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Method Statement For PSC Girders - Railways PDF
Method Statement For PSC Girders - Railways PDF
PUNE
PROJECT REPORT
Salient features of PSC girder used on v iaduct zone E-18 are as given below:
1. Clear sp an 26.18 m
2. Effective sp an 27.33 m
3. Len gth of Girder 29.68 m
4. Depth of Girder 3.034 m
5. Deck width inside ballast retainer 4.7 m
6. Girder width at bottom 3.03 m
7. Height of ballast retainer 0.765 m
8. Concrete mix M 40
9. Weight of girder
At the time of launching 385 MT
Comp lete 416 MT
10. Reinforcement 18.5 MT
11. Quantity of HTS wires 5600 m (4.35 MT)
12. No. of Cables
Workin g cab les 8 nos in each web
Future cables 20 (10 on each side of centre lin e)
Emergency /dummy cables 1 in each web
13. Pre-stressing strand p er cable
Cable no. 6 Dummy
Cable no. 3 9 nos
All other cables 12 nos
14. Total p re-stressing force
Cable no. 3 126.56 MT
Other cables 168.75 MT
15. Pre-stressing system Frey ssinet
16. No. of stages in concretin g Sin gle
17. Sheathin g Bright metal sheathing
Inner dia 75 mm
Outer dia 76 mm
18. Sp an arran gement 40x29.68 m
19. Standard of load in g MBG 1987
2. Records to be maintained at site
It is necessary to maintain the record of each activity at site. It is help ful not only
to ensure the quality of construction but also to assess the behavior of the girder and
to decide the remed ial action in case of problems in maintenance. Followin g registers
are to be maintain ed at site:
i. Site order Book
ii. Labour register
iii. M achinery register
iv. Cement Register
v. Steel register
vi. Cube testing register
vii. Fine aggregate register
viii. Coarse Aggregate Register
ix. Pre-stressing record register
x. Batching p lant register
xi. Trial mix register
xii. Concrete sup ervision register
xiii. Shuttering register
xiv. Girder cable profilin g register
xv. Girder History sheets
3. Collection of drawings
All the drawings p ertainin g to the work should be collected and kep t at site in a
separate file/folder in sequen ce. It should be ensured that drawings are as p er the
latest revision. A list of drawing for Viaduct at E-18 is indicated below:
As soon as the drawing for the girder is received, it should be studied in detail to
know about the grade of concrete to be used for casting of gird er. In case the drawin g
is old or it has been issued for another site, latest p rovisions of Concrete Bridge Code
should also be referred to ensure that the p rovisions regarding minimum grad e of
concrete as p er the exp osure conditions at the site are followed.
Contractor should be asked to select the source for the in gredients of the concrete
i.e. aggregate and water. Samp les should be taken and these should be sent to any
reputed laboratory for testing. All the tests to be carried out should be sp ecifically
mentioned and all tests should be got done in one go to avoid delay in decidin g the
source of material. Tests which are generally to be carried out are discussed in
followin g paras.
Instructions in Para 4.2 of IRS Con crete Bridge Code should be followed
regarding the p rop erties of aggregates.
4.3. Water
Code for accep tance values- IRS Con crete Brid ge Cod e
4.4. Cement
Cement test certificate is received alon g with the rake of cement. In addition,
testing should be done at site to confirm that it has not deteriorated during
transp ortation and storage. So me of these tests are as under:
Instructions in Para 4.1 of IRS Con crete Bridge Code should be followed
regarding the p rop erties of aggregates.
4.5. Admixtures
Large no. of products are available in the market but it is necessary to select the
correct p roduct since a wrong admixture may affect the life of concrete.
Admixture should be comp ly ing to IS : 9103 and it should b e co mp atible to the
cement bein g used for concretin g.
Instructions in Para 4.4 of IRS Con crete Bridge Code should be followed
regarding the use of admixtures.
A typ ical format for the letter to the testing laboratory , regardin g
concretin g materials, is shown in Ann.-A.
Codes and other such literature p ertainin g to the method of testing the materials
and concrete should b e collected and one cop y of each code should be kep t at site for
reference. Similarly , codes p ertaining to accep tance criteria are also to be kep t at site.
7. Mix Design
As soon as the source for the in gredients of the concrete are decided, d esign of
concrete mix has to be done. Specified procedure should be followed to decide the
ingredients of the mix. Help may also be taken from the mix used at other sites, with
the same source of materials. Trial may be carried out at site and op timum mix
should be decid ed as p er provisions for strength, durability and workability .
Mix adop ted for the work on viaduct zone E-18 was as under;
Grade of concrete M 40
Cement 500Kg
CA 20 mm 768.4 Kg
10 mm 512.3 Kg
FA 438.2 Kg
Water 185.0 litres
Admixture 0.8- 1.2%
W/C ratio 0.37
Drawing of the girder should be studied in detail to list out the requirement of
material for the castin g of girder. All the activities involved for the work should be
discussed with the site sup ervisors along with the requirement of material for the
same. All the material should be brou ght in advan ce to avoid the shortage at the time
of execution.
