Section 140-Bridge Bearing Spec

CONSTRUCTION AND COMPLETION OF LIGHT RAIL TRANSIT LINE 3 (LRT 3) FROM
BANDAR UTAMA TO JOHAN SETIA
Document No. : KVLRT3-MRCBGK-GEN-PMGT-SPC-000002

Revision : 03
CONSTRUCTION AND COMPLETION OF LIGHT RAIL TRANSIT LINE 3 TECHNICAL SPECIFICATION
(LRT3) FROM BANDAR UTAMA TO JOHAN SETIA KVLRT3-MRCBGK-GEN-PMGT-SPC-000002
SECTION 140 - BRIDGE BEARINGS

CONTENTS
TABLE OF CONTENTS PAGE

1.0 ELASTOMERIC BEARINGS ................................................................................. 2
1.1 General ....................................................................................................................... 2
1.2 Design Requirements ............................................................................................... 2
1.3 Sampling, Testing and Acceptance ....................................................................... 5
1.4 Installation ................................................................................................................ 7
1.5 Epoxy Mortar, Dowel Bars & Concrete Surface .................................................... 8
1.6 Warranty.................................................................................................................... 9
2.0 MECHANICAL BEARING .......................................................................................... 9
2.1 Description ............................................................................................................... 9
2.2 Design and Applicable Codes............................................................................... 10
2.3 Manufacturers ........................................................................................................ 10
2.4 Substituted Bearing ................................................................................................ 10
2.5 Materials.................................................................................................................. 10
2.6 Design Requirement .............................................................................................. 13
2.7 Submission ............................................................................................................. 14
2.8 Fabrication .............................................................................................................. 15
2.9 Testing .................................................................................................................... 17
2.10 Products Delivery Storage and Handling ............................................................ 18
2.11 Installation .............................................................................................................. 19
2.12 Epoxy Mortar, Dowel Bars & Concrete Surface .................................................. 20
2.13 Warranty.................................................................................................................. 21
SECTION 140 BRIDGE BEARING 1 of 21 REVISION: 03

1.0 ELASTOMERIC BEARINGS FOR BRIDGES
1.1 General
1. Elastomeric bearings shall be designed and supplied in accordance with this

Specification and the details on the Drawings and shall be installed at the
locations shown on the Drawings.
2.
ting wholly of rubber or one or more
vulcanized rubber slabs bonded to metal plates to form a sandwich arrangement.
3. All bearings shall be replaceable. The entire bearing assembly, between the
sole plate and the base plate shall be replaceable without damage to the
structure and without removal of any concrete, welds or anchorages
permanently attached to the structure and without lifting the superstructure
more than 7mm. Bearings shall not be recessed into plates that are
permanently attached to the structure. The design of bearings shall be
accompanied by a detailed method statement for their replacement.
4. Manufacture of bearings shall not commence until the WPC has received
preliminary approval of that type of bearing in writing from the PDP or his
representative.
5. At least 30 days prior to commencing manufacture the WPC shall submit to the
PDP or his representative for approval the design details and calculations of the
bearings. He shall include any relevant information concerning the methods and
materials he proposes to use for the bearing installation.
1.2 Design Requirements
1. The WPC shall design the rubber bearings in accordance with the requirements
of BS 5400 Part 9 or BS EN 1337 whichever is applicable.
2. The WPC shall provide complete detailed descriptions, drawings, specifications

and calculations of the bearings for the consideration of the PDP or his
representative.
3. The WPC shall ensure that his design complies with the other requirements of
this Section and that all bearings can be physically seated on abutments and
piers to the satisfaction of the PDP or his representative.
4. Materials
4.1 Natural Rubber

In preparing the rubber compound, good quality natural rubber complying
with the requirements of Standard Malaysian Rubber (SMR) 5 grade or
better shall be used. No reclaimed rubber or ground vulcanized rubber
shall be used. Local rubber requirements shall be referred to MS 671. All

ingredients shall be recognised rubber quality and shall be uniformly

dispersed.
(a) Physical Properties of Rubber
The physical properties of the vulcanized rubber when tested
according to appropriate standard shall conform to the
requirements of Table 140-1.
Table 140-1: Physical properties of Elastomer
Type A Type B Type C Methods of

Tests
Nominal hardness (IRHD) 46 to 55 56 to 65 66 to 75 ISO 48
Tensile Strength (N/sq.mm), 21 17 14
ISO 37
min.
Elongation at Break (%), 550 450 300
ISO 37
min.
Compression set after 24 30 30 30
hours at 75 deg. C and 25% ISO 815
compression (%), max.
Ozone resistance test after No No No
visible visible ISO 1431
96 hours at 25 pphm ozone, visible
cracks cracks Part 1
40 deg C, 20% strain cracks
Accelerated ageing for 168 ISO 188 (air
hours at 70 deg C. oven)
Accelerated ageing for 168
hours at 70 deg C.
Change in tensile strength, +15 +15 +15 ISO 37
(%)
Change in elongation at
-20 -20 -20
break, (%) ISO 37
4.2 Mild Steel Plates

Mild steel used for plate reinforcement shall comply with the
requirements of BS EN 10025 and have a minimum yield strength of 275
N/sq.mm.
The minimum thickness of the steel plates shall be 3 mm for the outermost
plates and 2 mm for innermost plates.

