CONCRETE BRIDGE

CODE
Reprint-2014
Corrected up to CS no. 3
VINEET GUPTA
SPB-1
 APPLICABLE TO:

- USE OF PCC, RCC & PSC IN RLY. BRIDGE

CONSTRUCTION.

- ROAD BRIDGE – IRC

TERMINOLOGY – AS PER IS 4845 & IS 6461.

 SCOPE
• 4 MATERIALS
• 5. CONCRETE
• 6. FALSEWORK AND FORM WORK
• 7. REINFORCEMENT & PRESTRESSING
TENDONS
• 8.TRANSPORTATION, PLACEMENT,
COMPACTION & CURING OF CONCRETE
• 9.GROUTING OF PRESTRESSING CABLE
 SCOPE
• 10.LIMIT STATE REQUIREMENTS
• 11. LOADS, LOAD COMBINATIONS AND
PARTIAL LOAD FACTORS
• 12. CHARACTERSTIC STRENGTHS AND PARTIAL
SAFETY FACTORS FOR MATERIALS
• 13. ANALYSIS OF STRUCTURE AND SECTION
• 14. PLAIN CONCRETE WALLS
• 15. DESIGN AND DETAILING: REINFORCEMENT
CONCRETE
 SCOPE
• 16.DESIGN AND DETAILING: PRESTRESSED
CONCRETE
• 17. DESIGN AND DETAILING: PRECAST AND
COMPOSITE CONSTRUCTION
• 18. LOAD TESTING
 SCOPE
• Materials
• Grades of concrete and basic design
values
• Production and placement of concrete
• Limit state requirements, load
combinations
• RCC design
• PSC design
• Quality check of materials
 FEW DEFINITIONS
• CAMBER – INTENTIONAL INITIAL CURVATURE
GIVEN TO A MEMBER TO COMPENSATE
DEFLECTION UNDER LOAD
• COLD JOINT- JOINT OR DISCONTINUITY
FORMED DUE TO HARDENING OF CONCRETE
BEFORE NEXT BATCH IS PLACED
• COMPOSITE CONSTRUCTION – CONSTRUCTION
MADE UP OF DIFFERENT MATERIALS
• CRACKING LOAD – TOTAL LOAD CAUSING
FIRST VISIBLE CRACK
 FEW DEFINITIONS
• CREEP IN CONC. – PROGRESSIVE INCREASE IN
PLASTIC DEFORMATION UNDER SUSTAINED
LOADING
• CREEP IN STEEL- PROGRESSIVE DECREASE OF
STRESS AT CONSTANT STRAIN
• BLEEDING – AUTOGENEOUS FLOW OF MIXING
WATER WITHIN OR ITS EMERGENCE FROM NEWLY
PLACED CONC.-DUE TO SETTLEMENT OF SOLID
MATERIAL OR DRAINAGE OF MIXING WATER
• SEGREGATION- DIFF. CONCENTRATION OF
CONSTITUENTS OF MIXED CONC.
 MATERIAL
• Cement
– 33 Grade OPC IS:269
– 43 Grade OPC IS: 8112
– 53 Grade OPC IS:12269
– Rapid hardening PC IS : 8041
– High Strength PC IRS: T-40
– Portland Slag cement IS:455
– Portland Pozzolona Cement IS:1489
– Sulphate resistance cement IS: 12330
 MATERIAL - CEMENT

• Mixing of 50% blast furnace slag not permitted at site.

CE may permit in special circumstances.

• Portland Pozzolana Cement shall not be used for PSC

Works.
– Can be used in RCC with 14 days damp curing and removal of
formwork after 75% strength gain

• Rate of development of strength in blended cement to be

taken care of in stages of PSC, curing and formwork
removal

• Compatibility of admixtures to be ascertained by trials

 SIZE OF AGGREGATE
• ≤ ¼ OF MIN THICKNESS OF MEMBER
• LESSER OF
– 5 mm LESS THAN THE MIN CLEAR DISTANCE
BETWEEN MAIN BARS
– 5 mm LESS THAN THE CLEAR COVER
• NOMINAL SIZE 20 mm
• SPECIAL CASES MAX 40 mm
• (MARINE AGG. TO BE WASHED BEFORE
USING)
 MATERIAL - WATER

• pH VALUE – 6 TO 8
• NOT LESS THAN 6
• NORMALLY POTABLE WATER IS GOOD
ENOUGH
 ADMIXTURES
• SHOULD NOT ADVERSELY AFFET
– STRENGTH
– VOLUME CHANGE
– DURABILITY
• SHOULD NOT HAVE ANY DELETERIOUS
EFFECT ON REINFORCEMENT
• CaCl2, containing CaCl2, Cl & SO3 ion, Nitrates
&Thiocynate based NOT TO BE USED
 CHLORIDE CONTENT
• Coarse Aggregate Max. 0.02%
• Fine Aggregate Max. 0.04%
• Water Max. 50 mg/l for PSC
• Cement Max. 0.06% PSC and
severe
• Total Max 2000mg/l for Plain CONC
• 1000 mg/l for RCC
• 500 mg/l for PSC
 CONCRETE

