BEARING OF MAIN FLYOVER & EXTENDED PART

Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing

(MT)

MODULE 22
1 83-501 ( R ) 300 Free
P 83
2 83-502 ( L ) 300 L Guided

3 82-401 ( R ) 800 Free

P 82
4 82-402 ( L ) 800 L Guided

5 81-301 ( R ) 900 T Guided

P 81
6 81-302 ( L ) 900 Fixed

7 80-201 ( R ) 800 Free

P 80
8 80-202 ( L ) 800 L Guided

9 79-101 ( R ) 400 Free

P 79
10 79-102 ( L ) 300 L Guided

MODULE 20
11 78-101 ( L ) 500 Free
P 78
12 78-102 ( R ) 500 L Guided

13 77-201 ( L ) 1000 Free

P 77
14 77-202 ( R ) 1000 L Guided

15 76-301 ( R ) 900 T Guided

P 76
16 76-302 ( R ) 900 Fixed

17 75-401 ( L ) 900 Free

P 75
18 75-402 ( R ) 900 L Guided

19 74-501 ( L ) 500 Free

P74/ M20
20 74-502 ( R ) 500 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE 19
21 74-101 ( L ) 300 Free
P 74/ M 19
22 74-102 ( R ) 300 L Guided

23 73-201 ( L ) 900 Free

P 73
24 73-202 ( R ) 900 L Guided

25 72-301 ( L ) 900 Free

P 72
26 72-302 ( R ) 900 L Guided
27 71-401 ( L ) 900 T Guided
P 71
28 71-402 ( R ) 900 Fixed

29 70-501 ( L ) 800 Free

P 70
30 70-502 ( R ) 800 L Guided

31 69-601 ( L ) 300 Free

P 69/ M 19
32 69-602 ( R ) 300 L Guided

MODULE 18
33 69-101 ( L ) 400 Free
P 69/ M 18
34 69-102 ( R ) 500 L Guided

35 68-201 ( L ) 800 Free

P 68
36 68-202 ( R ) 900 L Guided

37 67-301 ( L ) 700 T Guided

P 67
38 67-302 ( R ) 700 Fixed

39 66-401 ( L ) 700 Free

P 66
40 66-402 ( R ) 700 L Guided

41 65-501 ( L ) 400 Free

P 65/ M 18
42 65-502 ( R ) 400 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE 17
43 65-101 ( L ) 500 Free
P 65/ M 17
44 65-102 ( R ) 400 L Guided

45 64-201 ( L ) 1000 Free

P 64
46 64-202 ( R ) 800 L Guided

47 63-301 ( L ) 1000 T Guided

P 63
48 63-302 ( R ) 800 Fixed

49 62-401 ( L ) 1000 Free

P 62
50 62-402 ( R ) 800 L Guided

51 61-501 ( L ) 500 Free

P 61/ M 17
52 61-502 ( R ) 500 L Guided

MODULE 16
53 61-101 ( L ) 400 Free
P 61/ M 16
54 61-102 ( R ) 500 L Guided

55 60-201 ( L ) 800 Free

P 60
56 60-202 ( R ) 1000 L Guided

57 59-301 ( L ) 800 T Guided

P 59
58 59-302 ( R ) 1000 Fixed

59 58-401 ( L ) 700 Free

P 58
60 58-402 ( R ) 1000 L Guided

61 57-501 ( L ) 400 Free

P 57/ M 16
62 57-502 ( R ) 600 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE 15
63 57-101 ( L ) 300 Free
P 57/ M 15
64 57-102 ( R ) 500 L Guided

65 56-201 ( L ) 600 Free

P 56
66 56-202 ( R) 1000 L Guided

67 55-301 ( L ) 600 T Guided

P 55
68 55-302 ( R ) 1000 Fixed

69 54-401 ( L ) 700 Free

P 54
70 54-402 ( R ) 1000 L Guided

71 53-501 ( L ) 400 Free

P 53/ M 15
72 53-502 ( R ) 500 L Guided

MODULE 14
73 53-101 ( L ) 400 Free
P 53/ M 14
74 53-102 ( R ) 600 L Guided

75 52-201 ( L ) 600 Free

P 52
76 52-202 ( R ) 1100 L Guided

77 51-301 ( L ) 600 T Guided

P51
78 51-302 ( R ) 1000 Fixed

79 50-401 ( L ) 400 Free

P 50/ M 14
80 50-402 ( R ) 500 L Guided

MODULE 13
81 50-101 ( R ) 400 Free
P 50/ M 13
82 50-102 ( L ) 500 L Guided

83 49-201 ( R ) 800 Free

P 49
84 49-202 ( L ) 900 L Guided

85 48-301 ( R ) 800 T Guided

P 48
86 48-302 ( L ) 1000 Fixed

87 47-401 ( R ) 500 Free

P 47/ M 13
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)
P 47/ M 13
88 47-402 ( L ) 500 L Guided

MODULE 12
89 47-101 ( R ) 300 Free
P 47/ M 12
90 47-102 ( L ) 300 L Guided

91 46-201 ( R ) 800 Free

P 46
92 46-202 ( L ) 800 L Guided

93 45-301 ( R ) 900 T Guided

P 45
94 45-302 ( L ) 900 Fixed

95 44-401 ( R ) 800 Free

P 44
96 44-402 ( L ) 800 L Guided

97 43-501 ( R ) 300 Free

P 43/ M 12
98 43-502 ( L ) 300 L Guided

MODULE 11
99 43-101 ( R ) 500 Free
P 43/ M 11
100 43-102 ( L ) 400 L Guided

101 42-201 ( R ) 1000 Free

P 42
102 42-202 ( L ) 800 L Guided

103 41-301 ( R ) 1000 T Guided

P 41
104 41-302 ( L ) 700 Fixed

105 40-401 ( R ) 600 Free

P 40/ M 11
106 40-402 ( L ) 400 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE 10
107 40-102 ( R ) 300 Free
P 40/ M 10
108 40-101 ( L ) 400 L Guided

109 39-202 ( R ) 700 Free

P 39
110 39-201 ( L ) 800 L Guided

111 38-302 ( R ) 700 T Guided

P 38 38-301
112 (L) 700 Fixed
Rev1
113 37-402 ( R ) 700 Free
P 37
114 37-401 ( L ) 700 L Guided

115 36-502 ( R ) 400 Free

P 36/ M 10
116 36-501 ( L ) 400 L Guided

MODULE 09
117 36-102 ( R ) 400 Free
P 36/ M 09
118 36-101 ( L ) 300 L Guided

119 35A-202 ( R ) 900 Free

P 35 A
120 35A-201 ( L ) 500 L Guided

121 35-302 ( R ) 900 T Guided

P 35
122 35-301 ( L ) 600 Fixed
Rev1
123 34-402 ( R ) 800
P 34
124 34-401 ( R ) 600 L Guided

125 33-502 ( R ) 400 Free

P 33/ M 09
126 33-501 ( L ) 300 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE 08
127 33-501 ( R ) 400 Free
P 33/ M 08
128 33-502 ( L ) 500 L Guided

129 32-401 ( R ) 800 Free

P 32
130 32-402 ( L ) 800 L Guided

131 31-301 ( R ) 800 T Guided

P 31
132 31-302 ( L ) 800 Fixed

133 30-201 ( R ) 800 Free

P 30
134 30-202 ( L ) 800 L Guided

135 29-101 ( R ) 400 Free

P 29/ M 08
136 29-102 ( L ) 400 L Guided

MODULE 07
137 29-501 ( R ) 400 Free
P 29/ M 07
138 29-502 ( L ) 400 L Guided

139 28-401 ( R ) 800 Free

P 28
140 28-402 ( L ) 800 Free

141 27-301 ( R ) 800 T Guided

P 27
142 27-302 ( L ) 800 Fixed

143 26-201 ( R ) 800 Free

P 26
144 26-202 ( L ) 800 L Guided

145 25-101 ( R ) 400 Free

P 25/ M 07
146 25-102 ( L ) 400 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE 06
147 25-501 ( R ) 500 Free
P 25/ M 06
148 25-502 ( L ) 400 L Guided

149 24-401 ( R ) 800 Free

P 24
150 24-402 ( L ) 800 L Guided

151 23-301 ( R ) 800 T Guided

P 23
152 23-302 ( L ) 800 Fixed

153 22-201 ( R ) 800 Free

P 22
154 22-202 ( L ) 800 L Guided

155 21-101 ( R ) 400 Free

P 21/ M 06
156 21-102 ( L ) 400 L Guided

MODULE 05
157 21-501 ( R ) 300 Free
P 21/ M 05
158 21-502 ( L ) 300 L Guided

159 20-401 ( R ) 800 Free

P 20
160 20-402 ( L ) 800 L Guided

161 19-301 ( R ) 900 T Guided

P 19
162 19-302 ( L ) 900 Fixed

163 18-201 ( R ) 800 Free

P 18
164 18-202 ( L ) 800 L Guided

165 17-101 ( R ) 300 Free

P 17/ M 05
166 17-102 ( L ) 300 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE 04
167 17-501 ( R ) 300 Free
P 17/ M 04
168 17-502 ( L ) 300 L Guided

