Railway Construction

Testing
 Typical Section

1.676m
RAIL

BALLAST 2.750 m

0.3 m

BASE 0.325m
UPPER SUB BASE 0.500m
2.175m
SUB BASE 1.675m
UPPER PORTION

LOWER PORTION
 CONCRETE

SOIL TESTING STEEL

AGGREGATE
 Concrete

Mix Design

Monitoring temperature variation of thick concrete pours

 MIX Design
DOE (Design of normal concrete mixes ,Building research
Establishment)
Normal Concrete
OPC ,PPC (Ultra Tec)
5 -20mm aggregate
Quarry dust
River sand
Water
Admixture
 MIX Design contd.
Workability by Slump test
(BS 1881 Part 102-1983)

Air content
( design value + or - 1.5 %)
(BS -1881 Part 106:1983)

Concrete setting time

Initial & final setting time
Laboratory Trial mix Batching plant trial mix (ASTM C 403)
(Trial and Error method) (3 trials)
Fresh concrete Temperature
Below or at 32 0C
ICTAD SCA/5

Bleeding

28 days Compressive
strength of test cubes
Testing for Fresh and Harden
Concrete Properties
 Concrete Mix contd.
Concrete Usage Cement Content (Kg) Slump Range
(1m3 of Concrete ,PPC ,Ultra Tech)
Grade W/C (mm)
C15/20 Pile Cap Screed 280 0.59 15025
C20/20 Culvert screed 300 0.50 15025
C25/20 Shotcrete at 320 0.50
15025
tunnel
C30/20 Culvert inlet , pile 340 0.41
cap , pile stem , 15025
pile tray
C30/20(pile) Pile 400
20025
0.42
C40/20 Culvert base 380
,Top slab , wall, 0.42 17525
Tunnel Lining
C40/20(pile) Pile 420 0.40 20025
C50/20 Pile build up 460 0.35 15025
 Temperature Effects In Large
Concrete Pours
Limiting Temperatures
Placing Max 320C
Peak Hydration 750C SCA 5
Max difference 200C
Sizes of pours (Pile caps 4.9 X 5.9 x 2m)
Temperature controlling in concrete is needed
Avoiding DEF Durability issue
Minimizing cracks
 What is DEF ????
DEF occurs in relatively thick concrete sections with large pours

Expansion of concrete core after hardening of concrete

Map cracking is visible at the structure surface

Could be happened in immediately or later, even after 10 to20

yrs

High peak hydration temperature > around 700C during

hydration process.

DEF starts with presence of water

 What is DEF contd..
Crack width will be increased with time
Reinforcements will be corroded- durability of the structure is in
doubt.
Since the cracks would be developed to the concrete core,
structural integrity will be loosen. structural remedial works are
required.
Remedial actions are very costly and complex in design &
construction
Pile caps at STDP- KG section was affected badly
 How do we avoid DEF ?
Control peak hydration temperature below 70 0C
Preparation of Mock up representing the structure with Thermo
couples to see the reality.
Monitoring temp around 5-6 days with data logger & check
whether limits are exceeded.
Use of low heat cement as required
Stage construction - avoiding thick concrete pouring
Provision of heat insulation on 1st 3-5 days to control thermal
gradient <20 0C
Use of blended cements (Eg. fly ash), produce low heat of
hydration. Use of PPC instead of OPC or PLC
Water proofing of the structure
 How do we avoid DEF contd..

Lowering the concrete placing temperature.

Use of chilled water with shaded aggregates
Avoiding surface cracks at plastic stage of concrete enhancing
the curing & eliminating initial cracks.
Provision of sufficient RF for avoiding thermal & shrinkage
cracks
Application of water cooling system
Pile cap cracking- Map cracks
Pile cap Remedial works
Mock up casting (2m x 2m x 2m)

Insulated Non insulated

 Mock Up Casting
Conditions of Mock-up
Cement type : Fly ash blended(Ultra Tec)
Grade of concrete : 30
Cement content : 340Kg/m3
Mock up dimensions : 2m x 2m x2m

Method of insulation
Top surface:
Cover with mac-foil (5mm in thickness) immediately after the application of
curing compound ( curing compound name )
Apply about 300 mm layer of saw dust and cover polythene sheet
Vertical surfaces
Apply 5mm thickness mac-foil over the formwork
 Results
The maximum hydration temperature is 70 0C at the core at 48
Hours after starting of batching concrete

maximum temperature differential between the core and the

surface is 11 0C at 68 hours after starting of batching concrete.