• Concrete shall be in grades as

designated in table 2

• The characteristics strength is

defined as strength of material below
which not more than 5% of the test
results expected to fail
 TABLE 2
SPECIFIED CHARACTRISTIC
GRADE DESIGNATION COMPRESSIVE STRENGTH
AT 28 DAYS N/mm2
M 20 20
M 25 25
M 30 30
M 35 35
M 40 40
M 45 45
M 50 50
M 55 55
M 60 60
 CONC.- ELASTIC DEFORMATION
• MODULUS OF ELASTICITY – INFLUENCED BY
– ELASTIC PROPERTIES OF AGREGATE
– CONDITION OF CURING
– AGE OF CONCRETE
– TYPE OF CEMENT
– Normally related to compressive strength of concrete
– In absence of data, value may be taken from para
5.2.2.1

• SHRINKAGE – DEPENDS ON
– CONSITUENTS OF CONCRETE
– SIZE OF MEMBER
– ENVIORNMENTAL CONDITIONS
– MOST INFLUENCED BY TOTAL AMOUNT OF WATER AT THE TIME OF
MIXING
• TOTAL SHRINKAGE STRAIN – 0.0003
 CREEP
• DEPENDS ON FACTORS AFFECTING SHRINKAGE +
– STRESS IN CONCRETE
– AGE AT LOADING
– DURATION OF LOADING
• TILL STRESS IN CONC. ≤ ⅓ fck -
– CREEP ∞ STRESS
• 50% OF CREEP TAKES PLACE IN FIRST MONTH OF
LOADING
• 75% OF TOTAL CREEP TAKES PLACE IN THE FIRST 6
MONTH OF LOADING
• Creep in concrete be taken as 43x10-6 per N/mm2
of stress at the centriod of prestressing steel for
PSC
 THERMAL EXPANSION
• COEFFICIENT OF THERMAL EXPANSION
DEPENDS ON-
– NATURE OF CEMENT
– AGGREGATE
– CEMENT CONTENT
– RELATIVE HUMIDITY
– SIZE OF SECTION
• Value for different types of aggregate may be
taken from para 5.2.5
 CONCRETE - WORKABILITY

• WORKABILITY – ADEQUATE FOR

PLACEMENT AND COMPACTION

• MEASURED BY SLUMP
 CONCRETE- DURABILITY
• DEPENDS ON RESISTANCE TO
DETERIORATION AND ENVIORNMENT
• RESISTANCE TO WEATHERING,
CHEMICAL ATTACK, ABRASION, FROST
AND FIRE
• SUSCEPTIBILITY TO CORROSION-
COVER PROVIDED, PERMEABILITY
GENERAL ENVIRONMENT
• Moderate: sheltered from severe rain or
freezing whilst wet concrete exposed to
condensation. In contact with non
aggressive soil/ground water
• Severe: exposed to severe rain or alternate
wetting and drying or occasional freezing or
severe condensation. Exposed to
aggressive sub-soil water or coastal
environment
• Extreme: exposed to sea water, corrosive
fumes, abrasive action, surfaces of
members in tidal zone.
 REQUIREMENTS – BASED ON
ENVIORNMENT
– Maximum water cement ratio
• Moderate PCC 0.50 RCC 0.45 PSC 0.40
• Severe PCC 0.45 RCC 0.40 PSC 0.40
• Extreme PCC 0.40 RCC 0.35 PSC 0.35
– Minimum grade of concrete ( PSC and Imp)
• Moderate PCC M-25 RCC M-30 PSC M-35
• Severe PCC M-30 RCC M-35 PSC M-40
• Extreme PCC M-35 RCC M-40 PSC M-45
– Minimum grade of concrete ( other and sub.
Str)
• Moderate PCC M-15 RCC M-20
• Severe PCC M-20 RCC M-25
• Extreme PCC M-25 RCC M-30
– Minimum Cement Content (Kg/m3)
• Moderate PCC 240 RCC 300 PSC 400
• Severe PCC 250 RCC 350 PSC 430
• Extreme PCC 300 RCC 400 PSC 440

– Maximum cement content should be

limited to 500 Kg/m3
– Minimum Cover in MM

• Moderate Slab 25 Beam 35 Col 50 Found 50

• Severe Slab 35 Beam 50 Col 75 Found 75
• Extreme Slab 50 Beam 60 Col 75 Found 75
 PERMEABILITY TEST
• Permeability test is mandatory for
– All RCC/PSC bridges under severe and
extreme environment
– All major bridges in moderate
environment
• Depth of penetration not to exceed
25 mm when tested as per standard
procedure
 PERMEABILITY TEST
• Test specimen is of 200 mm dia and 120
mm thick shall be used

• After 24 hours of casting of specimen,

central circular area of 100mm diameter is
roughened with a wire brush on the side on
which the water pressure is to be applied.