169 16-401 ( R ) 800 Free

P 16
170 16-402 ( L ) 800 L Guided

171 15-301 ( R ) 900 T Guided

P 15
172 15-302 ( L ) 900 Fixed

173 14-201 ( R ) 800 Free

P 14
174 14-202 ( L ) 800 L Guided

175 13-101 ( R ) 300 Free

P 13/ M 04
176 13-102 ( L ) 300 L Guided

MODULE 03
177 13-501 ( R ) 300 Free
P 13/ M 03
178 13-502 ( L ) 300 L Guided

179 12-401 ( R ) 800 Free

P 12
180 12-402 ( L ) 800 L Guided

181 11-301 ( R ) 900 T Guided

P 11
182 11-302 ( L ) 900 Fixed

183 10-201 ( R ) 800 Free

P 10
184 10-202 ( L ) 800 L Guided

185 P9-101 ( R ) 300 Free

P 9/ M 03
186 P9-102 ( L ) 300 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE 02
187 P9-501 ( R ) 300 Free
P 9/ M 02
188 P9-502 ( L ) 300 L Guided

189 P8-401 ( R ) 800 Free

P8
190 P8-402 ( L ) 800 L Guided

191 P7-301 ( R ) 900 T Guided

P7
192 P7-302 ( L ) 900 Fixed

193 P6-201 ( R ) 800 Free

P6
194 P6-202 ( L ) 800 L Guided

195 P5-101 ( R ) 300 Free

P 5/ M 2
196 P5-102 ( L ) 300 L Guided

MODULE 01
197 P5-501 (R ) 300 Free
P 5/ M 01
198 P5-502 ( L ) 300 L Guided

199 P4-401 ( R ) 800 Free

P4
200 P4-402 ( L ) 800 L Guided

201 P3-301 ( R ) 900 T Guided

P3
202 P3-302 ( L ) 900 Fixed

203 P2-201 ( R ) 800 Free

P2
204 P2-202 ( L ) 800 L Guided

205 P1-101 ( R ) 300 Free

P 1/ M 1
206 P1-102 ( L ) 300 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE EM 12
207 P1-401 ( R ) 200 Free
P1/ EM 12
208 P1-402 ( L ) 200 L Guided

209 EP36-301 ( R ) 400 T Guided

EP 36
210 EP36-302 ( L ) 400 Fixed

211 EP35-201 ( R ) 500 Free

EP 35
212 EP35-202 ( L ) 500 L Guided

213 EP34-101 ( R ) 300 Free

EP 34/ EM 12
214 EP34-102 ( L ) 300 L Guided

MODULE EM 11
215 E 34-401 ( R ) 200 Free
EP 34/ EM 11
216 E 34-402 ( L ) 300 L Guided

217 E 33-301 ( R ) 400 Free

EP 33
218 E 33-302 ( L ) 500 L Guided

219 E32-201 ( R ) 500 T Guided

EP 32
220 E32-202 ( L ) 500 Fixed

221 E31-101 ( R ) 200 Free

EP 31/ EM 11
222 E31-102 ( L ) 300 L Guided

MODULE EM 10
223 E 31 -401 (R) 300 Free
EP 31/ EM 10
224 E 31 - 402 (L) 300 L Guided

225 E 30 - 301 (R) 600 Free

EP 30
226 E 30 - 302 (L) 600 L Guided

227 E 29 - 201 (R) 700 T Guided

EP 29
228 E 29 - 202 (L) 800 Fixed

229 E 28 - 101 (R) 400 Free

EP 28/ EM 10
230 E 28 - 102 (L) 400 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE EM 09
231 E 28 -401 (R) 400 Free
EP 28/ EM 09
232 E 28 - 402 (L) 400 L Guided

233 E 27 - 301 (R) 700 Free

EP 27
234 E 27 - 302 (L) 700 L Guided

235 E 26 - 201 (R) 700 T Guided

EP 26
236 E 26 - 202 (L) 700 Fixed

237 E 25 - 101 (R) 300 Free

EP 25/ EM 09
238 E 25 - 102 (L) 300 L Guided

MODULE EM 08
239 E 25 -401 (R) 300 Free
EP 25/ EM 08
240 E 25 - 402 (L) 300 L Guided

241 E 24 - 301 (R) 400 Free

EP 24
242 E 24 - 302 (L) 400 L Guided

243 E 23 - 201 (R) 500 T Guided

EP 23
244 E 23 - 202 (L) 500 Fixed

245 E 22 - 101 (R) 300 Free

EP 22/ EM 08
246 E 22 - 102 (L) 300 L Guided

MODULE EM 07
247 EP 22-201 300 T Guided
EP 22/ EM 07
248 EP 22-202 300 Fixed

249 E 21 - 101 (R) 300 Free

EP 21/ EM 07
250 E 21 - 102 (L) 300 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE EM 06
251 E 21 -401 (R) 200 Free
EP 21/ EM 06
252 E 21 - 402 (L) 200 L Guided

253 E 20 - 301 (R) 400 Free

EP 20
254 E 20 - 302 (L) 500 L Guided

255 E 19 - 201 (R) 500 T Guided

EP 19
256 E 19 - 202 (L) 500 Fixed

257 E 18 - 101 (R) 200 Free

EP 18/ EM 06
258 E 18 - 102 (L) 200 L Guided

MODULE EM 05
259 E 18 - 501 (R) 300 Free
EP 18/ EM 05
260 E 18 - 502 (L) 300 L Guided

261 E 17 -401 (R) 500 Free

EP 17
262 E 17 - 402 (L) 500 L Guided

263 E 16 - 301 (R) 500 T Guided

EP 16
264 E 16 - 302 (L) 500 Fixed

265 E 15 - 201 (R) 500 Free

EP 15
266 E 15 - 202 (L) 500 L Guided

267 E 14 - 101 (R) 300 Free

EP 14/ EM 05
268 E 14 - 102 (L) 300 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE EM 04
269 E 14 - 501 (R) 300 Free
EP 14/ EM 04
270 E 14 - 502 (L) 300 L Guided

271 E 13 - 401 (R) 500 Free

EP 13
272 E 13 -402 (L) 500 L Guided

273 E 12 - 301 (R) 500 T Guided

EP 12
274 E 12 - 302 (L) 500 Fixed

275 E 11 - 201 (R) 500 Free

EP 11
276 E11 - 202 (L) 500 L Guided

277 E 10 - 101 (R) 300 Free

EP 10/ EM 04
278 E 10 - 102 (L) 300 L Guided

MODULE EM 03
279 E10-501 ( R ) 300 Free
EP 10/ EM 03
280 E10-502 ( L ) 300 L Guided

281 E9-401 ( R ) 500 Free

EP 09
282 E9-402 ( L ) 500 L Guided

283 E8-301 ( R ) 500 T Guided

EP 08
284 E8-302 ( L ) 500 Fixed

285 E7-201 ( R ) 500 Free

EP 07
286 E7-202 ( L ) 500 L Guided

287 E6-101 ( R ) 300 Free

EP 06/ EM 03
288 E6-102 ( L ) 300 L Guided

MODULE EM 02
289 E6-201 ( R ) 300 T Guided
EP 06/ EM 02
290 E6-202 ( L ) 300 Fixed

291 E5-101 ( R ) 300 Free

EP 05/ EM 02
292 E5-102 ( L ) 300 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

MODULE EM 01
293 E5-501 ( R ) 300 Free
EP 05/ EM 01
294 E5-502 ( L ) 300 L Guided

295 E4-401 ( R ) 500 T Guided

EP 04
296 E4-402 ( L ) 500 Fixed

297 E3-301 ( R ) 500 Free

EP 03
298 E3-302 ( L ) 500 L Guided

299 E2-201 ( R) 500 Free

EP 02
300 E2-202 ( L) 500 L Guided

301 E1-101 ( R) 300 Free

EP 01/ EM 01
302 E1-102 ( L) 300 L Guided

MODULE EM 01B
303 A1-401 ( R ) 300 Free
EP A1/ EM 01B
304 A1-402 ( L ) 300 L Guided

305 A2-301 ( R ) 500 Free

EP A2
306 A2-302 ( L ) 500 L Guided

307 A3-201 ( R ) 500 T Guided

EP A3
308 A3-202 ( L ) 500 Fixed

309 A4-101 ( R ) 300 Free

EP A4/ EM 01B
310 A4-102 ( L ) 200 L Guided
Sl No. Pier No. Bearing ID. Bearing Capacity Type of Bearing
(MT)

PLAN VIEW AT TOP OF BEARING

PLAN VIEW AT BOTTOM OF BEARING

SIDE VIEW OF FIXED & FREE BEARING SIDE VIEW OF GUIDED BEARING
WORKING PROCEDURE OF PRECAST SEGMENTAL BRIDGE ERECTION/ SUPERSTRUCTURE
ACTIVITIES

