time was taken 2 min. per batch of mix ( 30 revolution ).per batch of mix ( 30 revolution ).

Transportation of mixTransportation of mixTransportation of concrete is an important Transportation of concrete is an important activity in the production of concrete. The time activity in the production of concrete. The time taken in the transit is a design parameter, as it taken in the transit is a design parameter, as it depends on the initial setting time as well as depends on the initial setting time as well as requirement of workability at the destination. We requirement of workability at the destination. We used wheel barrow four sets for transportation of used wheel barrow four sets for transportation of concrete mix . Concrete was carried out concrete mix . Concrete was carried out continuously up to construction joint. continuously up to construction joint.

Compaction Compaction 1. Bottom layer ,for haunch internal and external 1. Bottom layer ,for haunch internal and external

vibrator was used.vibrator was used.2. External surface vibrator provided at haunch 2. External surface vibrator provided at haunch

after interval of 2m.after interval of 2m.3. Needle vibrator was used for compaction.3. Needle vibrator was used for compaction.4. Over vibration and under vibration are harmful 4. Over vibration and under vibration are harmful

hence avoided.hence avoided.Curing of concreteCuring of concrete1. Concrete was kept constantly wet for a period of 1. Concrete was kept constantly wet for a period of

28 days.28 days.2. Concrete surface was covered with Hessian cloth 2. Concrete surface was covered with Hessian cloth

or similar absorbent materials.or similar absorbent materials.

StressingStressing1. Duct was cleaned of any foreign materials using 1. Duct was cleaned of any foreign materials using

high pressure water jet.high pressure water jet.2. Strand cut in required length was treaded in the 2. Strand cut in required length was treaded in the

duct and in anchorageduct and in anchorage3. The anchorage was rotated so that the strand 3. The anchorage was rotated so that the strand

wire become straight. wire become straight. 4. Jacking arrangement was made with help of 4. Jacking arrangement was made with help of

chain pulleychain pulley5. Before fixing jacks , the pressure dial gauge was 5. Before fixing jacks , the pressure dial gauge was

calibrated calibrated 6. Wedge and master key was fixed6. Wedge and master key was fixed

Contd.Contd.

7. Now stress was applied with incremental load7. Now stress was applied with incremental load8. The designed elongation was 135.56 mm and was 8. The designed elongation was 135.56 mm and was

measuredmeasured9. The jack pressure was also verified compatible with 9. The jack pressure was also verified compatible with

elongationelongation10. During measuring elongation zero correction was 10. During measuring elongation zero correction was

taken .taken .11. There are six cables provided in each girder,cable11. There are six cables provided in each girder,cable--

1,2,3,4,5 and 6.Cable are to stressed one by one .Each 1,2,3,4,5 and 6.Cable are to stressed one by one .Each cables are to be stressed from one end. Cable nocables are to be stressed from one end. Cable no-- 1,6,4 1,6,4 should be stressed left end. Cable noshould be stressed left end. Cable no--2,5,3 from the 2,5,3 from the right end. Here only cable noright end. Here only cable no--1 and 2 stressed shown 1 and 2 stressed shown in the chart. Balance cable will be stressed (3,4,5,6) in the chart. Balance cable will be stressed (3,4,5,6) after casting diaphragm slab attaining full strength. after casting diaphragm slab attaining full strength.

Post tensioningPost tensioning

View of stressing

Grouting of cableGrouting of cable

After one day of stressing the slip in cable was After one day of stressing the slip in cable was measured and if found ok cable duct was measured and if found ok cable duct was grouted with net cement slurry (1:1) with grouted with net cement slurry (1:1) with grouting pump . Non shrinkage compound grouting pump . Non shrinkage compound ((conbexconbex 100) was mixed with cement slurry. 100) was mixed with cement slurry. Cement used was fresh and sieve through 75 Cement used was fresh and sieve through 75 micron. Grouting carried out under pressure of 5 micron. Grouting carried out under pressure of 5 kg /kg /sqcmsqcm maintained for 1minute. While injecting maintained for 1minute. While injecting the slurry from one end the density of slurry the slurry from one end the density of slurry coming out from other end should be same. In coming out from other end should be same. In similar way others cables were grouted. similar way others cables were grouted.

�� -- Elongation required =135.56mmElongation required =135.56mm--Jack used multiple Jack used multiple fressinetfressinet cable stretchingcable stretchingjackjack

Observation of Cable No 1 Girder No 1 Observation of Cable No 1 Girder No 1 ( A1P1)( A1P1)

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Quality control was ensured as:Quality control was ensured as:

•) Testing and inspection of the various materials •

selected for use•) Clear and complete detailed working drawings•) Accurate stressing procedures•) Proper control of dimensions and tolerances•) Proper location of anchors•

Material testing at fieldMaterial testing at field

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Field Testing of Cement(Quick assessing the quality of cement )

�Date of manufacture –Because aging reduces the strength

� Open the bags – No lumps should be present (Mean no setting)

�Thrust your hand into the cement –There should be cool feeling (means no heat of hydration no setting)

�Pinch of cement between fingers-It should give smooth feeling (means no setting).

Contd.Contd.

�Handful of cement thrown on water –It should float initially before finally settling

�Take 100 gm of cement, make stiff paste, prepare cake with sharp edges, put on glass plate and Immerse in water– Shape shouldn’t be disturbed– It should set and attain strength.

Period of storage %age of strength

�Fresh 100%�3 months 80%�6 months 70%�12 months 60%�24 months 50%

Site snapSite snap

Staging of girder under progress

Site SnapSite Snap

Measurement of elongation and gauge pressure