• The unroughened part of the side of the test

specimen which is subjected to water
pressure is to be sealed with two coats of
cement water paste (W/C =0.4)
 PERMEABILITY TEST
• After 28 days of curing at first, a
pressure of 1 bar is applied for 48
hours, then 3 bar for 24 hours and 7
bar for 24 hours.

• Sample is broken and depth of water

penetration is measured
PERMEABILITY TEST APPARATUS
 CONCRETE MIX
– By designing the concrete mix, such
concrete called ‘ Design Mix Concrete ’
IS:10262 may be followed for mix
design
– By adopting nominal concrete mix, such
concrete shall be called ‘ Nominal mix
concrete ’ . Applicable for M-15, M-20
only.
 CONCRETE MIXING
• MECHNICAL MIXING
• UNIFORM IN THE DISTRIBUTION OF
MATERIAL IN THE MASS
• UNIFORM IN COLOUR AND CONSISTENCY
• MIXING TIME
– 1.5 TO 2 MIN FOR NORMAL MIXER
– 45 TO 60 SECONDS FOR HIGH RATED BATCHING
PLANTS
 RMC
• IS 4926
• EFFECT OF TRANSPORTATION- REDUCTION IN
WORKABILITY
• ADMIXTURE - LIKE WATER REDUCING
AGENT/RETARDERS
• RETANKERING NOT PERMITTED
• TIME PERIOD FOR DELIVERY
– 1½ HRS WHEN TEMP > 20°C
– 2 HRS WHEN TEMP ≤ 20°C
– MILLER ROTATION – 2 TO 6 REV/MIN
 FALSE WORK & FORM WORK

• FINISHING-
– NO SURFACE FINISH TO BE PROVIDED
– MINOR DEFECTS- SURFACE TO BE
RENDERED
– PRIOR APPROVAL OF ENGR FOR
RECTIFICATION
 TOLERANCE FOR FINISHED
CONCRETE
SHIFT FROM ALIGNMENT ± 25 mm
DEVIATION FROM PLUMB/BATTER
PIER 1 IN 150 MAX 0.05 X LEAST LAT. DIM
ABUTMENT 1 IN 125
CROSS SECTIONAL DIMENSION -5 mm + 20 mm
PLAN DIM OF FOOTING + 50 mm - 25 mm
THICKNES OF FOOTING + NO LIMIT - 5
FOOTING ECCENTRICITY 0.02 X WIDTH, NOT MORE THAN 50
mm
C/C DIST OF PIER & ABUTMENT ± 30 mm
C/C DIST OF BEARINGS ALONG SPAN ± 5 mm
 REINFORCEMENT AND
PRESTRESSING TENDONS
• BENT REBARS SHOULD NOT BE REBENT AT
THE SAME LOCATION
• COLD BENDING
• NO TACK WELDING
• 1.6 MM DIA G I BINDING WIRE – FREE ENDS
BENT INSIDE
• TOLERANCE FOR PLACING REBARS
– OVERALL DEPTH ≤ 200 MM - ± 10 MM
– OVERALL DEPTH > 200 MM - ± 15 MM
 WELDED JOINTS IN REINFORCEMENT

• MAY BE USED WITH ENGR’S APPROVAL

• TESTS TO PROVE STRENGH
• IF PROVIDED
– NOT NEAR BENDS
– STAGGERED
– IN LOW STRESS REGION
 MECHANICAL JOINTS

• WITH ENGR’S APPROVAL

• SCREWED COUPLING
• BOTTLE NUTS
• OTHER PATENTED SYSTEMS
 PRESTRESSING TENDONS

• BENDING/STRAIGHTENING – NO HEATING
• CUTTING – MECHANICAL CUTTER
• HTS BARS MY BE JOINED BY COUPLING
• WELDING NOT PERMITTED
• PLACING TOLERENCE - ± 5 MM
 STRESSING
• ALL WIRES/STRANDS IN A TENDON TO BE
STRESSED SIMULTENEOUSLY
• SLACK TO BE REMOVED BY SMALL INITIAL
TENSION
• PRESTRESSING FORCE – MEASURED BY-
– GAUGES
– EXTENSION – STRESS-STRAIN CURVE
• TWO SHALL BE WITHIN ± 5%
 TRANSPORT, PLACEMENT ,
COMPACTION & CURING
• COVER BLOCKS OF SAME STRENGTH
• COMPACTION WITH VIBRATOR
• PSC – FORM VIBRATOR
• CURING –
– MOIST – 14 DAYS
– CURING COMPOUND – ALONGWITH STRIPPING
– STEAM CURING- 18 HRS CURING CYCLE
• RATE OF TEMP RISE – 22-33°C PER HR
• RAPID TEMP CHANGE TO BE AVOIDED
 SAMPLING AND TESTING
• SAMPLING AS PER IS 1199, TESTING- IS 516
• FREQUENCY OF SAMPLING