Conclusion
Insulation method and concrete mix design are suitable for
construction work
Applications
 Aggregate
Concrete Aggregate
( 5-20mm Aggregate , River Sand ,Quarry Dust)
Base Material (ABC)
Ballast
 Coarse Aggregate
Sieve Analysis

Specific Gravity & Water Absorption

Fine Content

Physical Flakiness Index

Properties

AIV

ACV
Coarse Mechanical
Aggregate Properties TPF

Soundness

Chemical Properties Cl- & Soluble SO4 2- Content

 Coarse Aggregate
Test Test standards Specification Limits Detection
Frequency
Sieve analysis BS 812-part-103-1- Table 3:BS 882:1992 200 m3
1985
ICTAD Section 1701.2
Flakiness Index BS 812-part- not exceed 35% for Coarse 200 m3
105:1989 Aggregate
BS 812-part- Shall not exceed 30% for
112:1990 aggregate in concrete in
Aggregate Impact wearing surface or
Value (AIV) concrete with grade 200 m3
greater than 40.
Not more than 45% in all
other concretes
Aggregate Crushing BS 812-part- - As requested
Value (ACV) 110:990 by Engineer
Ten Percent Fines BS 812 part BS 882-1992 ,Table 02 As requested
Value 111:1990 by Engineer
 Coarse Aggregate contd..

Test Test standards Specification Detection

Limits Frequency
Specific gravity BS 812 Part 2 1995 For the mix design Each source or as
requested by
engineer
Surface Moister in ASTM C -70-94 Concrete mixes Each day
aggregate
Clay ,Silt and dust BS 812.103.1:1985 BS 812:Cl.5.4 200m3
content (Fines) Shall be equal or
less than 4%
Sodium chloride & Sodium chloride Each source
Soluble Sulphate < 0.05 %
Soluble Sulphate
< 0.25%
 Fine Aggregate

Sieve Analysis

Physical Properties Specific Gravity & Water Absorption

Fine Content

Fine Aggregate

( River Sand &

Quarry Dust)

Chemical Properties Cl- & Soluble SO4 2- Content

 Fine Aggregate contd.
Test Test standards Specification Detection
Limits Frequency
Sieve analysis BS 812-Part 103 -1 BS 882 : 1992 100 m3
-1985 ,Table 4
Specific gravity BS 812 Part 2 1995 For the mix design Each source
Surface Moisture in ASTM C 70-94 - Each day
Aggregate
Clay ,silt and dust BS -812.103.1 BS 812:cl.5.4(T6) 100m3
Content (fines) :1985 less than 4%
uncrushed gravel
sand
Less than 16% for
crushed rock sand
Sodium Chloride & Sodium chloride Each Source or as
Soluble Sulphate < 0.1% requested by
Soluble Sulphate engineer
< 0.25%
Storing of Aggregates at Batching Plants
 Base Material (ABC)
Sieve Analysis

Bulk Specific Gravity

Fine Content
Physical
Properties
Flakiness Index

Elongation

Base Material
(ABC)

AIV

LAAV
Mechanical
Properties Modified Proctor Compaction Test

Soaked CBR
 Base Material (ABC)
Test Test standard Specification limit Detection
frequency
Sieve analysis SCA/5 Table 1602.1 ICTAD SCA-5,Table 1701-5 300m3
BS 812-part 103-1-1985
Bulk Specific SCA/5 Table 1602.1 - As requested by
gravity the engineer
Flakiness SCA/5 Section 1801.6 and ICTAD Section 1701.3 not 1000m3
Index table 1602.1 BS 812-part- exceed 35% for Coarse
105.1;1989(2000) Aggregate
Elongation SCA/5 Section 1801.6 and ICTAD Section 1701.3 not 1000m3
Index table 1602.2 exceed 35% for Coarse
BS 812 part-105.1:1989 Aggregate
(2000)
AIV SCA/5 Section 1701.3 BS ICTAD Section 1701.3 not 300m3
812-part -112;1990 exceed 30% for Coarse
Aggregate
Clay ,Silt and SCA/5 section 402.2, Section ICTAD SCA/5,Section As requested by
Dust Fraction 1801.2 405.2 and table 1701.5 the engineer
ASTM C117-95 ,Particles less than 75m
shall not exceed 12% Refer
SCA/5 Section 405.2
 Base Material (ABC) contd...
TEST Test standard Specification limit Detection frequency
Water Absorption SCA/5 ,Table 1602.1 - 500m3
Soaked CBR SCA/5 Section 1701.3 ICTAD SCA/5 ,Section 1000m3
AASHTO T-193- 1701.3 shall not be
99(2007) less than 80 %
Modified Proctor SCA/5 , Table 1602.1 - 50m3
Compaction Test AASHTO-T-180-95
Layer Thickness SCA/5 ,Table 1602.1 As decided by Regularly as
engineer requested by the
engineer
Degree of compaction SCA/5 Section 1701.3 95% Minimum Two tests for
and field moister AASHTO-T-191- 500m2
content 93(1996)
Plastic index SCA/5 Table 1602.1 Shall preferably be non AS requested by the
Section 1701.3 plastic , in no case engineer
shall exceed 6%
LAAV SCA/5 Table 1602.1 ICTAD Section 1701.3 300m3
AASHTO-T-96 Not exceed 40%
Applications.
 Ballast
Sieve Analysis

