QUALITY CONTROL BOOKLET

Bridge - 289

Antagarh – Taroki Section

in
Dallirajhara – Rowghat New Line Project

Raipur Division, South East Central Railway

Rail Vikas Nigam Ltd., Raipur
1. Silent Features:

Bridge number 289

River name Jogidhara river
Chainage 60.055 km (1012/8-1013/0)
Section Antagarh – Taroki
Span 6 × 18.3 m
Type PSC ‘I’ Girder
Year of construction 2019-2022
RDSO drawing No. RDSO/B-10273
CE’s GAD number BR/R/289/RB/3966/2018 (Approved by CBE/SECR)
Skew angle, if any No skew
Curve on bridge, if any Straight track
Gradient on bridge, if any Level
60 kg 90 UTS rail with 60 kg ordinary PSC sleeper
Details of track
having density of 1660 over 350 mm ballast cushion.
Details of corrosion protection measures
IPN coating
taken, if any
Loading standard 25 MT
Details of drainage arrangement of
Drain pipe provided in deck slab
(Girder/Slab)
Design discharge 2722.377 m³/sec

Any RAW/RAT up to 50 km on u/s No

Rail level 368.870 m

Top of bed block level 365.542 m
Danger level 364.682 m
Design HFL 359.496 m
Vertical clearance 6.386 m
Free board 8.636 m

Details of jacking points of girders Provided as per RDSO/ B-10273

Girder weight (per span and total) 108 MT per span, Total: 648 MT
Permanent/temporary speed restriction,
No
if any
Expansion joints/Arrangements Provided as per Drg. No RDSO/B-1757 R
Wearing coat, type and thickness etc. M-30, 80 mm thickness
 2. Foundation

2.1 General

Abutment Abutment
Description of item Pier-1 Pier-2 Pier-3 Pier-4 Pier-5
A-1 A-2
Foundation Type Open Open Open Pile Pile Pile Open

Bore log

SBC at founding level

39 45 55 > 230 > 230 > 230 50
(T/m2)
Founding pressure
37 34 32 230 230 230 38
(T/m2)
Grade of concrete M25 M35 M35 M35 M35 M35 M25
Scour level (meter) 352.91 351.685 348.956 348.956 348.956 348.956 352.91
Bottom level of
350.592 350.000 346.700 341.780 339.470 337.294 348.929
foundation (meter)
Top level of
354.792 352.000 348.700 351.456 351.641 351.641 353.129
foundation (meter)
Footing/Pile cap
4.2 2 2 2 2 2 4.2
thickness (meter)
Founding level below 2.318 1.685 2.256 7.176 9.486 11.662 3.981
scour level (m) (Rock) (Rock) (Rock) (Rock) (Rock) (Rock) (Rock)
As per para 6.1 of IRBM, founding level should be more than 1.75 m below scour level in soils while that of 1.5 m in
rocks (Para 403 IRBM)
2.2 Tests:

2.21 Initial Pile Load Test (IS 2911, Part IV-2013)

Location of pile Test pile near Abutment A2

Type of pile Uniform bored cast in situ pile
Type of test Vertical load test
Diameter of pile 1200 mm
Length of pile 14.83 m
Grade of concrete M-35
Date of casting 26.05.2019
Date of testing 10.01.2022 to 12.01.2022
Safe load (Design load) 260 MT
Test load 650 MT
Total displacement 6.127 mm
Rebound after load removal 3.097 mm
Net displacement 3.030 mm
Result: Less than permissible limit of 18
mm. Hence, OK

2.22 Routine Pile Load Test (IS 2911, Part IV-2013)

Location of pile Pile – 1 in P5

Type of pile Uniform bored cast in situ pile
Type of test Vertical load test
Diameter of pile 1200 mm
Length of pile 14.589 m
Grade of concrete M-35
Date of casting 10.06.2020
Date of testing 05.12.2020
Design load 260 MT
Test load 390 MT
Total displacement 2.790 mm
Rebound after load removal 2.245 mm
Net displacement 0.545 mm
Result: Less than permissible limit of 18
mm. Hence, OK
2.23 Pile Integrity Test