1 Casting of Bearing Pedestal

2 Bearing installation & bottom grouting

3 LG Erection

4 LG Load Test

5 Bearing top grouting

6 Support Erection

7 Segment erection

8 Dry Matching, Gluing & Temporary Prestressing

9 CIP Casting

10 Cable threading

11 Prestressing

12 Span Releasing

13 Auto launching

14 Cable duct water leackage test

15 Cable duct grouting

16 Precast crash barrier erection

17 Stitch Concrete

18 Metal beam crash barrier

19 Median barrier casting

20 Precast Median barrier installation

21 Hand rail installation

22 Light pole installation

23 Painting of C/B, Median & Hand rail

24 Recess filling

25 Wearing course (Water proofing membrane & BC)

26 Expansion joint (Transverse & Longitudinal)

27 Drainage spout fixing

28 Lane Marking

1751
1. BEARING PEDESTAL :

I) Bearing pedestal is a support concrete for bearing on top of the pier cap

ii) PVC Duct pipe are placed in position according to bearing lug of bearing bottom plate

The outer dia of the PVC pipe is 40 mm higher than the bearing lug, considering 20 mm grout sorrounding
iii)
the bearing lug

iv) Pedestal top RL = FRL - BWC - SH - WT - TG - BH - BG +/- super elivation, Where

BWC = Bituminous wearing course

SH = Segment height

WT = Average wedge thickness

TG = Bearing Top Grouting (During casting of pedestal it is considered as 20 mm)

BH = Bearing Height

BG = Bearing Bottom Grouting (During casting of pedestal it is considered as 20 mm)

v) Concreting to be done by crane & bucket system

vi) Ggrade of concrete is C40 & Slump is 175 +/- 25 mm

vii) Pedestal size & height for various component of Flyover is given in the table below :

Size of Pedestal
Height (mm)
(mm x mm)
Sl
COMPONENT Remarks
No.
Drawing Practical Drawing Practical

1 Main Flyover 1050 x 1050 1150 x 1150 500

Practical Some times the bearing lug
Height of position is going to be
Pedestal =
2 Extended part 900 x 900 100 x 100 500 Pedestal top placed outside the pedestal,
RL (iv) - Pier so it requires to increase the
pedestal size on site
cap top RL.
3 Ramp 900 x 900 100 x 100 500

1851
ix) Equipment & Manpower :

Equipment Required Time Engr Supervisor Technician Labour

Manpower Time (Hour)Total Man Hour

Hydra/ 25 Ton Crane 3 1 2 6 2 x 24 288

2. BEARING INSTALLATION & BOTTOM GROUTING :

The bearing is defined as a structural device that transmits loads while facilitate translation and/ or
rotation. The selection of a bearing is influenced by many factors such as loads, geometry, maintenance,
i)
available clearence, displacement, rotation, availability of bearing, construction tolerance, cost etc. In this
project Pot cum PTFE (Poly Tetra Fluro Ethylene) bearings are used

ii) There are three types of Pot cum PTFE Bearing :

1. Fixed bearing : It restraint horizontal movement in all direction but allows rotation in all direction

2. Free bearing : It allows horizontal movement and rotation in all direction

3. Guided bearing : It allows horizontal movement in one direction but allows rotation in all direction

iii) Sample of Bearing Installation at Module M01 on various types of pier is Shown below :

Expansion Free Pier Fixed Pier Free Pier Expansion

Pier Pier

Free Free T Free

Guided

Free

P5 P4 P3 P2 P1
L
Guided
L Guided
L Guided Free
L Guided

Uplift Disc bearing : It restraint the bearing to lift up, It can be guided or free. It is used where the radius of
iv)
curvature is more

v) Before bearing installation the PVC duct in the pedestal for bearing lug must be removed

vi) The bearings are placed to its true position according to its level & alignment

vii) Bearing type, Size & Capacity, lug dia & length to be checked thoroughly before installation

1951
 Bearing top RL is calculated as Pedestal top RL (1- iv), where the bearing height & bottom grout is not
viii)
deducted

Bearing Bottom is grouted by a non shrink grout at site we are using Sika 214 mixing with water (168 ml/kg
ix) of Sika 214) by a grout mixing machinee/ drill machine of RPM maximum 500 (Product data sheet of sika
214 page 2)

x) For grouting minimum thickness is 10 mm & maximum thickness is 100 mm

For grout thickness more than 100 mm, it is necessary to mix sika 214 with graded 10 mm silt free
xi)
aggrigate

xii) The quantity of aggrigates should not exceed 1 part aggrigate to 1 part sika 214

xiii) The purpose of use of aggrigate is to minimize the temperature rise generated during curing stage

xiv) Initial Setting time 4:30 hrs

xv) Compressive strength 1 day 25 mpa, 7 days 50 mpa, 28 days 60 mpa (100 mm cube)

xvi) Attachment : 01, Approved Bearing

3. LG ERECTION :

Trustle(400x400 crib) erection in between pier P1 & P2 and 24m behind the pier P1 to make a temporary
i)
stage for LG

ii) Erection of a temporary tower just behind the pier P1 which will be anchored with P1

iii) Erection middle support II over the temporary tower

iv) Fixing front support bracket on top of pier cap P2 with the help of mac alloy bar (40 mm dia)

v) Erection of box no.1 on front support & trustle with the help of crane (160 ton)

Then erection of box no. 2 to box no. 7 & joined the boxes each other by splice plate & HSFG (High
vi)
strength friction grip) bolt

vii) Erection of grab hoist & slider beam

viii) Placing of span jack on position over both the pier (4 nos on each pier)

ix) Pier segment over P2 erection, level & alignment as pre drawing and place on span jack

x) Anchoring the segment with pier with the help of macalloy bar

xi) Trustle to be removed from between the span P1-P2

xii) Erection of a launching girder requires about 30 to 35 days ( Sl I to x )

xiii) Dismantling of a launching girder after erection of all span requires 15 to 20 days

xiv) A launching girder can be erect a curved span having its redius of curvature 200 m

xv) Minimum Span length 24m & Maximum span length 38m for precast segment erection by LG

xvi) Details of Launching Girder :

LG ID LG1 LG2 & LG3

2051
 SIZE : 2.50 m x 3.25 m LG2 & LG3 = 2.00 m x 3.25 m

Weight Weight
(A) BOX DETAILS Length (m) Remarks Length (m) Remarks
(Ton) (Ton)

Box No. S1 9.25 27.92 9.25 25.5

Box No. S2 9.25 30.20 9.25 29.9

Box No. S3 9.25 27.25 7.50 24.1

Box No. S4 9.25 30.76 9.25 31.6

Box No. S5 9.25 37.10 9.25 30.5

Box No. S6 9.25 33.25 11.50 25.4

Box No. S7 9.25 16.39 11.50 20.96

Box No. S8 9.25 20.52 11.50 19.25

Box No. S9 9.25 19.22 0 0

SUB TOTAL (A) 83.25 242.61 79.00 207.21

B. SUPPORT DETAILS

Front Support 12 12

Middle Support 1 20 20

Middle Support 2 20 20

Rear Support 15 13

Rear Trolly 15 15

Sliders (3 ton x 14 Nos.) 42 42

Grab Hoist 12 12

Counter Weight 80 80

Lifting Beam 1.5 1.5

Balancing Beam 1.5 1.5

SUB TOTAL (B) 219 217

TOTAL (A+B) 461.61 424.21

4. LG LOAD TEST :

i) After LG erection all the trustle is removed between front support & middle support

2151
ii) Pier segment is erected ove P2, level & alignment complete, then anchor it with pier

iii) Middle support-1 is brought on to pier segment & anchor it with pier segment

iv) De activate the front support & move the LG by 1.5 m in forward direction

The top level of LG is taken at L0 (C/L fo MS-2), L/4, L/2, 3L/4 & L (C/L of MS-1) for self weight of LG and it is
v)
considered as datum

vi) All the slider beams are erected with suspender bars and levels are taken at the same nodes

vii) Expansion pier segment S01 erected over P1 towards middle support-2

viii) Segment no. S3 to S9 is erected one by one from P1 side

ix) Segment no. S14 to S12 is erected one by one from P2 side

x) Segment no. S10 is hang with the long suspender bar & leave the entire setup for about 2 hrs

xi) Level is taken at all node points as final reading

xii) Erection of all segment of the span, gluing, CIP casting & stressing is completed

xiii) Once again level is taken at the same node points

xiv) Theoritical deflection of LG During Load Test :

Deflection due to Precast Total

Initial Reading Deflection due to slider
Node Point segment Deflection
(mm) (mm) (mm) (mm)

L0 0 mm 0 mm 0 mm 0 mm

L/4 0 mm 5.082 mm 46.179 mm 51.261 mm

L/2 o mm 6.590 mm 65.793 mm 72.383 mm

3L/4 o mm 3.744 mm 47.085 mm 50.829 mm

L o mm 0 mm 0 mm 0 mm

5. BEARING TOP GROUTING :

After pier segment Anchoring with the pier cap Bearing top grouting is done with same material as Bottom
i)
grout (Sika 214 with water 168 ml/kg of sika grout)

It should be notted that before bearing top grouting pier segment must be in proper position of level &
ii)
alignment according to GFC drawing

Bearing top/bottom grouting can be done even stressing if Bearing not available or any other proplem at
iii)
site