Steel plates shall be free from flaws, tears and rough edges, and shall be
completely encased in rubber. The minimum thickness of encasement
shall be 3 mm for the upper and lower faces of the bearing and 6 mm for
the sides of the bearing.
4.3 Bonding Agent
(a) Type
All bonding of elastomer to steel shall be carried out during vulcanization.

Thus, the bonding agent to be used shall be of the type intended for
bonding natural rubber to metal during vulcanization
(b) Bonding Strength
The bond strength, when tested in accordance with ISO 813 (90° Peel
Test), shall be in excess of 9 N/mm.
1.2.1 Manufacture
Forming of Elastomer
a. Plain Pad Bearings and Strip Bearings

Plain pad bearings shall be moulded in one piece or comprise single
pieces cut from previously moulded strips of slabs. Cutting shall produce a
smooth surface without injurious heating of the elastomer.
b. Laminated Bearing
A laminated bearing shall be moulded as a single unit under pressure and
heat.
c. Spacers In Moulds
When spacers are used in moulds to ensure correct cover to outer plates,
they shall comply with the following requirements: -
i. The resulting exposed steel surfaces shall eventually be
covered when the bearings are installed in the bridge
structure.
ii. The spacers shall be located with a minimum distance of
10 mm from the reinforcing plate edge of the spacer.
iii. The size of the hole left at the surface of the ring shall not
exceed 10 mm diameter.
iv. The minimum practical number of spacers shall be used to
ensure correct location of plates but in no case shall the
total area of spacers exceed 3% of the bearing
compression area.

1. Following successful completion of type approval tests, in accordance with

relevant Part of BS 903 the WPC shall submit proposals for a manufacturing
schedule. This schedule shall provide for bearings to be ready well ahead of
the time the WPC expects to be ready for installation. Allowance shall be
made for time for acceptance testing and for manufacture and testing of
replacement bearing in the event of failure.
2. The WPC shall also provide information about in-house quality control and
the data that will be available for the PDP or his representat
3. Each bearing shall be indelibly marked by imprinting during moulding the

following information:
a) Name of project
b) Name of manufacturer
c) Date of manufacture
d) Serial number
e) Other identification marks as directed by the PDP or his

representative e.g. load capacity, type
1.3 Sampling, Testing and Acceptance
Frequency of Testing
1. For sampling, testing and acceptance purposes, a lot shall consist of bearings of
a single size and design. The size of a lot shall be chosen to reflect the size of
the manufacturing batch and shall be agreed between the WPC and the PDP or
his representative provided that no lot shall exceed 100 bearings.
Procedure
2. At least 3 months before the WPC is ready to commence installation of the

bearings, and before delivery to the Site, he shall request the PDP or his
representative to sample and test the finished bearings in accordance with the
relevant Part of BS 903.
Sampling
3. Sampling shall be performed by the PDP or his representative.
Approved Laboratory
4. Testing shall be carried out at the Rubber Research Institute of Malaysia or at

another laboratory approved by the PDP or his representative. Testing shall
preferably be carried out in the presence of the PDP or his representative. If the
WPC so wished, he may also be present.

Testing and Acceptance
5 Test Method
Unless otherwise agreed by the PDP Representative, all performance tests shall
be conducted in accordance with the test methods as specified.
a) Stiffness In Direct Compression

Stiffness in direct compression shall be determined in accordance
with Appendix B of MS 671. It shall not be less than that specified on
the Drawing.
b) Stiffness In Shear
Stiffness in shear shall be determined in accordance with Appendix
B of MS 671. It shall not be greater than that specified on the
Drawing.
c) Damping ratio
Damping Ratio shall be determined in accordance with BS EN
15129.
6. Test Pieces
The test required for elastomer shall be performed on specially moulded test
pieces. When, additionally, the PDP Representative directs tests to be made on
samples cut from a finished bearing, these samples shall be obtained as specified
in Specification Clauses 7 and 8 are prepared in accordance with BS 903 : Part A
36.
7. Test samples from Surface of Bearing
Test pieces for the determination of hardness, tensile strength and elongation at
break, ageing resistance and ozone resistance shall be such that one of the layer
surfaces is part of the outer surface of the bearing.
8. Test Samples from Body of Bearing

Test pieces for the determination of compression set shall be taken from as
near the middle of the bearing as possible.
9. Bond Strength Test Piece

Sampling of bond strength test piece shall be determined in accordance with
Appendix A of MS 671. Samples shall be tested in accordance with ISO 813.
10 In the event of the sample bearings meeting all the requirements of this
Specification, the entire lot of bearings from which the samples were drawn shall
be accepted.