Number of piles tested 18 (All piles tested)

Date of testing 10.12.2020

Wave speed 3500 – 4200 m/sec

Defects found Nil

Pile Integrity Satisfactory

3. Piers and Abutments

3.1 General Details

# Item Description A-1 A-2 P-1 P-2 P-3 P-4 P-5

1.0 Grade of Concrete

1.1 Abutment & Pier M25 M35

1.2 Bed block M35 M35

1.3 Deck slab M35 M35

2.0 Height (m) 10.75 12.413 13.542 16.842 14.084 13.901 13.901

2.1 Bed block size (m) 7.85 × 2 × 1.3 7.80 × 3.7 × 2

3.2 Concrete Cube Testing

# Description of item A-1 & A-2 Piers Bed Block

1 Grade of concrete M25 M35 M35
2 Total concrete quantity (m3) 2254 1914 378
3 No. of sample required 48 42 35
4 No of sample tested 159 193 35
5 Required strength (N/mm2) > 29 > 39 > 39
6 No. of sample failed Nil Nil Nil

3.3 Permeability Test (IRC Concrete Bridge Code – 1997)

# Particulars Value
1.0 Test Procedure

1.1 Sample Size Diameter: 200 mm, Height: 120 mm.

1.2 Pressure application 1 bar for 0 – 48 Hr, 3 bar for 48 – 72 Hr, 7 bar for 72 – 96 Hr

2.0 Limit < 25 mm as per IRC CBC para 5.4.2.1

3.0 Results for bed block A1 P1 P2 P3 P4 P5 A2

(M35)
13 16.67 17 16.67 15.67 19 16.67
4. Bearing:

4.1 General

 Type: Elastomeric Bearing

 Drawing number: RDSO/B-10273
 Size: 640 mm × 460 mm × 90mm
 Supplier: Polymer Products, Navi Mumbai (RDSO approved vendor)

4.2 Laboratory Tests (As per UIC 772-2R:1989& ISO 6446:1994)

# Particulars Permissible limit Field Results

Hardness test 60
1. 60 ±5
(IRHD)
Tensile strength 20.74
2. 17 (Min)
(MPa)
Elongation at Break 550%
3. 400% (Min)
(%)
Adhesion strength 13.29
4. 7 (Min)
(kN/m)
Shear Modulus (G) 8.16 ± 15% 8.19
5.
(kg/ cm2) (6.936 to 9.384)

4.3 Reduced Top Level of Pedestal

Span Levels (m) Remarks

A1 P1
A1 -P1 L R L R
365.793 365.793 365.792 365.792
P1 P2
P1- P2 L R L R
365.792 365.792 365.794 365.794
P2 P3 Reduced level of
P2- P3 L R L R pedestal top is
within permissible
365.793 365.793 365.791 365.791
tolerance ± 5mm,
P3 P4 as per para 6.5 of
P3- P4 L R L R IRS Concrete
365.792 365.792 365.792 365.792 Bridge Code.
P4 P5
P4- P5 L R L R
365.792 365.792 365.794 365.794
P5 A2
P5- A2 L R L R
365.793 365.793 365.792 365.792
4.3 Field Observations

Flattening of Elastomers Nil

Separation of Layers of Elastomer Nil

Splitting of layers of Elastomer Nil

Tearing of layers of Elastomer Nil

Bulging of Elastomer Nil

Tilt in Elastomeric Bearing Nil

Any corner lifting No

5. Girders

5.1 General

Drawing Number RDSO/B-10273

Weight of girder 529.17 kN

Depth of girder 1.850 m

Concrete used M-45

Span load test &

Tests done
Permeability test

5.2 Pre-Stressing Details

5.21 HTS wire details

Particulars Permissible range Obtained value

Diameter 12.55 – 13.36 12.87 – 12.91

(mm)
Modules of Elasticity 185 – 205 199 – 201
(kN/mm2)
Breaking load 183.700 192 – 194.7
(kN)
Manufacturer: M/S USHA Martin. Ranchi, Jharkhand