2251
6. SUPPORT ERECTION :

i) Middle Support-1 to be erected over anchored pier segment at P2 & ahchoring it with Pier segment

ii) Front support to be de activated by using telescopic leg

iii) Auto launching the LG by 1.5 m

7. SEGMENT ERECTION :

i) Segments are shifted from casting yard to the site by Low Bed Trailer

Prestressing beams are fixed at top & bottom of the segment with the help of 80 ton capacity hydraulic
ii)
jack

iii) Lirfting wires are fixed with the prestressing beam at the top of the segment

iv) Segment lifting position is at a distance 15.6 m from front support

v) Exp. Pier Segment no. S1 to be erected, Shifting to the position over P1

vi) Segment no. S3 to S7 to be erected & shifted towards P1

vii) Segment no. S10 to S12 to be erected shifted towards P2 to balance both side of LG

viii) Segment no. S8 & S9 to be erected

ix) Simultenously Segment no. S1 can be adjusted for level & alignment

8. DRY MATCHING, GLUING & TEMPORARY PRESTRESSING :

i) Expansion pier segment S1 over P1 level & alignment completed

Segment no. S3 shift to its position as per design level & alignmet keeping the gap of CIP segment S2 as per
ii)
GFC drawing

iii) All the loose or unstable fragment must be removed from segment surface to joined each other

Segment no. S4 bring near S3, Match the male & female shear key of S3 & S4, Stress the joint with the help
iv)
of stress bar, it is called dry match

v) De stress the stress bar, open the joint & keep a gap of about 600 mm to apply epoxy bonding agent

In any case if there is any damage to the joint surface, it should not repair /patch by concrete or mortar,
vi)
during application of glue the damaged area should be filled with epoxy glue to the surface level

Any loose or unstable material must be removed & Clean the surface by air blower & make the surface dry
vii) before use of epoxy

Component A mix thorougly in its container until homogeneity is reached for about 10 seconds by a glue
viii) mixing machine/ drilling machine of RPM maximum 400 (FIP 4.4)

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 ix) Component B is to be added and Mix thoroughly for about 3 min

Apply the glue on the surface 2mm for single surface and about 1 mm for both surface. Around duct about
x)
30-40 mm gap to be kept free free from bonding agent

After applying glue on the segment surface thoroughly, both the segments are brougt together, apply
xi)
temporary prestressing with the help of pulling bar & 80 ton capacity hydraulic jack having 100 mm stroke

xii) It is better to use single surface with 2 mm in thickness to reduce time

xiii) Theoritical requirement (FIP 4.1) : 3.2 to 3.6 kg/ m 2

xiv) Practical requirement (as per site) : 4.2 to 4.8 kg/ m 2 including wastage

xv) open time minimum 60 min (FIP 5.2)

xvi) Level & alignment of these two segment S3 & S4 to be adjusted

xvii) All the joint to be completed in the same procedure (Sl no iv to xv)

xviii) Epoxy bonding agent : Sikadur -31 SBA S-02 for segment joint gluing

There are two component of Sikadur -31 SBA S-02 : Component A is Epoxy resin & Component B is
hardner

Mixing ratio of A:B = 2:1 (4kg :2 kg)

Pot life : minimum 20 min (FIP 5.1)

Open time minimum 60 min (FIP 5.2)

Compressive strength (FIP 5.12) 1 day minimum 60 mpa, 7 days minimum 75 mpa

Three different formulations of Epoxy bonding agent depends of ambient temperature (FIP 3.2)

a. Fast reacting formulation for ambient temperatures at site from 5˚C to 20˚C

b. Medium fast reacting formulation for ambient temperatures at site from 15˚C to 30˚C

c. Slow reacting formulation for ambient temperatures at site from 25˚C to 40˚C (we are using at our site)

9. CIP CASTING :

After completion of all joint gluing & temporary prestressing both the CIP gap become fixed as per drawing
i)
(a little adjustment in level & alignment can be done if required)

ii) CIP outer shutte fixed from bottom side with the help of tie rod

iii) CIP rebar installation & Sheathing pipe joining

iv) Some epoxy glue can be used at the joint of Sheathing pipe to ensure leak proof duct during CIP casting

v) CIP inner shutter fixing

vi) Concreting by crane & bucket

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vii) Grade of concrete : C40, Practically using C50 to reduce time

viii) Slump of concrete 175 +/- 25 mm

ix) Shutter can be removed @ CIP strength 20 mpa

x) Normal CIP size : 300 mm

10. CABLE THREADING :

Prescribed nos of strand to be insert in to the prescribed cable duct as per design. It is called cable
i)
threading

ii) HT Strands to be cut according to the required length.

Cutting length = Design length + bearing 80 mm x 2 + 650 mm at Jacking end/ Live end + 300 mm at Dead
iii)
end

iv) Workers standing on a platform are pushing the strands one by one into the cable duct

v) Normally 19 nos strand to be provided in a single cable duct as per design

vi) Cable cutting & threading requires about 24 hours

11. PRESTRESSING :

i) Anchor head/ bearing (19T15) to be fixed at both end of cable after completion of cable threading

ii) At the live end jack to be fixed with the help of crane & chain Pully

iii) Prestressing can be started @ CIP cylinder strength 40 mpa or 36 hours after CIP casting which ever latter

iv) Design consideration :

1. Cross sectional area of each Strand : 140 mm 2

2. Modulus of elasticity of Strand : 195 KN/mm 2

3. Wobble coefficeint ( k ) : 0.006/m for bright metal sheathing & 0.002/m for HDPE Sheathing

4. Friction coefficeing ( µ ) : 0.25/Radian for bright metal sheathing & 0.17/ Radian for HDPE sheathing

5. Ultimate tensile strength of Strand : 1860 mpa

6. Ultimate tensile force per Strand : 260.7 KN

7. Applied force on each Strand : 200.5 KN

Design elongation ( δ ) = PL/AE, where P = Design force, L = Length of cable, A = Area of strand and E =
v)
Modulus of elasticity

2551
vi) Average design elongation is 6.74 mm per m length of cable

Modified elongation in mm = (Design elongation in mm x Design area strand in mm 2 x Design modulus of

vii)
elasticity in KN/mm2 )/ (Actual area in mm2 x Actual modulus of elasticity in KN/mm 2)

Modified Pressure in kg/cm2 = (Design force x Nos of strand x 1000)/ (9.81 x Jack efficiency x Ram area in
viii)
mm2 )

ix) Acceptable limit of both pressure & elongation is 95 % to 105%

If the modified elongation reached beofre the pressure is obtained, need to continue tensioning till the
pressure achieved 100% & the elongation should not be more than 105%

If the modified elongation is not reached at the modified pressure, need to continue tensioning till the
elongation achieved 100% & the pressure should not be more than 105%

After completion of stressing, the cable has to be locked at 70% of the total pressure

x) Types of cable in a span : 1. Main cable, 2. Blister/ Stritch cable, 3. Module cable & 4. Wing cable

1. Main cable : Main cable is from one pier to another pier only for one span

Types of Main cable : a) Web Cable, b) Top cable, c) Bottom cable

Maximum nos of main cable used in a span is 20 & Minimum is 13

a) Web cable (W) : Maximum nos of web cable used in a span is 6 & Minimum is 2

b) Top cable (T) : Maximum nos of Top cable used in a span is 8 & Minimum is 4

c) Bottom cable (B) : Maximum nos of bottom cable used in a span is 6 & Minimum is 4

2. Blister cable (S) : The blister cables is used over every pier except expansion pier as extra top to make a
continuous span in a module.

Maximum nos of blister cable used in a span is 8 & Minimum is 4

3. Module cable (P) : There are 2 nos top & 2 nos bottom duct in each module

If there is any shortfall in any shortfall in top cable, Top Module cable (P2 & P3) to be used to compensate
the same

If there is any shortfall in bottom cable, bottom module cable (P1& P4) to be used to compensate the same

4. Wing cables (C) : 2 nos wing cable are used in every span in which there are 4 strands in each duct

There are some provision for future ducts inside the Segment box for post tensioning force of about 10%
xi) of the positive & negative moment of primary prestressing forces. Practically we are providing 8 nos 75
mm inner dia duct at both top & bottom of the pier segment in each span

xii) After completion of 60% stressing of main cable,Stressing of blister cable can be started

xii) The cable position is shown in the figure below :

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 C1 T13 T11 P2 P3 T15 T17 C2
T14 T12 T16 T18

W12
W11 W13
W15
W14 W16

B13 B16

B12 B15

B11 B14
W16
P1 P4

S11 S15
Short Blister Short Blister

S12 S16
Short Blister Short Blister

S13 S17
Intermediate Intermediate

S14 S18
Long Blister Long Blister

xiii) Cable ID :

The cable ID is marked in such a way that, the first letter indicates the position of the cable, the first digit
indicates the serial no. of the span in that module & the second digit indicates the serial no. of cable in that
position.