Test Statements
11 A certified statement giving details of the test results and proposed locations of
the bearings which have passed the tests shall be forwarded to the PDP or his
representative.
Retesting and Rejection
12 In the event of any sample bearing failing to comply with any of the requirements
of this Specification the PDP or his representative may, at his discretion,
authorise two further bearings to be selected at random from the failed lot and
retested. Both bearings must meet all the requirements of this Specification for
the lot to be accepted.
In the event of any one of the two bearings failing to meet the specified
requirements, then the entire lot from which the samples are drawn shall be
rejected.
Subsequent Rejection
13 Notwithstanding anything to the contrary herein contained, the inspections and

examination of materials or work by the PDP or his representative and any
consent to proceed resulting from such inspections and examinations shall not
be taken as preventing the PDP or his representative from making a further
inspection and examination of the materials and work and subsequently rejecting
the materials and work if shown by such further inspection and examination to be
in non compliance with this Contract.
Waiver of Tests
14 The PDP or his representative, may at his discretion, reduce the intensity of
testing or waive some of the tests provided he is satisfied that manufacturer's in-
house quality control and production give sufficient assurance of consistently
high quality bearings.
1.4 Installation
Storage
1. Prior to installation, the bearings shall be stored in a location away from direct
sunlight, sources of heat, hydrocarbon oils, electrical machines and welding
equipment (which generate high concentration of ozone which may be
detrimental to rubber).
Approval Before Installation
2. No bearings shall be installed in the Works until they have been accepted in
writing by the PDP or his representative

3. Epoxy mortar bedding plinths shall extend at least 50 mm beyond the edge of a
rubber bearing.
Tolerances
4. Elastomeric bearings and epoxy mortar bedding shall be installed to the following
tolerances:
(a) The level of the top surface of the elastomeric bearing when installed on
the epoxy mortar bedding shall not vary from that shown on the Drawings
by more than 3mm.
(b) No point on either surface in contact with any bearing shall vary from the
plane of that surface by more than 1.0mm.
(c) The slope of each face of the bearing shall not vary from that specified by
more than 0.5mm per 100mm.
(d) The horizontal position of any point on any bearing shall not vary from the
location shown on the Drawings by more than 10mm.
5. Epoxy mortar bedding which does not meet these tolerances may be repaired by
either grinding the surfaces which will be in contact with the bearings to achieve
the desired tolerances, or by roughening the surfaces and casting a layer of
approved epoxy material over the complete surface to a minimum thickness of
3mm.
6.
satisfaction the bedding plinth shall be removed and replaced.
1.5 Epoxy Mortar, Dowel Bars & Concrete Surface
1. Epoxy Mortar for the bearing pads shall have a compressive strength of at least
50 N/mm2 at 7 days. The WPC shall submit samples of the fine aggregate to the
PDP or his representative for testing in accordance with Sub-clause 2.2. Fine
aggregates shall be dry. Damp or wet aggregate shall not be permitted in the
epoxy mortar.
2. At least 20 days before the WPC proposes to commence placing the epoxy
mortar bedding he shall submit to the PDP or his representative for approval
details of the mix he proposes to use which shall include the 7-day cube strength,
the grading of the fine aggregate in the mix, the mix proportions used and the
temperature at testing. No work shall commence until the trial mix has been
approved in writing by the PDP or his representative.
3. The equipment used to make the trial mix shall be the equipment to be used
during the work. Three standard 70mm test cubes shall be cast, cured for 7 days
and compression tested in accordance with BS 1881 'Method of Testing
Concrete' Part 3 and Part 4. The compressive strength, at 7 days, of each cube
shall be at least 50 N/mm2.

