Bearings Section 2000 2003.1.4 Cast Steel Cast steel shall be in accordance with Clause 1009.1 of these Specifications, For the purpose of checking the soundness, castings shall be ultrasonically examined following procedures as per |S:7666, with acceptance standard as per |S:9565. The castings may also be checked by any other accepted method of non-destructive testing as specified in IS:1030, Quality level of castings shall be Level 3 as per IS:9565, 2003.1.5 Stainless Stee! Stainless steel shall be in accordance with Clause 1009.7 of these Specifications. 2003.1.6 Welds Welding of steel conforming to 1S:2062 shall be as per |S:1024 using electrodes as per 1$:814, 2003.1.7 Grease ‘The grease for bearings shall conform to the requirements of IS:503 (Grade 4). 2003.2 Construction Operations a) All work of steel bearings shall conform strictly to the drawings and shall be in accordance with the provisions of this Section. Care shall be taken to ensure that all parts of an assembly fit accurately together. The workmanship shall satisfy all relevant provisions laid down in Section 1900 of these Specifications. b) Knuckle pins, rolling surfaces of the rollers and bearing surface of the bearing plates shall be machined and all bolt holes shall be drilled. The whole bearing shall be fitted and finished as required for good quality machined work to the satisfaction of the Engineer. However, in case of bearings which are to be grouted or bedded on a suitable yielding material, any surface which is to be in permanent contact with the grout or the yielding material, may be left unmachined. ©) In prestressed concrete construction involving launching of girders, slipping or jumping of rollers due to vibration or jolts, shall be avoided and adequate measures shall be taken to ensure thatthe roller assembly isnot disturbed. It is normal practice to provide rocker bearings at the 625Section 2000 Bearings launching end and place the beam on the rocker slightly in advance of placing on the roller. 6) During concreting of girders, the bearings shall be held in position securely by providing temporary connection between the top and bottom plates in case of fixed bearings and between top plate, base plate and saddle plate in case of roller-cum-rocker bearings or by any other suitable arrangement which prevents the relative displacement of the components. e) _ Inprecast prestressed girders, where recesses are lefton the underside of girders to receive the anchor bolts, grout holes extending to the sides of top of the beam shall be provided. The grout hole shall be filled with cement sand grout of mix 1:1 or with grout made of non-shrink high strength mortar. Alternatively, the precast girder may be fitted with a template screwed or bolted into sleeves already cast in the concrete, which can be removed and replaced by the top plate of the bearing at the time of ere of superstructure. 2003.3, Workmanship a) Fabrication shall be carried out by an organization sufficiently experienced and qualified to undertake precision engineering of this type as approved by the Engineer. b) Workmanship shall be of good quality such as to achieve neat finish and good appearance. c) Castings shall be true to the forms and dimensions shown on the drawings and shall be free from pouring faults, sponginess, cracks, blow holes and other defects, affecting their appearance or strength. Warped or distorted castings shall not be accepted. Exposed surfaces shall be smooth and dense. d) All castings shall be cleaned by sand or shot blasting to remove sand or scale and to present a clean uniform surface. e) Allirregulattties, fins or risers shall be ground off flush with the adjacent surface. Castings with visible cracks, blow holes or similar blemishes shall be rejected if the imperfections are located in bearing surfaces or cannot be remedied to the satisfaction of the Engineer. 1) _ Imperfections which are not located in bearing surfaces shall be cleaned : out, filled with weld metal of the appropriate composition and ground flush. 9) All surfaces of major components like top plates, saddle plates, base plates and rollers of the bearings shall be machined all over for correct alignment, interchangeability and proper fiting. 626EIOIpemerrreearaeeeaEEEEEEE sie Bearings Section 2000 2003.4 Tolerances Tolerances for individual components or of the assembled bearings shall be as shown on the drawings and subject to the approval of the Engineer. Unless otherwise specified, the following tolerances shall be maintained. i) Rollers and Curved Surfaces Tolerances on diameter of rollers and all convex surfaces shall conform to K7 of IS:919. Tolerances on diameter of all concave surfaces shall conform to D8 of Is:919. ii) Height of Bearings Tolerances on height of any component shall not exceed +0.5 mm, No minus tolerance shall be allowed. The edges of all ribs shall be parallel throughout their length. ii) Plates Tolerance on length and width of the plates shall not exceed +1.0 mm; tolerance on the thickness of the plate shall not exceed +0.5 mm. No minus tolerance shall be allowed. All rocking, rolling and sliding surfaces shall have a machine smooth finish to 20 micron maximum, mean deviation as per |S:3073. iv) Castings No minus tolerance shall be allowed in the thickness of any part of the castings. The edges of all ribs shall be parallel throughout their length, 2003.5 Install 2003.51 General a) Bearings shall be placed in the position as shown on the drawings with all bearing surfaces in full contact and to the tolerances as specified. b) Roller and rocker bearings shall be placed so that their axes of rotations are horizontal and normal to the direction of movement of the members they support. Upper and lower bearing plates shall be set horizontal in both directions. ¢) During installation, the bearings shall be pre-set with respect to the bearing axis to account for the movement due to the following : i) Temperature variation between the average temperature prevailing at the time of installation and the mean design temperature. 627Section 2000 2003.5.2 2003.5.3, Bearings ii) Shrinkage, creep and elastic shortening of prestressed girders. d) _ Forbridges in gradient, the bearing plates shalll be placed in a horizontal plane. Placing a) On supporting structures, pockets shall be provided to receive anchor bolts; one side of the pocket shall project beyond the bearing plate. The pocket shall be filled with mortar and the concrete bearing area also shall be finished level by a thin and stiff mortar pad (of thickness not exceeding 12 mm) just before placing of bearing assemblies or bottom plate on the concrete seat. The mortar shall be of mix 1:1 or of the non- shrink prepacked type. b) In case of precast girders a recess of 6 mm shall be provided on the underside with a level finish for housing the bearing plate. A thin and stiff mortar pad with thickness not exceeding 3 mm, shall be provided over the top plate before lowering the precast beam in position in order to ensure full and even pressure on the plate surface. c) It shall be ensured that while placing the girders, the bearings are in their exact positions as indicated on the approved drawing and not displaced therefrom. d) Allconcrete surfaces to be in contact with the mortar shall be thoroughly cleaned and wetted for a period not less than 24 hours before placing mortar. Operations are to be carried out when the surface temperatures of the exposed bearings are the minimum practicable. e) No mortar that is more than 30 minutes old after completion of mixing, shall be used. f) After placing and finishing the mortar, the bearing shall be checked for position and shims or other temporary supports removed and the mortar made good. If the bearing has moved, it shall be lifted, the mortar removed and the whole procedure repeated. 9) Exposed faces of the mortar shall be cured under damp hessian for 7 days. h) Placing of the bearing and mortar shall only be carried out in the presence of the En¢ Checking, Cleaning and Lubrication a) Before installation, each bearing shall be uncrated, dis-assembled and checked. Any damaged parts shall be made good for approval. 628 7