Example : Cable no. B32

Here B means Bottom cable
3 means the third span of the module
2 means second cable according to serial at bottom of the segment

xiv) Sequence of stressing in a module :

Cables
Stage Description Cable to stressed in sequence Normally
used

2751
 1 W12
2 W11 & W13
3 W15
4 W14 & W16
After completion of final
alignment, Rechecking of 5 T14 & T18
geometry, Applying epoxy 6 B13 & B16 19 T 15
State I
glue, Temporary
(First span of the Moduel) 7 T13 & T17
prestressing, CIP segment
casting, Required cylinder 8 B12 & B15
strength of CIP
9 T12 & T16
10 B11 & B14
11 T11 & T15
12 C1 & C2 4 T 15
13 W22
14 W21 & W23
15 W25
16 W24 & W26
17 T24 & T 28
18 B23 & B26
After completion of final
alignment, Rechecking of 19 T23 & T27
State II geometry, Applying epoxy 20 B22 & B25 19 T 15
(Second span of the glue, Temporary
Moduel) prestressing, CIP segment 21 T22 & T26
casting, Required cylinder 22 B21 & B24
strength of CIP
23 T21 & T25
24 S14 & S18
25 S13 & S17
26 S12 & S16
27 S11 & S15
28 C3 & C4 4 T 15
29 W32
30 W31 & W33
31 W35
32 W34 & W36
33 T34 & T36
34 B33 & B36
After completion of final
alignment, Rechecking of 35 T33 & T37
State III geometry, Applying epoxy 36 B32 & 35 19 T 15
(Third span of the glue, Temporary
Moduel) prestressing, CIP segment 37 T32 & T36
casting, Required cylinder 38 B31 & B34
strength of CIP
39 T31 & T35
40 S24 & S28
41 S23 & S27
42 S22 & S26
43 S21 & S25
44 C5 & C6 4 T 15
45 W42
46 W41 & W43
47 W45
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 48 W44 & W46
49 T44 & T48
50 B43 & B46
After completion of final
alignment, Rechecking of 51 T43 & T47
State IV geometry, Applying epoxy 52 B42 & B45 19 T 15
(Fourth span of the glue, Temporary
Moduel) prestressing, CIP segment 53 T42 & T46
casting, Required cylinder 54 B41 & B46
strength of CIP
55 T41 & T45
56 S34 & S38
57 S33 & S37
58 S32 & S36
59 S31 & S35
60 C7 & C8 4 T 15
Aftre completion of all 61 P2 & P3
Stage V * 19 T 15
span of the Module 62 P1 & P4

Note : *19 T 15 : Nos of strands (Please reffer 11. Prestressing note x - 3 in Module Cable)

12. SPAN RELEASING :

Before Prestressing all the segment of the span are hanging by the LG with the help of slider and
i) suspender bar, After completion of prestressing, the load of all the segment are transferred from LG to the
prestressing tendon and it is called span releasing

Span releaing is started from centre of the span towards both end with the help of 60 ton capacity
ii)
hydraulic jack having 200 mm stroke

iii) Due to hogging, it requires less pressure to release the centre segment than the end segment

After releasing all the segment, prestressing beams are removed and bring down to the ground by the
iv)
crane for the preparation of next span

13. AUTO LAUNCHING :

i) Thhe movement of LG towards the next span is called auto launching

After completion of span releasing auto launching is started by 25 ton capacity hydraulic jack with 1200
ii)
stroke

iii) Auto launching upto 9.5 m, then box no. 8 is erected & joined with box no. 7

iv) Auto launching upto 19 m, then box no. 9 is erected & joined with box no. 8

2951
v) Front support bracket is fixed on top of next pier cap P3

vi) Auto launching completed upto pier no P3

vii) Side shifting of the LG if required (for a curved span)

viii) Front support is activated over the bracket

ix) Segment erection is started and step by step is followed to complete the span

14. CABLE DUCT WATER LEACKAGE TEST :

i) For water test lime water is used, Quantity of lime is 0.2 kg/ltr of water (AASHTO LRFD 10.11.2)

ii) 3 hp capacity Positive displacement type pump is used for cable duct water test

iii) Only the outlet is kept open & all other vents is kept closed

iv) After water passing through outlet, outlet is closeed

v) To check the leackage, 5 kg/cm2 pressure is kept for at least 1 min

vi) If any leackage found, it is to be rapaired & once again test for leackage

vii) When no leackage found, water is flashed out by air jet with the help of air compressor

viii) The same procedure is followed for each & every cable

15. CABLE DUCT GROUTING :

i) There are two types of tendon 1) Bonded tendons & 2) Unbonded tendons

1. Bonded tendons : When there is adequate bond between the prestressing tendon & the concrete, it is
called bonded tendon. Pre-tensioned & grouted post-tensioned tendons are bonded tendons.

Generally cement (at site we are using OPC Seven Ring Gold-52.5N) with suitable admixture (at site we are
using Sika Intra plast NN 1% by wt. of Cement) is used for grouting of tendon

3051
 The use of admixture is to reduce the shrinkage of grout

2. Un-bonded tendons : When there is no bond between the pre-stressing tenton & concrete, it is called
un-bonded tendon

ii) In this projet we are using bonded tendon

The use of grout is to save the tendon from corrosion, So Grouting should be done as soon as possible after
iii)
stressing as per the following three region (AASHTO 10.4.2.2.1)

a) within 7 days for very dump atmosphere, humidity more than 70% & over salt area

b) within 15 days for moderate atmosphere, humidity 40 - 70 %

c) within 20 days for very dry atmosphere, humidity less than 40%

iv) 3 hp capacity Positive displacement type pump is used for cable duct grouting

v) Maximum W/C ratio 0.45 (AASHTO 10.11.4), at site we are using 0.42

vi) All the vent pipes & outlet are kept open during grouting

vii) There are two valves are fixed at the inlet & outlet point of the duct

viii) A flexible PVC pipe upto the ground is connected with the outlet valve

ix) The grout pump is connected with the inlet valve and start grouting if the water temperature is as per
specification

x) When the grout is passing through all the vents and outlet then all the vents are closed

xi) The grout passing through outlet is collected

xii) Grouting will be continue untill the flowability of the collected grout from outlet is found as per
specification

xiii) Then the outlet valve is closed & pressure is kept @ 5 kg/cm 2 for at least 1 min

xiv) Then inlet valve is closed & the grout pump is connected with another duct

xiv) If any leackage found, it is to be flash out by water, after rapairing it will be grouted again

xv) The same procedure is followed for each & every cable

3151
 xvi) Setting Time of the grout : (ASTM C 953)

a) Initial setting time more than 3 hrs

b) Final Setting time less than 12 hrs

xvii) Compressive Strength of the grout : (ASTM C942)

a) 7 days strength 21 mpa

b) 28 days strength 35 mpa

xviii) Grout temperature is 23˚C +/- 2˚C (as per ASTM C 939)

Sl No. Item of Work Equipment Required Manpower Time Man Hour

1 Bearing Pedestal Rebar work & Casting Hydra/ Crane 6 2 x 24 288

2 Bearing installation & Bottom grouting Hydra/ Crane 6 1 x 24 144

3 Trustle erection 25 Ton Crane 15 10 x 24 3600

4 LG Erection 160 Ton Crane 15 15 x 24 5400

5 Segment erection Hydra 15 2 x 24 720

6 Bearing top grouting 6 5 30

7 Gluing & Temporary Prestressing 15 15 225

8 CIP Rebar & Casting Works 25 Ton Crane 15 1 x 24 360

9 Cable cutting & threading Hydra 15 1.5 x 24 540

10 Prestressing 25 Ton Crane 15 1 x 24 360

Span Releasing including beam

11 25 Ton Crane 15 15 225
lowering

12 Auto launching 15 18 270

13 Cable duct water test 5 5 25

14 Cable duct grouting 15 15 225

3251
 15 LG Dismantling 15 15 x 24 5400

Under Slang
20 Support erection 15 3 x 24 1080

21 Segment erection & Gluing 15 2.5 x 24 900

22 Support Dismantling 15 3 x 24 1080

23

24

25

1 Launching GirA launching girder can erect a curved span with a minimum radius of 200 m, LG erection require 30 days and dism

2 Under Slang An under slang can erect a curved span with a minimum radius of 150 m, Support erection requires 4 days & dism

3 Low Bed Trail120 ton 4 nos, & 150 ton 1 no.

4 Mobile Crane160 ton 1 no, 100 ton 1 no, 25 ton 2 nos.

5 Hydra 12 ton 1 no. for each LG

6 Zip Crane 1 no for precast crash barrier erection

7 DG set 150 kva 1 no. for each LG & 65 kva 1 no. for each LG

8 Dump Truck 1 no. - 9 ton common for all LG & under slang

9 Mini Truck 6 ton - 2 nos.

10 Concrete Buc 1 m3 capacity

11 Vibrator For pedestal casting 1 no & for CIP casting 3 nos. vibrator required

12 Air Blower To clean dust from pedestal & CIP

13 Glue Mixer/ DRPM maximum 400 for glue mixing (FIP 4.4), RPM maximum 500 for Sika grout mixing (Product data sheet of sika

3351
14 Power Pack ( 7.5 hp - 2 nos (for Mono strand/ Slider Shifting), 5 hp - 2 nos (1 for auto launching & 1 for middle support), 3 hp -