4. During construction of the epoxy mortar bedding the WPC shall cast a standard
70mm test cube from the mix for each batch for compression testing. The cubes
shall be air-cured on site in a sheltered location. Should the compressive
strength of any test cube fail to reach the specified strength the PDP or his
representative shall have the right to reject the beddings from which such cube
was taken.
5. No epoxy mortar bedding shall be loaded until its control cube has attained the
specified compressive strength.
Dowel bars
6. Dowel bars shall be galvanized. Where ever shown on the drawings the dowel
bars shall be accurately placed in preformed holes. The annular space around
the dowel bars shall be filled with an approved epoxy grout or an approved non-
shrink grout.
Concrete Surface
7. The concrete surface areas on which the epoxy mortar bedding is to be installed
and the bearing surfaces on the pre-stressed concrete beams shall be kept free
of oil, grease, dirt, laitance and all other foreign materials. Prior to placing the
epoxy mortar bedding or beams the contact areas shall be clean and dry to the
satisfaction of the PDP or his representative. Immediately prior to placing the
epoxy mortar the concrete surface which is to receive the epoxy mortar shall be
primed with a 0.8mm thick cast of the epoxy resin binder used in the mortar.
1.6 Warranty
Warranty shall be given by the designated contractor together with the scheduled
maintenance, replacement and inspection plan. The format shall be agreed with the
PDP or his representatives.
2.0 MECHANICAL BEARINGS
2.1 Description
The work specified in this Sub-Section includes the supply, manufacture and
installation of pot type bearings.

2.2 Design and Applicable Codes
The bearings shall be designed, manufactured and installed in accordance with this
Specifications and the applicable requirements of the following Standard Codes and
Specifications: -
(a) British Standards BS 5400: Part 9: 'Bridge Bearing'.
(b) Standard Specification for Highway Bridges adopted by AASHTO Part I & II.
2.3 Manufacturers
The bearing manufacturer proposed as supplier for the bearings shall have not less
than 7 successful experience in manufacturing similar type and capacity
bearings and shall be subjected to the approval by the PDP or his representative.
2.4 Substituted Bearings
The WPC may submit alternative pot bearings based on pot bearings of similar design
to that shown for consideration and approval by the PDP or his representative provided
they comply with the following: -
(a) Equal or better load carrying and movement capacity;
(b) Fabricated by an approved manufacturer;
(c) All control dimensions are maintained; no change in overall height; bearing must
fit within limits of detailed masonry plate;
(d) Use unfilled Polytetrafluoroethylene;
(e) Use elastomeric material as a confined medium within the pot.
(f) Equal or better than the bearings shown on the drawings in all structural
respects.
2.5 Materials
2.5.1 Metals
(a) Stainless Steel
Stainless steel sliding surface shall either be stainless clad steel plate or solid
stainless steel meeting the following requirements: -

Stainless steel clad plate shall conform to the requirements of BS 1449: Part 2.
The grade of material for sliding surfaces shall be 316 S16. The backing steel of
base metal shall be of Grade 43A to BS 4360. The stainless steel and based
metal shall be mill rolled under heat and pressure until they are integrally bonded
over their entire interface.
Solid stainless steel plate shall conform to the requirements of BS 1449: Part 1.
(b) Structural Steel
Structural steel components of the bearing shall comply with requirements of BS

4360. For pot bearings, the based pot shall be machined from a solid steel plate.
All ferrous metal (other than stainless steel) shall be fabricated from the grade
steel specified above with the additional requirements that the steel shall contain
0.35 to 0.5% copper to enhance its weathering characteristics.
Bolts
Anchor Bolts, Hex Nuts and Washers
Anchor Bolts, Hex Nuts and Washers shall be fabricated from the steel Grade 43
and complying with the requirements of BS 4360 and be sized and threaded in
conformance to the requirements of BS 3692 for Anchor Bolts and Hex nuts and
BS 4320 for washers.
Anchor Bolts, Nuts And Washers
Anchor Bolts, Nuts and Washers shall be galvanised and complying with the
requirements of BS 729.
Countersunk Screws
Countersunk Screws shall be carbon steel (equivalent to alloy 43; BS 4360)

cylindrical head cap screws, meeting the applicable requirements of BS 4933.
End Welded Shear Studs
End Welded Shear Studs shall be galvanized. The manufacturing shall be in

accordance to the requirements of BS 4360.
2.5.2 Polytetrafluoroethylene (PTFE)
PTFE resin shall be 100 per cent virgin material. Meeting the requirements of BS 3784:
Grade A.
The composition of filled PTFE shall be such that its coefficient to friction is not more
than twice the coefficient of friction of pure PTFE when measured under the same
conditions.
(a) Filler Material

Filler material, when used, shall be milled glass fibers, carbon or other approved
inert filler materials.
(b) Adhesives
Adhesives for bonding PTFE to backing plates shall produce a bond with a
minimum peel strength of 4N/mm width when tested in accordance with BS 5350:
Part C9. They shall be resistant to the action of lubricants, atmospheric and
biological agents and temperature to which bearing may be subject.
(c) Lubricant
The lubricant used shall retain its properties within the temperature range of -
27°C to +-47°C. It shall not change its consistency or affect the constituent.
Parts of the bridge bearings. The lubricant shall have the following properties: -
Worked penetration range of 240 to 280 determined in accordance with BS 5296.
A solidification point < - 40°C.
A bleeding < 4% when tested in accordance with BS 5297, using 150°C for 24
hours.
BS 4360.
2.5.3 Elastomer
(a) Elastomer material shall be good quality natural rubber complying with the
requirements of MS 3.51: SMR 5 Grade or better shall be used. All ingredients
shall be uniformly dispersed.
(b) The-physical properties of the vulcanized rubber when tested according to