A typ ical list of material required for casting of P SC girder is shown below:
Bar bendin g schedule for the steel reinforcement should be p rep ared as per the
details given in the drawin g. Shap e, size and location of each bar should b e clearly
mentioned to avoid confusion.
Instructions in Para 6.2, 6.2 & 6.4 of IRS Concrete Bridge Code should be
followed regard in g the finishin g, treatment and stripp ing of formwork.
Detail of co llapsible shuttering used at site of viadu ct zone E-18 is shown in Ann.
B
16. S taging
If the gird er is to be caste in situ, stagin g has to be erected for shuttering. Detailed
checkin g of stagin g should be done and followin g items should necessarily be
checked :
a. Members in stagin g should be as per approved drawing. Drawing no.
should be sp ecifically recorded.
b. Deviations from the drawin g should be recorded and these should not be
allowed unless app roved.
c. Condition of weldin g should be checked. Sometimes, tack weldin g is done
in p lace of structural weld in g to facilitate the reuse of the same member in
next stagin g. This p ractice should not be allowed.
d. All the packing should be of h ard wood.
e. Verticality of the members should be check ed
f. All the nuts and bolts should be tight.
In case the casting is in situ, level of bottom shuttering has to be taken to ensure
that the gird er is as p er drawin g. Similarly , level of casting bed should b e taken in
case of casting in y ard. A typ ical format for recording the levels is as indicated
below:
Distance from JAT end 0 5 10 15 20 25 28.33
Centre
Left
Right
Detailed check lists have to be p rep ared for various stages of construction.
Contractor should check and fill up the details in ch eck list and it should be
submitted to Railway sup ervisor for allowing further work. Entries should be
checked by the Railway officials and necessary rectifications should be got done, if
required. Further activity should be allowed only after ensuring that arrangements
are as p er app roved drawings/code p rovisions.
Check list used for allowin g the p lacing of inside shuttering on E-18 is attached as
Ann- C. It indicates the checks to be made before allowin g the p lacin g of inside
shuttering. M ajor items to be checked are listed below:
Check list used for allowin g the concreting on E-18 is attached as Ann- E. It
clearly indicates the checks to be made before allowin g the concreting. M ajor items
to be checked are listed below:
Prestressing cables should be moved during the concretin g to avoid jammin g due
to leakage of cement slurry inside the sheathing. Concreting in the end portion
should be done carefu lly with the concrete havin g desired workability. This p ortion
of girder consists of heavy reinforcement includ in g the p restressing cones, helical
reinforcement etc. Lot of effort and close sup ervision is requ ired to avoid any hollow
p ortion in this area.
Casting of Diaphragm is done in the next p hase. Check list used for allowing the
casting of Diap hragm is shown in Ann. F.
Prop er curing of the gird er is essential for p reventing evap oration from the
surfaces. It is normally done by establishing a high humidity environment. Curing
comp ounds may also be used in p lace of traditional methods such as continuous
water curing.
23. Prestressing
Prestressing steel
Prestressing steel to be used in gird ers is specified in Para 4.6 of IR S Concrete
Bridge Code. However, drawing should be studied to know regardin g the exact
quality of steel considered while designin g and only that steel should be allowed.
Every Coil of steel comes with a tag for identification of coil. This tag should be
checked and carefully kep t for reference. In case this tag is lost, it may not be
p ossible to know about the exact p rop erties of the steel. A test certificate is sent by
the manufacture alon g with the material. This certificate should be kept in record as
these p roperties are required while calculatin g the actual elon gation and p restressing
force in field. Generally , uncoated stress relieved low relaxation strands conforming
to IS : 14268 are used for the PSC girders. A samp le test rep ort for p restressing steel
and sheathing is shown in Ann. G & H.
Prestressing operation
Calculations are simultaneously made to decide the p ressure and elon gation at
which lockin g has to be done. All the details should be directly filled on the register
to avoid confusion at a later stage. Actual slip should be measured after 24 hrs of
p restressing and it may be used while decidin g the lo cking p ressure in further work.
25. Grouting
Grouting should be done as early as p ossible after stressing.
Grouting of lower ducts should be done first to avoid chances of leakage of
grout into ducts.
Grouting with cement grout is the most widely used method of p rotecting
tendons in the ducts of p ost-tensioning systems.
The initial disch arge will be contaminated with the oil and discolored: it must
be discarded.
Grout should be dense and homogen eous so as not to leave voids alon g the
steel.
The grout must also be thoroughly mixed by machine to ensure comp lete
mixin g and to obtain workable grout for injection.
After mixing, the grout should be kep t continuously agitated or movin g.
The groutin g p ump should be p ositive displacement p ump , cap able of
p roducing the discharge p ressure and havin g adequate seals to prevent
introduction of oil, air, or other foreign substances into the grout.
The grout should be screened p rior to introduction into the p ump .
Standby water flushing equip ment p owered by a sep arate p ower source
should be available.
Grouting must be continuous until the consistency of the grout emergin g
from the vents is the same as that being in jected, without visible slu gs of
water or air.