15 Power Pack fo500 ton Capacity - 2 nos (Made in India by Dynamic Prestressing Ltd.

16 Multi Pull Jac 500 ton Capacity - 2 nos, Maximum Stroke 200 mm (Made in India by Dynamic Prestressing Ltd.

17 Single Pull Ja 25 ton Capacity - 2 nos, Maximum Stroke 200 mm (Made in India by Dynamic Prestressing Ltd.

18 Span Jack for 400 ton Capacity - 4 nos (for each pier segment), Minimum 20 nos required for a 4 span module for 1 LG

19 Span Jack for 100 ton Capacity - 4 nos (for each pier segment), Minimum 8 nos required for a span

20 Jack for all S Middle Support-I & II : 250 ton capacity 4 nos x 2 with 250 mm stroke, (for LG1 Middle support II - 300 ton capaci

21 Jack for Supp End & Middle support : Mech. Jack 125 ton capacity 4 nos at each support (Minimum 16 nos required for 1 span)

22 Pulling Jack f Prestressing beam fixing & Temporary prestressing : 80 ton capacity 4 nos with 100 mm stroke, segment level & a

23 Pulling Jack f Prestressing beam fixing & Temporary prestressing : 80 ton capacity 3 nos with 100 mm stroke

24 Pressure Gua Prestressing : Capacity 600 kg/cm 2 (2 nos x 2 ), Cable duct grouting : Capacity 30 kg/cm2 1 no

25 Temporary pr4 nos on top & 2 nos at bottom of each segment, Minimum 56 nos for top & 28 nos at bottom required for 1 span

26 Mac alloy barSegment lifting : ф 40 mm x 7.5 m length 28 nos, Temporary Prestressing at Bottom : ф 40 mm x 2 m length 28 no

27 Wire Rope/ Sl28 nos

28 HT Strand 7 Ply strand, Made in India (TATA / Usha Martyn), Dia of Centre wire should be 0.1016 mm higher than any outer

3451
29 Anchor Head/For Main Cable : 19 T 15 (Made in India by Dynamic Prestressing Ltd), 200 mm dia x 70 mm thickness, Nos of hole

30 Wedges These are conical in shape and fixed with to the strands with the bearing plate. Live Wedge : 46 mm long, wt. 70

31 Steel Pipe forStainless Steel pipe 20 mm Dia x 1m long

32 Proper accessIt may be stair or Ladder

33 Platform for sFor the workers to work properly

34 Chain Pully For Prestrssing : 5 ton capacity 2 nos x 2 = 4 nos at front & 4 nos for Blister, For Front Support : 10 ton capacity 2

35 Petroll For cleaning the wedges, HT strand, Anchor head/ Bearing etc.

36 Safety net Should be provided below CIP segment before casting & below segment joint during gluing

37 Cement OPC Seven Ring Gold - 52.5N for cable duct grouting, maximum W/C ratio 0.45 (AASHTO 10.11.4), Setting Time :

38 Admixture forSika Intra plast NN, to be used 1% by wt. of Cement

39 Grout Pump 3 hp pump Positive displacement type for grout, Grout temperature is 23˚C +/- 2˚C (as per ASTM C 939)

40 Water Tank 2 nos water tank ( 1 for lime water for water test & 1 for fresh water for grout), For water test lime to be used 0.2

41 Grout Mixer Capacity 100 kg cement can be mixed at each batch

42 Flow cone Flowability : 11 to 30 min (1725 +/- 5 ml grout to be passed through a discharge tube of 12.7 mm dia. (as per AST

3551
43 Eopxy Glue Sikadur -31 SBA S-02 for segment joint gluing, Component A base & Component B hardner, Mixing ratio A:B = 2:1

44 Sika 214 For bearing bottom & top grouting, Water mixing ration 168 ml water/kg, 10 mm to 100 mm can be grout, For m

45 Bearing Three types of Pot cum PTFE bearing : 1. Fixed bearing (Restraint movement in all direction but allows rotation in

46 Bearing Lug Diameter : 56 mm, 70 mm, 75 mm & 90 mm, Length : 155 mm & 175 mm

47 Level & alignment

48 Grinder with cFor cutting the HT Strand

2 UNDER SLANG

A. Supports End Support 2 nos

Middle support 1/2 nos
Steel Grid Beam
Segment Trolly

3651
 EQUIPMET AND MACHINERIES AS WELL AS MATERIALS REQUIRED FOR PRECAST
SEGMENTAL BRIDGE ERECTION
Sl No Equipments Description

A launching girder can erect a curved span with a minimum radius of 200 m, LG erection
1 Launching Girder
require 30 days and dismantling 15 days after completion of all span erection.

An under slang can erect a curved span with a minimum radius of 150 m, Support erection
2 Under Slang
requires 4 days & dismantling requires 3 days after completion of each span

3 Low Bed Trailer 120 ton 4 nos, & 150 ton 1 no.

4 Mobile Crane 160 ton 1 no, 100 ton 1 no, 25 ton 2 nos.

5 Hydra 12 ton 1 no. for each LG

6 Zip Crane 1 no for precast crash barrier erection

7 DG set 150 kva 1 no. for each LG & 65 kva 1 no. for each LG

8 Dump Truck 1 no. - 9 ton common for all LG & under slang

9 Mini Truck 6 ton - 2 nos.

10 Concrete Bucket 1 m3 capacity

11 Vibrator For pedestal casting 1 no & for CIP casting 3 nos. vibrator required

12 Air Blower To clean dust from pedestal & CIP

13 Glue Mixer/ Drill RPM maximum 400 for glue mixing (FIP 4.4), RPM maximum 500 for Sika grout mixing
Machine (Product data sheet of sika 214 page 2)

Power Pack (Pump) 7.5 hp - 2 nos (for Mono strand/ Slider Shifting), 5 hp - 2 nos (1 for auto launching & 1 for
14
for LG middle support), 3 hp - 3 nos (for temporary prestressing). For 1 LG

Power Pack for

15 500 ton Capacity - 2 nos (Made in India by Dynamic Prestressing Ltd.
Prestressing

500 ton Capacity - 2 nos, Maximum Stroke 200 mm (Made in India by Dynamic Prestressing
16 Multi Pull Jack
Ltd.

25 ton Capacity - 2 nos, Maximum Stroke 200 mm (Made in India by Dynamic Prestressing
17 Single Pull Jack Ltd.

400 ton Capacity - 4 nos (for each pier segment), Minimum 20 nos required for a 4 span
18 Span Jack for LG module for 1 LG

Span Jack for

19 Underslang 100 ton Capacity - 4 nos (for each pier segment), Minimum 8 nos required for a span
 Front Suppot : 150 ton Capacity x 2 nos with 250 mm stroke, Middle Support-I & II : 250 ton
Jack for all Supports
20 capacity 4 nos x 2 with 250 mm stroke, (for LG1 Middle support II - 300 ton capacity 4 nos
of LG
with 300 mm stroke, Rear Support : 100 ton capacity 6 nos with 300 mm stroke.

End & Middle support : Mech. Jack 125 ton capacity 4 nos at each support (Minimum 16 nos
Jack for Supports of required for 1 span), for segmnt trolly Mech. Jack 25 ton capacity 4 nos, for span lowering :
21
Underslang 60 ton capacity hydraulic jack 4 nos with 200 mm stroke at each support (Minimum 16 nos
required for 1 span)

Prestressing beam fixing & Temporary prestressing : 80 ton capacity 4 nos with 100 mm
stroke, segment level & alignment and span releasing : 60 ton capacity 8 nos with 200 mm
22 Pulling Jack for LG stroke, Side shifting : 25 ton capacity 2 nos with 750 mm stroke, Slider shifting : 25 ton
capacity 2 nos x 2 with 120 mm stroke, Auto launching : 25 ton capacity 1 no with 1200 mm
stroke

Pulling Jack for Prestressing beam fixing & Temporary prestressing : 80 ton capacity 3 nos with 100 mm
23
Underslang stroke

Prestressing : Capacity 600 kg/cm 2 (2 nos x 2 ), Cable duct grouting : Capacity 30 kg/cm2 1
24 Pressure Guage
no

Temporary 4 nos on top & 2 nos at bottom of each segment, Minimum 56 nos for top & 28 nos at
25
prestressing beam bottom required for 1 span

Segment lifting : ф 40 mm x 7.5 m length 28 nos, Temporary Prestressing at Bottom : ф 40

26 Mac alloy bar
mm x 2 m length 28 nos, Temporary Prestressing at Top : ф 32 mm x 3 m length 56 nos

Wire Rope/ Sling

27 assembly 28 nos

7 Ply strand, Made in India (TATA / Usha Martyn), Dia of Centre wire should be 0.1016 mm
higher than any outer 6 wire, Nominal Diameter of Strand : 15.24 mm, Nominal Area of Steel
28 HT Strand : 140 mm2, Grade/ Ultimate Tensile Strength : 270 ksi/ 1860 mpa, Breaking strength : 260.7
KN, Yield strength : 221.5 KN, Design Force : 200.5 KN, Modulus of Elasticity : 195 KN/mm 2,
Unit wt. : 1.102 kg/m, Elongation : 6.74 mm/m length of strand