BS 903 shall conform to the requirements of the Specifications .
2.5.4 Coal Tar Epoxy
Coal Tar Epoxy shall comply with the requirements of BS 5493 Ref Kf 3B.
2.5.5 Preformed Fabric Pads
Preformed Fabric Pads shall be compressed of multiple layers of 227 grain cotton duck
impregnated and bound with high quality natural rubber or of equivalent and equally
suitable materials compressed into resilient pads of uniform thickness. The number of
plies shall be such as to produce the specified thickness, after compression and
vulcanizing. The finished pads shall withstand compression loads perpendicular to the
plane of the laminations of not less than 69 N/sq.mm without detrimental reduction in
thickness or extrusion.

2.5.6 Sealing Rings
Sealing rings for containing the confined medium in pot bearings shall meet the
following requirements: -
(a) Non-corrosive materials;

(b) Withstands or transmit all impose loads;
(c) Allow free movement of the piston;
(d) Contains the confined medium within the pot under the maximum static and
dynamic loading.
(e) Prevents contamination of the confined medium with foreign matter.
(f) Designed to be flushed with the outside surface of the elastomer to ensure
proper sealing.
2.5.7 Grouts
Non-shrink grouts for setting anchor bolts shall be of an approved quality and tested in
accordance with the requirements of BS 1881, BS 4550, BS 4551 and BS 5075: Part 2.
2.6 Design Requirement
Design parameters shall comply with the following requirements: -
2.6.1 Elastomeric Disc
The maximum design compressive stress shall be 40 N/sq.mm.
2.6.2 Sliding Surfaces
Sliding surface shall accommodate translation by sliding of a hard mating surface of

stainless steel across a PTFE surface.
(a) Stainless Steel
Stainless Steel Sliding Surface shall be accurate, flat surface with Brinnell
hardness of 125 minimum. It shall comply with the following requirements: -
(i) Stainless steel sliding surface shall completely cover the PTFE surface in, all
operating positions of the bearing.
(ii) Stainless steel sliding surface shall be positioned so that the sliding
movement causes the dirt and dust accumulation to fall from the surface of
the stainless steel without contaminating the PTFE.

(b) PTFE Sliding Surface
Holes in PTFE sliding surface shall not be permitted.
(c) Coefficient of Friction
Unless otherwise specified, the minimum coefficient of friction used in the design
shall be as Table 140-2.
Table 140-2: Coefficient of Friction for Sliding Surface
Bearing Stress
Coefficient of Friction
(N/sq.mm)
5 0.08
10 0,06
20 0.04
30 and over 0.03
2.6.3 Rotation
The rotation of pot bearings about a horizontal axis shall not exceed 0.15.
2.6.4 Movement
The pot bearings shall accommodate the expansion and contraction movements, as
shown on the Drawings.
2.6.5 Welding
Welding to steel plate that has a bonded PTFE surface may be permitted provided
welding procedures are established which restrict the maximum temperature reached
by the bond area to less than 150°C as determined by temperature indication wax
pencils or other suitable means approved by the PDP or his representative.
2.7 Submission
2.7.1 Shop Drawings
The WPC shall, before the fabrication of any bearings, submit shop drawings to the
PDP or his representative for approval. The shop drawings shall include: -
a) Plan and elevation of the bearing;

b) Complete details and sections showing all materials incorporated with the
bearing:

c) All BS, ASTM or other material designations;

d) Vertical and horizontal load capacity:
e) Rotation and translation capacity:
f) Compression stress on all sliding surfaces, as well as on surfaces of the confined
medium, at maximum and minimum design loads;
g) Complete design calculations to demonstrate compliance with the specifications;
h) Details of corrosion properties to metal components;
i) Details of fixing to both the superstructure and the substructure;
j) Method of installation;
k) All other information required by the PDP or his representative to facilitate his
consideration of the WPC's proposal.
The WPC's submission shall be made at least one month prior to the date by which
approval of his proposals is required. The WPC shall be responsible for ensuring that
sufficient time is allowed for the submission and approval of his proposals; and for the
testing and delivery of the bearings, to avoid delaying the Works.
2.7.2 Certifications
The WPC shall furnish Certified Test Reports, Material Certificates and a Certificate of
instructions.
2.8 Fabrication
2.8.1 PTFE
(a) Bonded PTFE
The surface of PTFE to be bonded shall be prepared for bonding in accordance

with BS 5350: Part Al. The minimum bond strength between the PTFE 'and its
backing plate, when tested in accordance with BS 5350 Part C9, shall be 4N/mm
width.
(b) Confined PTFE
Confined PTFE shall be recessed into metal backing plate. The shoulders of the
recess shall be sharp and secure to restrict the flow of PTFE. The thickness of
the PTFE and its protrusion from the recess shall be related to its maximum plan
dimension in accordance with Table140-3.