CONC. QTY IN M3 SAMPLES

1-5 1
6-15 2
16-30 3
31-50 4
51 & ABOVE 4 + 1 FOR EVERY ADDL
50 M3 OR PART
 TESTING
• TEST STRENGTH OF A SAMPLE-AVERAGE OF
STRENGTH OF 3 SPECIMEN
• INDIVIDUAL VARIATION - ± 15% OF AVERAGE
• STANDARD DEVIATION- AT LEAST FOR 30
SAMPLES
• TO BE BROUGHT UPTO DATE
• TABLE 8 BE FOLLOWED FOR SD IF
SUFFICIENT SAMPLE RESULTS NOT
AVAILABLE
 ACCEPTANCE CRITERIA
• MEAN STRENGTH OF ANY GROUP OF FOUR
CONSECUTIVE TEST RESULTS-
COMPRESSIVE ST. FLEXURE
> fck + 3 N/mm2 > fck + 0.3 N/mm2
• INDIVIDUAL RESULTS-
COMPRESSIVE ST. FLEXURE
≥ fck - 3 N/mm2 ≥ fck - 0.3 N/mm2
• POROUS AND HONEYCOMBED CONC. IS LIABLE TO
BE REJECTED
COATING OF CONCRETE
LIMIT STATE REQUIREMENTS
• Serviceability Limit State (SLS)
– No local damage
– Crack width control in RCC, no crack in
PSC
• Ultimate Limit State (ULS)
– No collapse due to rupture, buckling or
overturning under extreme loads
– No excessive deflection
 CRACK WIDTH

• MODERATE ENVIRONMENT- 0.25 MM

• SEVERE – 0.20 MM
• EXTREME ENVIRONMENT- 0.10 MM
• PSC – NO CRACKS AS NO TENSILE
STRESS PERMITTED
 SAFETY FACTORS FOR MATERIALS

• SERVICEBILITY
• CONCRETE
– BENDING -0.50 fck FOR RCC & 0.40 fck FOR
PSC
– AXIAL COMPRESSION - 0.38 fck FOR RCC &
0.30 fck FOR PSC
• STEEL REIN. 0.75 fy

• ULTIMATE
– 1.5 FOR CONCRETE AND 1.15 FOR STEEL
SAFTY FACTORS FOR LOADS
• AS PER TABLE 12
• FOR LOAD COMBINATION 1

LOAD SLS ULS

DEAD WEIGTH OF CONCRETE 1.00 1.25
SUPERIMPOSED DEAD LOADS 1.20 2.00
EARTH PRESSURE 1.00 1.70
RELIEVING EFFECT OF EARTH - 1.00
PRESSURE
LIVE LOAD ON FOOT PATH 1.00 1.50
LIVE LOAD 1.10 1.75
 LOAD COMBINATIONS

1. PEMANENT LOADS + LIVE LOAD

2. PEMANENT LOADS + LIVE LOAD + WL
OR EQ + ERECTION
3. PEMANENT LOADS + LIVE LOAD +
RESTRAINT + ERECTION
4. PEMANENT LOADS + LIVE LOAD +
FRICTION AT BREARING
5. PEMANENT LOADS + DERAILMENT
LOADS
 IMPORTANT POINTS

• For span greater than 30m, temp.

gradient to be considered
• In analysis of a beam, axial forces can be
neglected if does not exceed 0.1 fck X
cross-sectional area
• Enhanced shear near supports
• Construction joint details in appendix A
• Form work to be designed for all forces
including pre-stressing forces
 LOAD TEST

• Not a substitute for normal design and

construction procedure
– Additional test of quality
• Mandatory?
• Number of tests?
 LOAD TEST
• To be done as soon as possible after 28 days
– Can be conducted early if quality of
concrete is not in doubt and CS has
reached
• DL + 1.25 LL
• If DL is deficient >> compensate
• To be properly supported on bearing
• Maximum load to be kept for 24 hours
• No cracks should appear
 LOAD TEST
• Measure deflection
– If < 40 L2/h mm OK
– If > 40 L2/h Remove load, measure
recovery
– If Recovery > 85 % OK
– If Recovery < 85 % Again load and measure
recovery
– If Recovery > 85 % OK otherwise
FAIL

L is effective span in meters and h overall depth in mm