For Main Cable : 19 T 15 (Made in India by Dynamic Prestressing Ltd), 200 mm dia x 70 mm
Anchor Head/ thickness, Nos of hole 19, Hole dia outer 30 mm & inner 17 mm, For Wing Cable : 4 T 15
29
Bearing (Made in Bangladesh), 115 mm dia x 60 mm thickness, Nos of hole 4, Hole dia outer 30 mm
& inner 17 mm

These are conical in shape and fixed with to the strands with the bearing plate. Live Wedge :
30 Wedges 46 mm long, wt. 70 gm, Outer dia 26 mm & 16 mm at both end before inserting strand,
Master Wedge : 60 mm long, wt. 95 gm

Steel Pipe for Wedge

31 Stainless Steel pipe 20 mm Dia x 1m long
fixing

Proper access with

32 It may be stair or Ladder
Hand rail
 Platform for
33 For the workers to work properly
stressing work

For Prestrssing : 5 ton capacity 2 nos x 2 = 4 nos at front & 4 nos for Blister, For Front
34 Chain Pully
Support : 10 ton capacity 2 nos, For pier segment alignment : 5 ton/ 3 ton 2nos,

35 Petroll For cleaning the wedges, HT strand, Anchor head/ Bearing etc.

36 Safety net Should be provided below CIP segment before casting & below segment joint during gluing

OPC Seven Ring Gold - 52.5N for cable duct grouting, maximum W/C ratio 0.45 (AASHTO
10.11.4), Setting Time : (ASTM C 953) Initial setting time more than 3 hrs, Final Setting time
less than 12 hrs, Compressive Strength : (ASTM C942) 7 days strength 21 mpa, 28 days
37 Cement strength 35 mpa, Grouting should be done after stressing a) within 7 days for very dump
atmosphere, humidity more than 70% & over salt area, b) within 15 days for moderate
atmosphere, humidity 40 - 70 % and c) within 20 days for very dry atmosphere, humidity less
than 40% (AASHTO 10.4.2.2.1)

Admixture for duct

38 Sika Intra plast NN, to be used 1% by wt. of Cement
grout

3 hp pump Positive displacement type for grout, Grout temperature is 23˚C +/- 2˚C (as per
39 Grout Pump
ASTM C 939)

2 nos water tank ( 1 for lime water for water test & 1 for fresh water for grout), For water
40 Water Tank
test lime to be used 0.2 kg/ltr (AASHTO LRFD 10.11.2)

Grout Mixer
41 Capacity 100 kg cement can be mixed at each batch
Machine

Flowability : 11 to 30 min (1725 +/- 5 ml grout to be passed through a discharge tube of 12.7
42 Flow cone
mm dia. (as per ASTM C 939)

Sikadur -31 SBA S-02 for segment joint gluing, Component A base & Component B hardner,
Mixing ratio A:B = 2:1 (4kg :2 kg), Pot life : minimum 20 min (FIP 5.1), Open time minimum
43 Eopxy Glue
60 min (FIP 5.2), Compressive strength (FIP 5.12) 1 day minimum 60 mpa, 7 days minimum
75 mpa

For bearing bottom & top grouting, Water mixing ration 168 ml water/kg, 10 mm to 100 mm
can be grout, For more than 100 mm grout, 50% 10 mm aggrigate can be used with sika,
44 Sika 214
Initial Setting time 4:30 hrs, Compressive strength 1 day 25 mpa, 7 days 50 mpa, 28 days 60
mpa

Three types of Pot cum PTFE bearing : 1. Fixed bearing (Restraint movement in all direction
but allows rotation in all direction), 2. Free bearing (Allows movement and rotation in all
45 Bearing
direction), 3. Guided bearing(allows movement in 1 direction but allows rotation in all
direction), Uplift Disc bearing (Restraint the bearing to lift up)

46 Bearing Lug Diameter : 56 mm, 70 mm, 75 mm & 90 mm, Length : 155 mm & 175 mm
47 Level & alignment

Grinder with cutting

48 For cutting the HT Strand
disk

1 LAUNCHING GIRDER

LG1 SIZE = 2.5m x

i) LG2 & LG3 SIZE = 2m x 3.25m
3.25m
A. Box LG1 LG2 & LG3
NOS. OF BOX LENGTH (M) WEIGHT (TON) LENGTH (M) WEIGHT (TON)
Box No. 1 9.25 27.92 9.25 25.5
Box No. 2 9.25 30.20 9.25 29.9
Box No. 3 9.25 27.25 7.50 24.1
Box No. 4 9.25 30.76 9.25 31.6
Box No. 5 9.25 37.10 9.25 30.5
Box No. 6 9.25 33.25 11.50 25.4
Box No. 7 9.25 16.39 11.50 20.96
Box No. 8 9.25 20.52 11.50 19.25
Box No. 9 9.25 19.22 0
SUB TOTAL 83.25 242.61 79.00 207.21
B. Supports Front Support 12 12
Middle Support 1 20 20
Middle Support 2 20 20
Rear Support 15 13
Rear Trolly 15 15
Sliders (3 ton x 14 Nos.) 42 42
Grab Hoist 12 12
Counter Weight 80 80
Lifting Beam 1.5 1.5
Balancing Beam 1.5 1.5
SUB TOTAL 219 217
SUB TOTAL (A+B) 461.61 424.21

2 UNDER SLANG

A. Supports End Support 2 nos

Middle support 1/2 nos
Steel Grid Beam
Segment Trolly
3
 WORKING PROCEDURE OF PRECAST SEGMENTAL BRIDGE ERECTION
Sl
Description
No
1 Casting of Bearing Pedestal

2 Bearing installation & bottom grouting

3 LG Erection

4 LG Load Test

5 Bearing top grouting

6 Support Erection/ Position

7 Segment erection

8 Dry Matching, Gluing & Temporary Prestressing

9 CIP Casting

10 Cable threading

11 Prestressing

12 Span Releasing

13 Auto launching

14 Water test

15 Cable duct grouting

16 Bearing lock removal

17 Recess filling

18 Expansion joint

19 Precast crash barrier erection & stich conc

20 Steel Barrier installation

21 Median barrier casting

22 Precast Median barrier installation

23 Hand rail installation

24 Bituminous wearing course

25 Light post erection

26 Painting

27
1 BEARING PEDESTAL :

i) Duct pipe to be placed in position according to dowel bar of bearing bottom plate shown in the GFC drawing.

ii) Pedestal top Level & alignment to be checked as per GFC drawing

iii) Duct pipe size & position to be checked as per GFC drawing

Bearing pedestal top RL = FRL - BC wearing course - Segment height - Average Wedge thickness - 20 mm bearing
iv)
top grouting - bearing height - 20 mm bearing bottom grouting +/- super elivation

v) Concreting to be done by crane/Hydra & bucket

vi) Ggrade of concrete is C40.

vii) Slump of concrete 175 +/- 25 mm

2 BEARING INSTALLATION & BOTTOM GROUTING :

i) Three types of Pot cum PTFE Bearing

1. Fixed bearing : It restraint horizontal movement in all direction but allows rotation in all direction

2. Free bearing : It allows horizontal movement and rotation in all direction

3. Guided bearing : It allows horizontal movement in one direction but allows rotation in all direction

ii) Uplift Disc bearing : It restraint the bearing to lift up

iii) Bearing to be installed at proper position and direction according to GFC drawing

iv) Level & alignment to be checked as per GFC drawing

v) Bearing type, Size & Capacity, Dowel dia & length to be checked as per GFC drawing

Bearing top RL = FRL - BC wearing course - Segment height - Wedge thickness - 20 mm bearing top grouting +/-
vi) super elivation

vii) Bottom grouting to be done by Sika 214 mixing with water (168 ml/kg of Sika 214)

viii) For grouting minimum thickness is 10 mm & maximum thickness is 100 mm

ix) For grout thickness more than 100 mm, it is necessary to mix sika 214 with graded 10 mm silt free aggrigate
x) The quantity of aggrigates should not exceed 1 part aggrigate to 1 part sika 214

xi) The purpose of use aggrigate is to minimize the temperature rise generated during curing stage

xii) Initial Setting time 4:30 hrs

xiii) Final setting time :

xiv) Compressive strength 1 day 25 mpa, 7 days 50 mpa, 28 days 60 mpa (100 mm cube)

xv) Attachment : 01, Approved Bearing

3 LG ERECTION :
Trustle(400x400 crib) erection in between pier P1 & P2 and 24m behind the pier P1 to make a temporary stage for
i)
LG

ii) Erection of a temporary tower just behind the pier P1 which will be anchored with P1

iii) Fixing front support bracket on top of pier cap P2 with the help of mac alloy bar (40 mm dia)

iv) Erection of box no.1 on front support & trustle with the help of crane (160 ton)