Table 140-3: Thickness and Protrusion of PTFE

Maximum dimension of
Minimum Thickness Maximum projection
PTFE (diameter or diagonal)
(mm) above recess (mm)
(mm)
< 600 4.5 2.0
> 600 < 1200 5.0 2.5
> 1200 < 1500 6.0 3.0
2.8.2 Bolts and Bolts Holes
Bolt holes shall be drilled or reamed. Where specified by the PDP or his
representative, bolts or screws shall be of a vibration resistant type. Taper washers of
the correct angle of taper shall be provided under all heads and nuts bearing on
levelled surfaces.
2.8.3 Welding
(a) General
Welding procedure shall be as such as to minimize distortion of the bearing
components and to avoid damage to finished work or bonded materials.
(b) Aluminum
Metal arc welding of aluminum shall be in accordance with the recommendations

of BS 3019: Part 1.
(c) Stainless steel
Welding of stainless steel sheet to a mild steel backing plate shall be by an inert
gas-shielded metal-arc tungsten inert gas metal-arc process. Electrodes used
with the former method shall be austenitic steel electrodes complying with BS
2926.
2.8.4 Protective Measures
Permanently exposed surface shall be protected against corrosion as specified or

approved by the PDP or his representative.
(a) Dissimilar Materials
Care shall be taken to prevent electrolytic action between dissimilar metals in

contact by the use of suitable insulation and prevention of moisture penetration.
(b) Damaged Areas
Any damaged area of protective treatment shall be made good to the satisfaction
of the PDP or his representative or the damaged parts replaced.

Permanently exposed surfaces shall be protected against corrosion in accordance with

the following painting specification to BS EN ISO 12944.
1. Sand blast SA 2.5
2. Primer coat with 2 pack zinc rich primer with Epoxy, Polyurethane, aromatic or
aliphatic binder priming coat = 60 µm minimum dry film thickness (MDFT)
3. Undercoat with 2 pack epoxy, Polyurethane, aromatic or aliphatic binder base

coat (MIO) = 220 µm MDFT
4. Finishing coat with 2-pack Epoxy, Polyurethane, aromatic or aliphatic binder top
coat = 100 µm MDFT
Touch up with epoxy paint or re-apply of corrosion protection system on the bolts are
required after bolts tightening.
2.9 Testing
The WPC shall inform the PDP or his representative at least one month in advance of
the date and place of manufacture and test of the bearing. The WPC shall make
necessary arrangement for the PDP or his representative to inspect the manufacturing
process or test. If the place of manufacture or testing is located overseas, the WPC
shall allow the cost for all expenses incurred by two officers nominated by the PDP or
his representative for the inspection and testing of bearings. The WPC shall provide
the PDP or his representative with all facilities at the places of manufacture and testing
necessary for such inspection.
2.9.1 Procedures and Compliance
(a) Load Testing
Bearings shall be tested for compression and tension (if any) and tests shall
include all bearings components in the most adverse combinations as specified
on the Drawing or in the Schedule of Bearings. Load transfer due to tilting of
bearing shall be taken into account. Before recorded measurements, the bearing
shall be embedded in by applying a load equal to the serviceability limit state and
then releasing it. The test loads shall then be applied in increments and load
deflection measurements shall be recorded for each increment. The rate of
loading shall be slow enough to avoid any adverse shock effects and the
maximum load shall be maintained until any obvious short-term creep has
ceased.
The load shall then be removed in decrements and load deflection

measurements made each decrement. After complete unloading, the amount of
set shall be checked and if significant, the loading and unloading cycle shall be
repeated. If the set is shown to be progressive, then the bearing is deemed not
to comply with this Specification.

For compliance, tested bearing shall show no sign of visible damage or

permanent deformation of any part due to loading cycles subsequent to the initial
bedding-in cycle.
(b) Friction
Friction testing of sliding surfaces shall be carried out as follows: -
(i) A vertical load equal to the permanent load specified on the drawing or
listed in the Schedule of Bearings shall be applied to a pair of sliding
surfaces mounted back to back between the plates of a compression
testing rig. A horizontal force shall be applied to the pair of sliding plates
sufficient to cause movement of not less than 25mm between the stainless
steel and PTFE sliding surface. The maximum force required to cause this
movement shall be recorded. The load shall then be removed from the rig
and inspected.
(ii) The coefficient of friction shall be calculated as

