SSGTPL/Q&M/F/016

Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

Method Statement
For Implementation of
Pre-stressing work 4 Lane Flyover at
Bachupally Package-1

Client : Hyderabad Metropolitan Development Authority ( HMDA)

PMC : K&J Projects Pvt Ltd.
Contractor : CIPPL-VEDPL-RNC JV
PT Agency : M/s Stresza Systems Global Tech Pvt Ltd.

Prepared BY Checked: Approved Date Issue Revision

07-10-2023 First 0
PC BVN

Stresza global tech pvt ltd

Plot 31, 4-69-26
Lawsons Bay colony,
Visakhapatnam – 530017
Call: + 91 8135855815
Email: info@streszasystems.in;
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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

Contents:

1) Purpose
2) Scope
3) Tools & Equipment
4) Materials (Prestressing steel & Specifications)
5) Prestressing Equipment & specification
6) LRPC strand cutting and record
7) Stressing Operation
8) Grouting Operation
9) Records

1) Purpose:
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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

The purpose of this document is to define the equipment, materials and methods for installation, stressing
and grouting of prestressing tendons. The objective of this document is to follow the proper
methodology and to perform in accordance to approved drawing sequence and codes of practice.]

2) Scope:
This procedure is developed for application in the scope of work and applies to anchorage,
strands, and wedges installation for the longitudinal post tension works.

3) Tools and Equipment

All tools and equipment for task shall be in a safe condition and fit for its purpose. Wherever
applicable, registration paper and certifications are to be produced.
At the start of each shift, equipment shall be visually checked for mechanical and structural
soundness. All equipment shall be carefully examined and all hoses and coupling checked for
leaks and general condition.
4) Materials
Prestressing materials for the PSC Girder work

 LRPC Strands 12.90 mm dia as per IS 14268 CL II

Anchorage Strand d As Ms fpk Fpks

type (mm) (mm2) (g/mm) (N/mm2) (kN)

19T13 12.90 100 0.775 1860 186

 Prestressing hardware & Consumable

o Bearing plates 19T13/SZM1905
o Wedges suitable 12.90 dia strands.
o Cement,
o Potable Water
o Admixture
LRPC Strands: HT Strands of 12.90 mm dia encased by plain HDPE pipes in free lengths
and grout bonded in fixed lengths

Technical Data Sheet: HT Strands

The Pre-stressing strand shall be formed 12.90 mm dia uncoated 7 wire Low Relaxation HT
strand conforming to IS 14268 – 1995. Relevant specifications of the strands are as follows:
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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

TECHNICAL DATA SHEET FOR 7- PLY CLASS - II Ø 15.2 mm LRPC STRAND

IS:14268/1995 (Latest)

SL NO DESCRIPTION 15.2 mm (CLASS - II)

1 Name of manufacturer TATA/DP/UM
2 Name of local agent 
3 Type of prestressing Wire Low Relaxation
4 Nominal Diameter in mm 15.2
5 Nominal cross-sectional area (mm2) 140.0
6 Nominal Weight (gm/m) 1102
Variation of Diameter(mm) (+ 0.66) , ( - 0.15)
7 Variation cross-sectional area (mm2) (+ 4.0%) , (- 2.0%)
Variation of Weight (gm/m) (+ 4.0%) , (- 2.0%)
8 Lay Direction/Lay Length LH or RH , 12D - 16D
Chemical composition :
i> Carbon 0.60-0.90
ii> Silicon 0.10 -0.35
9
iii> Manganese 0.50 -0.90
iv> Sulfur 0.04 Max
v> Phosphorus 0.04 Max
10 Modulus of Elasticity(kN/mm2) 195 (±10)
11 Coefficient of linear expansion/degree centigrade 11.5 X 10 -6
12 Tensile Strength(N/mm2) 188.8~209.10
13 Load at 1.0 % elongation(kN) 239.3
14 Tensile load (kN) 260.7
15 Elongation (%) Min 3.5
16 % Relaxation Value after 1000 Hrs at 70% of MBL Max 2.5
17 Wire Surface Smooth
18 Coil
i>Internal diameter of coil(cm) Min 90
ii> Length of Wire per coil (m) 2900 - 3500
iii> Width of coil (cm) Min 75
iv> Weight of wire per coil (kg) 2350-3700

Grouting Material and Admixture

The cement to be used for grouting is OPC obtained from approved manufacturer / supplier.

The admixture if required will be used. It is free of Alumina and is a plasticizer and a retarding
agent having the following properties.
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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

( ANY MAKE)

CEBEX-100 (or) Equivalent

5. Prestressing equipment and specification

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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

Model type STRESZA 425Ton/ 150MM

Suitable for stressing 12T13, 19T13, 12&15, 19T15 and 22T15 system
Effective Ram Area of Jack: 659.75 Sq-cm

Capacity 425 Tons, Wedge Lock off pressure: 100 Kg/sq-cm

Injection Grout Plant

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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

Model – SDDGP 150 LITR

Type – Screw pump power driven 3Ph
Capacity – - 0- 15 Kg/sq-cm 10 Liter/ min
Mixing capacity in Agitator -2 Bags
Dimensions – 3 m x 2m x 1.50 m

6. LRPC strand cutting register

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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

Site team will maintain the following register to identify the LRPC strands
coil wise consumption into the tendon ducts. (Sample only)

Installation of strands Bearings plates and wedges & equipment

Once the curing period is compete the tendon duct are inspected for freeness and the strands
are threaded, Anchor heads are assembled on both sides and to the same by securing strands
with live wedges.