Then erection of box no. 2 to box no. 7 & joined the boxes each other by splice plate & HSFG (High strength friction
v) grip) bolt

vi) Erection of grab hoist & slider beam

vii) Placing of span jack on position over both the pier (4 nos on each pier)

viii) Pier segment over P2 erection, level & alignment as pre drawing and place on span jack

ix) Anchoring the segment with pier with the help of macalloy bar

x) Trustle to be removed from between the span P1-P2

xi) Erection of a launching girder requires about 30 to 35 days ( Sl I to x )

xii) Dismantling of a launching girder after erection of all span requires 15 to 20 days

xiii) A launching girder can be erect a curved span having its redius of curvature 200 m

xiv) Minimum Span length 24m & Maximum span length 38m for precast segment erection by LG
4 LG LOAD TEST :
After LG erection Level to be taken at top of LG at a distance L0 (Over Pier P2), L/4, L/2, 3L/4 & L (Over pier P1)
i)
where L is the span length

ii) Level to be checked at same points after lifting all slider

iii) Once again level to be checked after lifting all segmnt

iv) The deflection to be checked at every stage

v) Acceptable deflection in Load Test : (As per Bridge con designer)

a) With all slider : 6.5 mm at L/2 & 5 mm at L/4

b) With all segment : 66 mm at L/2 & 47 mm at L/4

5 BEARING TOP GROUTING :

After pier segment Anchoring with the pier cap Bearing top grouting to be done with same material as Bottom
i) grout (Sika 214 with water 168 ml/kg of sika grout)

ii) It should be notted that before bearing top grouting pier segment must be in proper position of level & alignment
according to GFC drawing

iii) Bearing top/bottom grouting can be done even stressing if Bearing not available or any other proplem at site

6 SUPPORT ERECTION/ POSITION :

i) Middle Support-1 to be erected over anchored pier segment at P2 & ahchoring it with Pier segment

ii) Front support to be de activated by using telescopic leg

iii) Auto launching the LG by 1.5 m

7 SEGMENT ERECTION :
 i) Segment lifting position is at a distance 15.6 m from front support

ii) Exp. Pier Segment no. S1 to be erected, Shifting to the position over P1

iii) Segment no. S3 to S7 to be erected & shifted towards P1

iv) Segment no. S10 to S12 to be erected shifted towards P2 to balance both side of LG

v) Segment no. S8 & S9 to be erected

vi) Simultenously Segment no. S1 can be adjusted for level & alignment

8 DRY MATCHING, GLUING & TEMPORARY PRESTRESSING :

i) Expansion pier segment S1 over P1 level & alignment completed

Segment no. S3 shift to its position as per design level & alignmet keeping the gap of CIP segment S2 as per GFC
ii)
drawing

iii) All the loose or unstable fragment must be removed from segment surface to joined each other

Segment no. S4 bring near S3, Match the male & female shear key of S3 & S4, Stress the joint with the help of
iv) stress bar, it is called dry match

v) De stress the stress bar, open the joint & keep a gap of about 600 mm to apply epoxy bonding agent

vi) In any case if there is any damage to the joint surface, it should not repair /patch by concrete or mortar, during
application of glue the damaged area should be filled with epoxy glue to the surface level

vii) Any loose or unstable material must be removed & Clean the surface by air blower & make the surface dry before
use of epoxy

viii) Component A mix thorougly in its container until homogeneity is reached for about 10 seconds

ix) Component B is to be added and Mix thoroughly for about 3 min

Apply the glue on the surface 2mm for single surface and about 1 mm for both surface. Around duct about 30-40
x) mm gap to be kept free free from bonding agent

xi) It is better to use single surface with 2 mm in thickness to reduce time

xii) Theoritical requirement (FIP 4.1) : 3.2 to 3.6 kg/ m 2

xiii) Practical requirement (as per site) : 4.2 to 4.8 kg/ m 2 including wastage

xiv) open time minimum 60 min (FIP 5.2)

xv) Level & alignment of these two segment S3 & S4 to be adjusted

xvi) All the joint to be completed in the same procedure (Sl no iv to xv)

xvii) Epoxy bonding agent : Sikadur -31 SBA S-02 for segment joint gluing

There are two component of Sikadur -31 SBA S-02 : Component A is Epoxy resin & Component B is hardner

Mixing ratio of A:B = 2:1 (4kg :2 kg)

Pot life : minimum 20 min (FIP 5.1)

Open time minimum 60 min (FIP 5.2)

Compressive strength (FIP 5.12) 1 day minimum 60 mpa, 7 days minimum 75 mpa

Three different formulations of Epoxy bonding agent depends of ambient temperature (FIP 3.2)

a. Fast reacting formulation for ambient temperatures at site from 5˚C to 20˚C

b. Medium fast reacting formulation for ambient temperatures at site from 15˚C to 30˚C

c. Slow reacting formulation for ambient temperatures at site from 25˚C to 40˚C (we are using at our site)

9 CIP CASTING :

i) After completion of all joint gluing & temporary prestressing both the CIP gap become fixed as per drawing (a little
adjustment in level & alignment can be done if required)

ii) CIP outer shutte fixed from bottom side with the help of tie rod

iii) CIP rebar installation & Sheathing pipe joining

iv) Some epoxy glue can be used at the joint of Sheathing pipe to ensure leak proof duct during CIP casting

v) CIP inner shutter fixing

vi) Concreting by crane & bucket

vii) Grade of concrete : C40, Practically using C50 to reduce time

viii) Slump of concrete 175 +/- 25 mm

ix) Shutter can be removed @ CIP strength 20 mpa

x) Normal CIP size : 300 mm

xi) Quantity of rebar :

xii) Quantity of concrete :

10 CABLE THREADING :

i) HT Strands to be cut according to the required length.

ii) Cutting length = Design length + bearing 80 mm x 2 + 650 mm at Jacking end/ Live end + 300 mm at Dead end

iii) Prescribed nos of strand to be insert in to the prescribed cable duct as per design. It is called cable threading

iv) Workers standing on a platform are pushing the strands one by one into the cable duct

v) Normally 19 nos strand to be provided in a single cable duct as per design

vi) Cable cutting & threading requires about 24 hours

vii)

11 PRESTRESSING :

i) Anchor head/ bearing (19T15) to be fixed at both end of cable after completion of cable threading

ii) At the live end jack to be fixed with the help of crane & chain Pully

iii) Prestressing can be started @ CIP cylinder strength 40 mpa or 36 hours after CIP casting which ever latter

iv) Design consideration :

1. Cross sectional area of each Strand : 140 mm 2

2. Modulus of elasticity of Strand : 195 KN/mm 2

3. Wobble coefficeint ( k ) : 0.006/m for bright metal sheathing & 0.002/m for HDPE Sheathing
 4. Friction coefficeing ( µ ) : 0.25/Radian for bright metal sheathing & 0.17/ Radian for HDPE sheathing

5. Ultimate tensile strength of Strand : 1860 mpa

6. Ultimate tensile force per Strand : 260.7 KN

7. Applied force on each Strand : 200.5 KN

Design elongation ( δ ) = PL/AE, where P = Design force, L = Length of cable, A = Area of strand and E = Modulus of
v)
elasticity

vi) Average design elongation is 6.74 mm per m length of cable

Modified elongation in mm = (Design elongation in mm x Design area strand in mm 2 x Design modulus of elasticity
vii)
in KN/mm2 )/ (Actual area in mm2 x Actual modulus of elasticity in KN/mm 2)

viii) Modified Pressure in kg/cm2 = (Design force x Nos of strand x 1000)/ (9.81 x Jack efficiency x Ram area in mm 2 )

ix) Acceptable limit of both pressure & elongation is 95 % to 105%

If the modified elongation reached beofre the pressure is obtained, need to continue tensioning till the pressure
achieved 100% & the elongation should not be more than 105%

If the modified elongation is not reached at the modified pressure, need to continue tensioning till the elongation
achieved 100% & the pressure should not be more than 105%

After completion of stressing, the cable has to be locked at 70% of the total pressure

x) Types of cable in a span : 1. Main cable, 2. Blister/ Stritch cable, 3. Module cable & 4. Wing cable

1. Main cable : Main cable is from one pier to another pier only for one span

Types of Main cable : a) Web Cable, b) Top cable, c) Bottom cable

Maximum nos of main cable used in a span is 20 & Minimum is 13

a) Web cable : Maximum nos of web cable used in a span is 6 & Minimum is 2

b) Top cable : Maximum nos of Top cable used in a span is 8 & Minimum is 4

c) Bottom cable : Maximum nos of bottom cable used in a span is 6 & Minimum is 4

2. Blister cable : The blister cables is used over every pier except expansion pier as extra top to make a continuous
span in a module.

Maximum nos of blister cable used in a span is 8 & Minimum is 4

 3. Module cable : There are 2 nos top & 2 nos bottom duct in each module

If there is any shortfall in any shortfall in top cable, Top Module cable (P2 & P3) to be used to compensate the same

If there is any shortfall in bottom cable, bottom module cable (P1& P4) to be used to compensate the same

4. Wing cables : 2 nos wing cable are used in every span in which there are 4 strands in each duct

There are some provision for future ducts inside the Segment box for post tensioning force of about 10% of the
xi) positive & negative moment of primary prestressing forces. Practically we are providing 8 nos 75 mm inner dia duct
on both top & bottom

xii) After completion of 60% stressing of main cable,Stressing of blister cable can be started

xii) Sequence of stressing is shown in the figure below

W12

W11 W13
W15
W14 W16