Maximum horizontal force
2 x vertical load
For each test position and shall in no case exceed Table 140-2.
(iii) After testing the stainless steel shall be checked for flatness, which must
be within the specified limits. The bond to the backing plate shall be
unaffected. The PTFE shall be free from mechanical damage.
(iv) The test shall be carried out at room temperature. The PTFE surface shall
be lubricated with the lubricant to be used in service.
For compliance, tested bearing shall show no apparent surface flaws.
(c) Rotation
One bearing of each type shall be tested in rotation to the value for rotation shown on
the Drawings rounded upwards to the nearest 0.005 radians while being loaded in
compression to the maximum vertical load specified. Bearings that are required to
resist lateral forces shall also have the specified lateral load applied during this test.
2.10 Products Delivery Storage and Handling
2.10.1 Assembly and Marking
Each pot bearing shall be assembled at the plant, -marked for identification and
delivered to the construction site as a complete unit. Each bearing shall be marked to
indicate the normal position of the bearing.

2.10.2 Care and Protection
During handling, transport, storage and installation, bearings shall be kept clean and
protected from mechanical damage, heat, contaminants and other deleterious effects.
2.11 Installation
2.11.1 General
Bearings which have been pre-assembled shall not be dismantled, except with the prior
approval of the PDP or his representative If for any reason the bearing has been
dismantled, it shall be done under expert supervision and the manufacturer's
assistance shall be sought.
All bearings whether required to provide horizontal restraint or not, shall be fixed to the
superstructure with the mechanical fixings or similar. Reliance on the friction between
the bearing and the superstructure or substructure to resist part of the horizontal forces
may be permitted provided a factor of safety of not less than 1% is applied to the
proven coefficient of friction. The worst combination of vertical load and horizontal load
shall be considered.
The WPC shall carefully check the level of any surface plinth or bed upon which a
bearing will rest and he shall make due allowance for any difference in the depth of the
bearing to be installed from that assumed on the Drawing. If necessary, WPC shall
adjust the levels of the substructure to ensure that the level of the superstructure will be
at the required level on completion.
Unless specified, all bearings shall be installed with bottom plate horizontal. For cases
where tapered top plate is required to take up the longitudinal elevation, welding or
bolting to the top of the bearings is not allowed. The tapered top plate must be
machined on the bearing itself.
Any temporary lock devices for bearings shall be removed before a post-tensioned
cast-in-place superstructure is stressed. For other type of superstructure, the time for
removal of any locking devices shall be agreed by the PDP or his representative.
Care shall be taken to avoid displacing bearings during formwork erection, steel fixing
and concreting.
Touch up with epoxy paint or re-apply of corrosion protection system on the bolts are
required after bolts tightening.
2.11.2 Tolerances
(a) Bearings shall be located so that their centerlines are within ±3mm of their
correct position. The level of bearing shall be within tolerance of ±0.0001 times
the adjacent span, or the lesser of the adjacent spans, but shall not exceed
±5mm. Bearings shall be set to their correct inclination within a tolerance of 1 in
200 in any direction.

(b) Departure from the plane between twin or multiple bearings shall be within
tolerance specified on the drawing.
(c) Bearings shall be installed so that the direction of their horizontal axis are within
a tolerance of ±0.005 radian from their correct alignment.
2.12 Epoxy Mortar, Dowel Bars & Concrete Surface
1. Epoxy Mortar for the bearing pads shall have a compressive strength of at least
50 N/mm2 at 7 days. The WPC shall submit samples of the fine aggregate to the
PDP or his representative for testing in accordance with Sub-clause 2.2. Fine
aggregates shall be dry. Damp or wet aggregate shall not be permitted in the
epoxy mortar.
2. At least 20 days before the WPC proposes to commence placing the epoxy
mortar bedding he shall submit to the PDP or his representative for approval
details of the mix he proposes to use which shall include the 7-day cube strength,
the grading of the fine aggregate in the mix, the mix proportions used and the
temperature at testing. No work shall commence until the trial mix has been
approved in writing by the PDP or his representative.
3. The equipment used to make the trial mix shall be the equipment to be used
during the work. Three standard 70mm test cubes shall be cast, cured for 7 days
and compression tested in accordance with BS 1881 'Method of Testing
Concrete' Part 3 and Part 4. The compressive strength, at 7 days, of each cube
shall be at least 50 N/mm2.
4. During construction of the epoxy mortar bedding the WPC shall cast a standard
70mm test cube from the mix for each batch for compression testing. The cubes
shall be air-cured on site in a sheltered location. Should the compressive
strength of any test cube fail to reach the specified strength the PDP or his
representative shall have the right to reject the beddings from which such cube
was taken.
5. No epoxy mortar bedding shall be loaded until its control cube has attained the
specified compressive strength.
Dowel bars
6. Dowel bars shall be galvanized. Where ever shown on the drawings the dowel
bars shall be accurately placed in preformed holes. The annular space around
the dowel bars shall be filled with an approved epoxy grout or an approved non-
shrink grout.
Concrete Surface
7. The concrete surface areas on which the epoxy mortar bedding is to be installed
and the bearing surfaces on the pre-stressed concrete beams shall be kept free of
oil, grease, dirt, laitance and all other foreign materials. Prior to placing the epoxy
mortar bedding or beams the contact areas shall be clean and dry to the
satisfaction of the PDP or his representative. Immediately prior to placing the

