LARSEN & TOUBRO LIMITED - ECC DIVISION

Name of Project Samakhiali Gandhidham Road Project

Job Procedure for Methodology for Precasting of P.S.C Girder

Job Procedure No Sl. No. – 015

CONTENTS

S. No. PAGE NO.

1 Scope

2 Reference

3 Method

4 Tolerance

5 Documentation

(5a) Inspection & Test Plan (ITP)

(5b) Formats

00 18/08/2011

Rev Date Prepared By Reviewed By Approved by

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 LARSEN & TOUBRO LIMITED
ENGINEERING, CONSTRUCTION AND CONTRACTS
PROJECT QUALITY PLAN
SITE: SAMAKHIALI GANDHIDHAM ROAD PROJET
FROM 306.800 TO 362.420
QUALITY MANAGEMENT

METHODOLOGY FOR PRE-CASTING OF P.S.C GIRDER

Sl. No. Description

1 Scope Precasting of P.S.C Girder

2 Reference Approved Drawings

3 Method Post Tensioning

4 Tolerance As per relevant specification
5 Documentation
Inspection & Test
(5a)
Plan (ITP)

(5b) Formats

MANPOWER REQUIRED:

1. Site Engineer
2. Supervisor
3. Operators
4. Workmen

EQUIPMENT REQUIRED:

Gantry 2 nos .each of 40 MT capacity, mould vibrators, needle vibrator, welding set,
gas cutting set, air compressor, prestressing jack/ pump, grouting pump/ agitator
etc., abrasive cutter, boom placer/ static concrete pump/ crane with concrete
bucket.

SCOPE OF WORK:

 26.10 (26.5m) M long PSC girder – 160 Nos.

 29.60 (30.0 m) M long PSC girder – 195 Nos.

Total Nos. of PSC Girder to be cast – 355 Nos.

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 1. Preparation of casting yard 25 m wide and 480 m long including rail track
for 2 nos. of 40 MT Gantry.
2. Yard will have two nos. of 40 MT capacity Gantry for shifting of PSC
girder from casting bed to stack yard and stack yard to dispatch.
3. Number of casting beds: 8 nos. for 26.5m girder and 8 nos. for 30.0 m
girder.
4. Reinforcement cage binding beds 16 nos. parallel to casting beds.

BED PREPARATION:
1. Between two Gantry tracks, area to be leveled and compacted.

2. Spread 150 thick layer GSB and compact properly.

3. Over GSB 100 mm thick PCC M-15 Grade with proper level ( PCC will be
done for casting area approx.. 250m length, stacking area will have a
compacted and leveled GSB layer )

CASTING BED:

1. Casting bed is resting on precast concrete sleeper fitted over that

ISMC75X40 B/B.

2. Place the Pre-cast sleeper and level it properly, check and ensure its
proper level and line.

3. Fix bottom shutter over the B/B channel with 12 mm dia. bolt with nut.

4. Check the line and level once again, and then grout the Pre-cast
sleeper bottom for uniform contact.

5. Fix side shutter panels from center line of girder towards both ends.
Provide Sponge in between bottom shutter and side panel, and all the
joints of Side panels to prevent leakage of concrete slurry.

6. Align the side shutter vertically and line properly.

7. Fabricate the reinforcement cage parallel. Bar bending schedule will be

prepared as per approved drawing. Binding of cut bend steel will be done
on cage binding bed. Jigs/ spacers for cable profiling will be welded at
required locations.

8. Lift Pre-fabricated cage by using lifting tackle and gantry and place it on
the casting bed in required position.

9. Support the cage with the vertical form work and detach the strong
back from Rebar cage.

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10. Place the metallic (GI coated) sheathing pipe inside the cage as per
approved cable profiling drawings. Sheathing pipe shall be joined by
using coupler in such a way that there will be an equal lap on either side
of joint. The joints of sheathing pipe should be wrapped well by insulation
tapes so as to prevent slurry entry while concreting.

11. Fix end block shutter on both sides fitted with tube unit.

12. Connect the sheathing to tube units and seal all joints of sheathing by
insulated tape properly.

13. Recheck the profile of sheathing as per approved drawing, provide

hanger spacer at required locations to keep the profiling intact in position.

14. Fix the second side shutter from centerline of the girder and proceed
both directions, provide tie rods in sleeves with PVC pipe.

15. Fix alignment angels/ tie rod at top and props/ turn buckles on both
sides. Align the shutter to required line / shape and plumb using props
and tie rods.

16. Check the formwork as per checklist and records.

17. Make platform for concrete.

18. Prepare pour card.

19. Arrange vibrator, needle, mould vibrator and high frequency vibrator.

20. Check all the equipments before starting the concrete from batching
plant.

21. Insert the dummy cable/ PVC duct within the sheathing pipe before
concreting and move it freely in the sheathing pipe while concreting by
moving it forward and backward from ends to prevent any type of
blockage.

22. Start pouring as per pour sequence attached with the pour card /
method statement.

23. Vibrate the concrete by needle or mould vibrator as required, avoid

over vibration.

24. Finish concrete surface to the required level.

25. Prepare construction joint after one hour from finishing of concrete
(roughen the concrete surface by wire brush or by some other mode.)

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 26. Sprinkle water immediately after initial set.

27. Cover the concrete surface by wet Hessian cloth and start water
curing.

28. Start de-moulding in between 12-48 hours from concrete.

29. Cover the concrete immediately after de-moulding with Hessian cloth
and cure the concrete continuously for 14 days.

30. Stages/Sequence of prestressing will be done as per approved

drawings. After completion of first stage prestressing girder will be lifted
from casting bed by gantry and will be stacked at stacking yard. Grouting
of 1st stage cables, 2nd stage stressing and 2nd stage grouting will be done
at stacking yard.

31. After completion of all stressing and grouting works, projected HT

strand will be cut, bearing plate and wedges will be applied with
anticorrosive paint and end face (grooves/ box cut) will be filled with same
grade of concrete as that of girder.

SAFETY PROCEDURE:

1. Proper PPEs viz, Safety shoes, Safety jackets etc. shall be used.

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