Before injectin g the grout, the duct should be cleaned.
Samp ling should be done durin g the concretin g and these samples should be
tested to get the idea regardin g the quality of construction. Instructions in Para 8.7
of IRS Concrete Bridge Code should be followed regard in g p rocedure, frequency of
samp ling and accep tance criteria of con crete.
Bearin gs are to be accomp anied with the test certificate from RDSO and markin g
from the RDSO should be checked. General checkin g, in cludin g the dimensions,
should be done so that there is no problem at the time of fixin g.
Other M iscellaneous jobs includ in g casting of Gap slab, Trolley refuge, fixin g of
railin gs etc. should be don e and the girder should b e finally finished.
It is essential to ensure the desired standard of quality for PSC construction. Some of
the imp ortant factors in this regard are:
33. Conclusions
An attempt has been made in this rep ort to prep are the method statement for PSC
girders, based on the experien ce gained during the construction of Viaduct E-18
(cast in y ard) and Bridge no. 100 (cast in situ) on Jammu-Udhamp ur Rail Link
Project. Desp ite technical advances, failure of con crete structures is taking p lace.
This is p rimarily due to lack of awareness regardin g p rop er p rocedure to be followed
during construction. There is a need to create the awareness amon gst
Engineers/sup ervisors to follow the p roper p rocedure durin g execution to achieve the
desired quality , safety , optimum use of resources, min imizin g delay and sy stematic
execution of works.
Ann.-A
_________Railway
Please find enclosed herewith following sealed samples for conductin g the
tests as p er p rocedure given in IS codes. Testing should be don e for jud gin g the
suitability of the material for con cretin g and should include the tests given in
Annexure-A.
Enclosures: As p er Ann-(i)
(Name)
(Designation)
Copy to:
i. __________________(supervisor) to ensure collection, sealin g and d elivery
of material to the testing laboratory.
ii. _________________ for information p lease.
Ann. (i)
List of Tests to be conducted
C. Water
a. Physical character
b. Organic solids
c. Inorgan ic solids
d. Sulp hate contents (as SO4)
e. Chloride contents (as Cl)
f. PH Value
g. Limit of acidity (with N/10 NaOH)
h. Limit of alk alinity (with N/10 HCl)
Ann. B
Detail of Shuttering
Ann.- C
D. Casting Bed
a. Centre line of Bed, p osition of deviator blocks
b. Cleanin g of b ed by comp ressed air
c. Oil used to p revent sticking of concrete
d. Levels
Distance from JAT end
Location 0m 5m 10 m 15m 20m 25m 28.33m
Centre
Left
Right
E. Form Work
a. Align ment
b. Verticality
c. Surface condition
d. Typ e of shuttering oil used
e. Condition of Joints
f. Rubber seal/d ense foam alon g the len gth of shuttering
g. Sealin g of jo ints with putty
h. Dimensions
F. Bearin gs
a. Position
b. Level
c. Thickness of p late
d. Whether hot dip galvanized
e. Fixin g in p osition
G. Cover to Reinforcement
a. Cover to reinforcement
J. Cable p rofilin g
a. Whether actual ordin ates of cable p rofile are taken and recorded
b. Whether sheathing, HTS strands and gu ide tubes are ap p roved
c. Test certificate no. and date for material testing includin g sheathin g
d. Detail of cables
Cable no. 1 2 3 4 5 6 7 8 9
Signature of contractor
Date.Time.
Signature of SE/JE
Date.Time.
Signature--------------
Designation-------------
Ann. - D
A. Form Work
a. Align ment
b. Verticality
c. Surface condition
d. Typ e of shuttering oil used
e. Condition of Joints
f. Rubber seal/d ense foam alon g the len gth of shuttering
g. Sealin g of jo ints with putty
h. Dimensions
B. Cover to Reinforcement
a. Cover to reinforcement
C. Reinforcement
E. Concreting material
J. Safety Requirements
a. Helmets
b. Safety belts
c. Fire extingu ishers
d. First aid and stretcher
e. Condition of wire rop e in winch
f. Condition of p ulley s and supports
g. Limitin g switch in p assenger hoist (if availab le at site)
h. Communication with winch operator
i. Railin gs
j. Safety net
K. Concreting p lan
k. Total quantity of concreting to be done
l. Outp ut of mixture p er hour
m. Total time required for concreting
n. Total no. of shifts
o. Whether p ouring sequence has been submitted
p . Whether p ouring sequence has been ap p roved by Engineer in charge
q. Whether mix design h as been ap p roved by engineer in charge
r. Detail of mix to be used
Signature of contractor
Date.Time.
Signature of SE/JE
Date.Time.
Signature--------------
Designation-------------
Ann. - F
Viaduct Zone E-18
Check Request for Casting of Diaphragm
D. Cover to Reinforcement
a. Cover to reinforcement
E. Reinforcement
F. Concreting material
Signature of contractor
1
Date.Time.
Signature of SE/JE
Date.Time.
Signature--------------
Designation-------------
Ann. - G
Launching S cheme