epoxy mortar the concrete surface which is to receive the epoxy mortar shall be
primed with a 0.8mm thick cast of the epoxy resin binder used in the mortar.
2.13 Warranty
Warranty shall be given by the designated contractor together with the scheduled
maintenance, replacement and inspection plan. The format shall be agreed with the
PDP or his Representatives.
END OF SECTION

Section 140-Bridge Bearing Spec

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Section 140-Bridge Bearing Spec

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CONSTRUCTION AND COMPLETION OF LIGHT RAIL TRANSIT LINE 3 (LRT 3) FROM

BANDAR UTAMA TO JOHAN SETIA

Document No. : KVLRT3-MRCBGK-GEN-PMGT-SPC-000002

SECTION 140 - BRIDGE BEARINGS

TABLE OF CONTENTS PAGE

1.1 General ....................................................................................................................... 2

1.2 Design Requirements ............................................................................................... 2

1.3 Sampling, Testing and Acceptance ....................................................................... 5

1.4 Installation ................................................................................................................ 7

1.5 Epoxy Mortar, Dowel Bars & Concrete Surface .................................................... 8

2.0 MECHANICAL BEARING .......................................................................................... 9

2.1 Description ............................................................................................................... 9

2.2 Design and Applicable Codes............................................................................... 10

2.3 Manufacturers ........................................................................................................ 10

2.4 Substituted Bearing ................................................................................................ 10

2.6 Design Requirement .............................................................................................. 13

2.7 Submission ............................................................................................................. 14

2.8 Fabrication .............................................................................................................. 15

2.9 Testing .................................................................................................................... 17

2.10 Products Delivery Storage and Handling ............................................................ 18

2.11 Installation .............................................................................................................. 19

2.12 Epoxy Mortar, Dowel Bars & Concrete Surface .................................................. 20

SECTION 140 BRIDGE BEARING 1 of 21 REVISION: 03

1.0 ELASTOMERIC BEARINGS FOR BRIDGES

1. Elastomeric bearings shall be designed and supplied in accordance with this

1.2 Design Requirements

2. The WPC shall provide complete detailed descriptions, drawings, specifications

4.1 Natural Rubber

SECTION 140 BRIDGE BEARING 2 of 21 REVISION: 03

ingredients shall be recognised rubber quality and shall be uniformly

Table 140-1: Physical properties of Elastomer

Type A Type B Type C Methods of

4.2 Mild Steel Plates

SECTION 140 BRIDGE BEARING 3 of 21 REVISION: 03

4.3 Bonding Agent

All bonding of elastomer to steel shall be carried out during vulcanization.

(b) Bonding Strength

a. Plain Pad Bearings and Strip Bearings

SECTION 140 BRIDGE BEARING 4 of 21 REVISION: 03

1. Following successful completion of type approval tests, in accordance with

3. Each bearing shall be indelibly marked by imprinting during moulding the

e) Other identification marks as directed by the PDP or his

1.3 Sampling, Testing and Acceptance

2. At least 3 months before the WPC is ready to commence installation of the

3. Sampling shall be performed by the PDP or his representative.

4. Testing shall be carried out at the Rubber Research Institute of Malaysia or at

SECTION 140 BRIDGE BEARING 5 of 21 REVISION: 03

Testing and Acceptance

a) Stiffness In Direct Compression

7. Test samples from Surface of Bearing

8. Test Samples from Body of Bearing

9. Bond Strength Test Piece

SECTION 140 BRIDGE BEARING 6 of 21 REVISION: 03

Retesting and Rejection

13 Notwithstanding anything to the contrary herein contained, the inspections and

Approval Before Installation

SECTION 140 BRIDGE BEARING 7 of 21 REVISION: 03

1.5 Epoxy Mortar, Dowel Bars & Concrete Surface

SECTION 140 BRIDGE BEARING 8 of 21 REVISION: 03

2.0 MECHANICAL BEARINGS

SECTION 140 BRIDGE BEARING 9 of 21 REVISION: 03

2.2 Design and Applicable Codes

(a) British Standards BS 5400: Part 9: 'Bridge Bearing'.

2.4 Substituted Bearings