Check list for installation

 Make sure the tendon duct is free from any blockage
 Grip length sufficient kept at stressing end and non-stressing end
 Safe access to the work place
 Safe stressing equipment handling gantry/ beam stand
 Power connections checked
 Bearing plates and wedges neatly cleaned and installed
 Tools and necessary tackles in place
 WARNING sign (STRESSNG OPERATION IN PROGRESS-ONLY AUTHORISED
PERSONNEL ENTRY) board displayed. Barricade provided
 Functioning of equipment/ Power control checked
 Calibration reports, elongation revised list, stressing report forms

STRESSING SEQUENCE/ DETAIL: REFER GENERAL ARRANGEMENT DRAWING

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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

Sequence of stressing: Numerical order of tendon

System of Stressing: 19T13
Span A1-P8 & P12-A2
Number of Strand and jacking force, elongation

Tendon Number Number of strands Jacking Force Elongation

(KN) (mm)
1 14 Strands 1954 204.0
2 14 Strands 1954 204.0
3 19 Strands 2650 203.50
4 19 Strands 2650 203.50

Type of Jacks: Stresza/425 – (425-ton capacity, 150 mm stroke)

Effective Ram Area of Jack :659.75 Sq.-cm
Efficiency of Jack: 97.22 % (Assumed)
Stress calculations:
Tendon 1 &2 : Jacking Force = 19542KN
= 1954000N
= 1954000/9.81
= 199184.50Kg
Pressure = F/A =199184.50/659.75Kg/Cm2
= 301.90 Kg/Cm2
Apply efficiency = 301.90 /97.22%
= 310.53 Kg/Cm2
Say =310kg/Cm2
Tolerance force: + 5% - 5%
326.05 Kg/cm2 294.5 Kg/cm2
Tendon 3&4 : Jacking Force = 2650KN
= 2650000N
= 2650000/9.81
= 278583.07kg
Pressure = F/A =270132.51/659.75Kg/Cm2
= 409.44 Kg/Cm2
Apply efficiency = 409.44/97.22%
= 421.15
Say =421kg/Cm2
Tolerance force: + 5% - 5%
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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

442 Kg/cm2 399.95 Kg/cm2

Elongation calculations ( Coil no : B696390090 ) values taken EXAMPLE )

Example
Theoretical Area = 100 mm2
Actual Area = 99.86mm2
Theoretical Modulus of Elasticity = 1.95*105 N/mm2
Actual Modulus of Elasticity = 194600 N/mm2
NOTE: as per drawing take 7.35mm /m of gap length
Tendon C1 & C2 :
Design Elongation = 204mm +Grip length elongation
= 204+6 (Given in Dawning)
=210 mm

Design Elongation∗Theoretical A∗Theoretical E

Modified elongation =
Actual A∗Actual E

210∗100∗195000
=
99.86∗194600

=210.72mm
(+5%) = 221.26mm (-5%) = 200.18mm
Tendon C3 & C4 :
Design Elongation = 203.5mm +Grip length elongation
= 203.5 + 6 (Given in Dawning)
=209.5 mm
Design Elon gation∗Theoretical A∗Theoretical E
Modified elongation =
Actual A∗Actual E

209.5∗100∗195000
=
99.86∗194600

=210.22mm
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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

(+5%) = 220.73mm (-5%) = 199.70mm

7. Stressing Operation:

1. LRPC Strands installation done with grip length checks.

2. Followed by bearing plates wedges installation.
3. Multi strand jack will be fixed at the one end and stressed to design force.

a) If the Required elongation is not achieved According to the design then,

stressing will be done in two stages.
b) operation elongation of tendon shall be simultaneously both ends and the
elongations to be noted at intervals of 50, 100, 150 and 200, 240 Kg/Sq.cm
until the final pressure is achieved.
c) Measurement of elongation is done as per PTI ( Post Tension Institute
specification)

Courtesy: PTI Terminology, Tech Advisory board

Method of measuring elongation during stressing operation using neat visible steel rule from
a fixed jack ram location. Clamp shown is (Optional)
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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

d) Once the desired force is applied and the elongation observed were found
within the specified tolerances then the tendon will be locked and the ram
will be retracted.
e) After removal of jack a mark will be done on strands at distance of 100 mm
at the both ends of the tendon to observe 24 hours slippage observations
purposes and – for any further wedge draw-in is occurred.