Flakiness Index

Physical
Properties Particle Shape

Fines Content

Ballast

Los Angeless Coefficient Test

Mechanical
Properties
Resistance to Attrition
 Ballast contd
Test Test Standards Specification limits Detection frequency

Sieve Analysis BS EN 933-1 ER 4.1.3. Table 4.1 One test per week

Flakiness Index BS EN 933-3 Shall not exceed 35 % One test per month
(ER 4.1.3. (4))

Particle shape BS EN 13450 -2000 Shall not exceed 4% One test per month
(ER 4.1.3. (4))

Fines Content BS EN 13450 -2000 Shall not exceed 0.5% One test per week
BS EN 13450 -2000

Los Angeles BS EN 1097 part-2 (BS Shall not exceed 20% Two test per year
Coefficient test EN 13450:2002) (ER- .4.1.3 (iii) )

Resistant to BS EN 1097 part-1 Shall not exceed 7% Two test per Year
Attrition(Micro (ER-.4.1.3 (iii) )
Deval)
Ballast Stock Pile
Applications at Madu Talaimannar
Railway Project
 Soil

Sieve Analysis (BS 1377 -2 :1990)

Atturberg Limits ( LL and PL , BS 1377-2:1990)
Modified Proctor Compaction (ASSHTO T180-95)
CBR (ASSHTO T193-99(2007))
Field Density ( ASSHTO T -191 )
 Typical Section of the Embankment

UPPER PORTION

UPPER SUB BASE

MDD > 1.6 g/cm3 ,CBR > 25% , Group B Material 0.500m
Degree of Compaction at site > 95%
2.175m
MDD > 1.6 g/cm3 ,CBR > 7% ,
Group B Material 1.675m
LOWER SUB BASE
Degree of Compaction at site > 95%

MDD > 1.6 g/cm3 ,CBR > 7% ,

Group C Material,
Degree of Compaction at site > 93%

LOWER PORTION
Soil Testing
 Soil For Embankment

source : Track area excavation

 Steel For Reinforcement Concrete

Weldable reinforcing steel-Bar Coil and de coiled product

Specification BS 4449:2005

Characteristic Yield strength -500MPa

Testing
 Steel Tests
Mass per meter run

Physical Nominal Cross sectional Area

Properties

Surface Geometry

Yield strength & Ultimate Tensile strength

Reinforcement Mechanical
steel Elongation at fracture
Properties

Re bend

Chemical Properties C ,S ,P ,N, Carbon Equivalent Value

 Steel Tests contd.
Test standard Specification detection frequency
limit

Mass per meter run

Nominal cross sectional BS 4449 One test per cast &

area :2005 nominal diameter

BS 4449:2005
Surface geometry
Clause -7.3
Re bend test
,Table-7
BS EN
Ultimate tensile strength One test piece per each
ISO-6892
Elongation at fracture 30ton with at least three
test pieces per nominal
Yield strength
diameter
 Steel Tests contd.
Test standard Specification detection
limit frequency

Carbon

Sulphur

Phosphorus
BS EN-15630-1 BS 4449:2005 One test per cast
Nitrogen
Clause 7 ,Table-
Carbon 2
equivalent Value
 Reinforcement Steel at Project
Lanwa (Sri Lanka )

Tianjin Tiantie Zhaer Steel (China )

Yield Strength , Ultimate Tensile Strength
& Maximum Elongation at Fracture
Re Bend Test
Thank You