5.22 Elongation details:

Permitted Elongation (mm) Actual Elongation

Cable Force
(Considering area & elastic (mm)
No (kN)
modulus correction)

1 2617.73 64.33 – 71.90 64.63 – 67.87

2 2617.73 64.55 – 71.86 64.90 – 70.00

3 2617.73 64.33 – 71.10 64.81 – 69.13

4 2204.40 64.31 – 71.07 66.00 – 68.20

Note:
 Jack Efficiency: 1st stage: 98.84%, 2nd stage: 99.22%
 Ram Area: 1st stage: 1058.94 cm2, 2nd stage: 563.72 cm2
5.3 Camber

Span/Girder A1-P1 P1-P2 P2-P3 P3-P4 P4-P5 P5-A2

LHS RHS LHS RHS LHS RHS LHS RHS LHS RHS LHS RHS
(after)
Launching 11 7 6 4 5.5 9.5 4 6 3 5.5 11 6

Deck slab
7.5 4 3 1.5 2 6 1.5 2.5 1 2 7.5 3
casting
2nd stage
13.5 12.5 11 9.5 11 14.5 9.5 11 8.5 10 16.5 11
stressing
Track laying 11.5 10 9 6.5 8 12.5 6.5 9 5 8 14.5 8

5.4 Eccentricity of Track wrt Girder

Span A1-P1 P1-P2 P2-P3 P3-P4 P4-P5 P5-A2

End A1 P1 P1 P2 P2 P3 P3 P4 P4 P5 P5 A2
Eccentricity
10 10 5 15 10 15 10 0 0 0 20 5
(mm)

5.4 Span Load Test

Test Load EUDL

437
(MT)
Deflection at L/2
4.54
(mm)
Design EUDL
334
(MT)
Limit as per IRCBC
5.972
(mm)

 The test conducted by M/s Shrirang Pande, NGP

 Concrete blocks used for loading purpose.
5.5 Concrete Testing:

5.51 Standard Deviation:

Grade of Feb – Apr Jan – Feb Feb – Mar Mar – May May – Jul
Concrete 2022 2022 2021 2021 2020
M15 0.95 0.88 0.70 0.84 -
M20 - - 1.5 0.92 1.15
M25 - 3.01 1.88 - 1.52
M30 - - - 2.38 -
M35 3.05 3.54 3.38 3.13 3.16
M45 - - - - 4.35

5.52 Cube Testing:

# Description of item Girder Deck Slab

1 Grade of concrete M45 M35
2 Total concrete quantity (m3) 282 186
3 No. of sample required 36 24
4 No of sample tested 36 24
5 Required strength (N/mm2) > 49 > 39
6 No. of sample failed Nil Nil

5.53 Permeability Test

# Particulars Value

1.0 Test Procedure

1.1 Sample Size Diameter: 200 mm, Height: 120 mm.

1.2 Pressure application 1 bar for 0 – 48 Hr, 3 bar for 48 – 72 Hr, 7 bar for 72 – 96 Hr

2.0 Limit < 25 mm as per IRC CBC para 5.4.2.1

3.0 Results in mm for Girders (M45)

A1-P1 P1-P2 P2-P3 P3-P4 P4-P5 P5-A2

LHS RHS LHS RHS LHS RHS LHS RHS LHS RHS LHS RHS

16.33 12 8.33 11.33 13 15 14.33 17 13 13.33 10 8.67

4.0 Results in mm for Deck Slab (M35)

A1-P1 P1-P2 P2-P3 P3-P4 P4-P5 P5-A2

12.33 11.67 16.67 16.33 14.67 15.33