4. Once the stressing of tendons is completed, strands are cut & the tendon prepared for
grouting.

Conclusion and correctness of stressing operation:

o Correctness of stressing operation is derived from the force applied Vs

elongation achieved. This phenomenon observed by the stressing
supervisor and makes a conclusion that tendon behavior with respect to
force and elongation relationship is linear.
o Achieved elongation are within specified limits as indicated in the
approved drawings.
8. Grouting Operation
 Grouting should be performed as soon as the stressing operation is complete
 The Grout material (Apple chem & Sika ) are using as per approved.
 Grout vents are provided at anchorages for each cable.
 Grout caps will be fixed on both sides of tendon-anchor heads and tightly secured.
 After the anchorage has been capped the tendon shall be water flushed through the grout hole
which projects from the top of the duct
 As soon as flushing is completed the grout operation shall start.
 Grout mix shall have the mix proportion of water/cement ratio as specified by the weight. The
additive admixture is mixed with cement in proportion as recommended by additive
manufacture.
 Typical proportions of grout mix are as follow.
Water cement ratio = 0.40 by weight not greater than 0.45

 Cubes 100 mm will be cast for compressive strength

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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

Setting: Grout samples shall be collected and tests to be carried for

compressive strength at 7 days and 28 days and the results should satisfy 17 N/mm 2
and 27 N/mm2 respectively.

 After completion of grouting the projected portion of grout vent shall be cut flat to the girder
edges level by means of abrasive disc.

9. RECORDS:
Check list before placing concrete
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Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

Check list with tendon checks and before concrete placing

Road Widening between Bachupally to Mallampet up to Bourampet S ervice

Road at ORR and Additional Interchange to ORR Road between Exit No.4
and Exit No.5 at mallampet P ackage-1 (From Km 0.000 to Km 2.430)

Format No : S S GTP L/Q&M/F/ 001

Client Hyderabad Metropolitan Development Authority ( HMDA)
P MC K&J P rojects P vt Ltd.
Contractor CIP P L-VEDP L-RNC JV
P T Contractor M/s S tres za s ys tems Global Tech P vt Limited.

PROFILING CHECK LIS T REPORT

Location : Date :
Girder ID
Chainage : Span :
Checked
S.No Description NA Remarks
Yes

1 Vertical Alignment of Tendons

2 Horizontal Alignment of Tendons

3 Form work Alignment

4 Bursting Links fixed as per Drawings

5 Number of Tendons as per Drawings

6 Proper sealing of all joints(ducts & anchors)

7 Grout INLET and OUTLET provided / vents

8 Dummy pipe inserted during concrete

9 Safe access provided

SSGTPL Contractor Consultants Client

Name

Signature

Date

Stressing Record Form

The stressing record form would be used during the process of stressing:
 SSGTPL/Q&M/F/016
Prestressing work Method statement 4 lane Flyover at Bacupally Package-1

Road Widening between Bachupally to Mallampet up to Bourampet S ervice

Road at ORR and Additional Interchange to ORR Road between Exit No.4
and Exit No.5 at mallampet P ackage-1 (From Km 0.000 to Km 2.430)

Format No : S S GTP L/Q&M/F/ 003

Client Hyderabad Metropolitan Development Authority ( HMDA)
P MC K&J P rojects P vt Ltd.
Contractor CIP P L-VEDP L-RNC JV
P T Contractor M/s S tres za s ys tems Global Tech P vt Limited.

S TRES S ING REPORT

Span no : Cable No : Girde r Numbe r:

Dat e o f Cab le Ins t allat io n:
STRESSING EQUIPMENT
2
Type o f Jack:CDC425To n *200 mm Stro ck Ram are a o f Jack(cm ): 659.75Sq cm
Jack SI numbe r: Po we r pack Sl numbe r:

Pre s s ure gauge no :

CALCULATION
2
Mo difie d Pre s s ure (Kg/ cm ) Max: Min:
Mo difie d Elo ngatio n (mm) at e ach e nd Max : Min:
St re s s ing re c o rd
Sid e A Sid e B
Pre s s ure applie d Ne t Cumulative Ram Ne t Cumulative
2 Ram re ading Re marks
Kg/ Cm Elo ngatio n Elo ngatio n re ading Elo ngatio n Elo ngatio n
mm
mm mm mm mm mm

SSGTPL Contractor Consultant Client

Grouting Record Form

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The grouting record form would be used during the process of grouting.

Road Widening between Bachupally to Mallampet up to Bourampet S ervice

Road at ORR and Additional Interchange to ORR Road between Exit No.4
and Exit No.5 at mallampet P ackage-1 (From Km 0.000 to Km 2.430)

Format No :S S GTP L/Q&M/F/004

Client Hyderabad Metropolitan Development Authority ( HMDA)
P MC K&J P rojects P vt Ltd.
Contractor CIP P L-VEDP L-RNC JV
P T Contractor M/s S tres za s ys tems Global Tech P vt Limited.

GROUTING REPORT
Location : Date :
P roject :
S pan No: RFI No:
Chainage :
Type of cement : 53 grade
Week & Year cement manufacture:
Admixture if added/,ix details : cebex-200
W/C ratio : 0.40
P re Grouting checks : cap Checking
Anchorage s urface Inlet Yes No Yes No's
Blot holes & clear Vents Yes No Yes No

TENDON NO. S TART TIME FINIS H TIME REMARKS / OBS ERVATION

SSGTPL Contractor Consultant Client