SPECIFICATIONS, TESTING

AND INSTALLATION OF
NEOPRENE BEARINGS
IRC 83 (Part II)
                                              

        
 Load range & movement in
Bearings
Type of bearing Load (T) Movement
(mm)
Steel sliding plates. 20-133 25

Roller bearing 60-266 100

Elastomeric Bearing 30-220 60

Pot bearing 20-1780 No limit

 Suitability of Bearing for Steel spans
Type of bearing Bridge & Spans (m) Remarks
Both end steel plates. Plate girders 9.15, 12.2, Elastomeric on local
18.3, 24.4, 30.5 conditions

phosphor bronze Composite 9.15, 12.2, For U/S O/W - 30.5

18.3, 24.4, 30.5 (With one end fixed)

Rocker & Roller O/W through girders- 30.5, One end fixed & other
45.7(2 rollers), 61.0, 76.2 free
(4 rollers)

Rocker & Roller with oil O/W through girders more -do-
bath than 76.2

POT PTFE bearings are being used for longer spans

Suitability of Bearing for PSC spans

Type of Bridge & Spans Remarks

bearing (m)
Elastomeric I section/ BOX As per Cl. 16.9.13 of
Concrete Bridge Code,
Bearing section girders Elastomeric bearings shall
be restricted for clear spans
more than 30.5 m
POT / PTFE All PSC spans
bearing ≥ 30.5 M

Earthquake restraint shall be provided for

longer spans
 ELASTOMERIC BEARINGS
•• Elastomer
Elastomer is is aaform
formof of rubber,
rubber, a class
a class of polymeric
of polymeric
substance obtainedafterafter
substance obtained vulcanization.
vulcanization. (making(making
rubber strongerand
rubber stronger andmoremore elastic
elastic by treating
by treating with with
sulphur
sulphur at
at high
high temperature)
temperature)
•• As As aaresult
resultof of vulcanization,
vulcanization, rubber
rubber molecules
molecules are are
cross
cross linked
linked with
with sulphur,
sulphur, making
making the
the rubber
rubber stronger
stronger
•• It possesses rubber
It possesses rubber like
like properties
properties i.e.
i.e. ability
abilityto toregain
regain
shape almost
shape almost completely
completely even
even after large after large
deformations
deformations
•• These are very
These are veryflexible
flexibleininshear
shearbutbut very
very stiffstiff in bulk
in bulk
compression
compression
•• Design
Design asas per
perUIC772-2R
UIC772-2R1989 1989 and
and as as
perper
IRCIRC 83 83
 Shape Factor
• Compressive strength of the bearing
depends upon the ratio of loaded area to the
area of bearing free to bulge. This is known
as Shape Factor “S” which is a
dimensionless parameter
• Greater compressive stiffness is ,therefore,
obtained by dividing elastomer in to many
layers by introducing very thin, usually 1 to
3mm steel reinforcement plates.
 ELASTOMERIC BEARINGS
• The elastomeric bearings offer a number of
advantages as listed below:
1. Minimum maintenance- as no moving parts
2. Installation is easy
3. Permits movement in all directions
4. Occupies small space
5. Serves as a shock absorber due to anti-vibrations
properties of elastomer
6. As an aid to better management of longitudinal
forces.
 c l
c

laminate b

c
SHEAR/ TRANSLATION
ACTION
ROTATION/ BENDING ACTION
 ACTION UNDER VERTICAL
LOAD

• Vertical load gets converted to shear in the

elastomer/ laminate interface
 IMPORTANT FINDINGS BY
ORE FRANCE
• Elastomer doesn’t follow hook’s law & E
is not constant
• But G = Constant & G is more relevant
than E
• µ between elastomer & base material
unaffected by nature of contact surface
• µ reduces with increased normal
loads(N) µ=0.1+0.6/N
 IMPORTANT FINDINGS BY
ORE CONTD.
• Performance of elastomer not affected
by temp variation with in range of (-15
to +50oC)
• Under cyclic load, it becomes flexible
• Tendency to slip, when normal
pressure is less than 2MPa.
 NEOPRENE BEARINGS (912.1)

• IRC 83
– Rectangular in plan
– Internal layers shall be of equal thickness
– Bearings safeguarded against displacement by
interface friction without the aid of adhesive or
external anchoring device
– No dowel holes in elastomer/ laminate, even when
filled up subsequently
 RAW MATERIAL (915.1)
• Polychloroprene (synthetic rubber) only
shall be used (natural rubber-poly
isoprene is highly reactive with ozone
which causes surface cracks)
• Reclaimed rubber or vulcanized wastes or
natural rubber shall not be used
• Polychloroprene content>60%
• Ash content <5%
 RAW MATERIAL (915.1)
• Neoprene WRT, Bayprene 110,
Skyprene B-5 And Denka S-40V shall
be used as elastomer
• EPDM (Ethyl Propylene Dimonomer)
shall not be used
– Infrared spectrography shall be done for
polymer identification ,as per ASTM
D3677
 PROPERTIES OF ELASTOMER
(915.2)
Property Test method Value
I.S. specified
Specification
reference
1. Physical Properties :
1.1 Hardness* IS:3400(Part II) 60 + 5 IRHD
1.2 Mini. tensile strength IS:3400 17 MPa
1.3 Mini. elongation at break (Part I) 400%
2.0 Max comp. set
(comp strain of 25 % given for IS:3400 35 % of
duration 24 (+0, -2) hr & (Part X) initial
temp 100o C (+ 1o C)
 PROPERTIES OF ELASTOMER
(915.2)
Property Test method Value
I.S. specifi
Specification
ed
reference
3.0 Accelerated ageing (When it is heated for a
duration of 70 h & at temp 100 ± 1o C)

3.1 Maximum change in hardness IS:3400 (Part

IV)
+15
IRHD
3.2 Maximum change in tensile strength -15 %
3.3 Maximum change in elongation -30 %
4.0 Ozone Test There should be no
20% strain, 40o C, 50pphm ozone conc., for 96 cracking or disintegration.
hours
 PROPERTIES OF BEARINGS
(915.2, 915.3)
• Shear modulus of elastomer bearing shall
be not less than 0.80 MPA and not more
than 1.20 MPA
• Adhesion strength of elastomer to steel
plates as per IS:3400 Part XIV > 7 KN/M
• Laminated Mild Steel To IS:226 shall be
used
– Fiber glass or similar fabric shall not be used
 DIMENSIONING RULES
(916)
• Thickness of internal layers shall only be
– 8 mm, 10 mm, 12 mm or 16 mm (for special use)
• Thickness of outer layer
– ½ Of inner layer, max 6 mm
– Side cover 6 mm for all
• l0/b0≤2
• h≤b0/5 & h≥b0/10
 DIMENSIONAL TOLERANCES
(APPENDIX I)
SN ITEMS TOLERANCES
1. Overall plan dimensions -0, +6 mm
2. Total bearing thickness -0, +5%
3. Parallelism
Of top surface of bearing w. r. t. the 1 in 200
bottom surface as datum
Of one side surface w. r. t. the other as 1 in 100
datum
4. Thick. of individual internal elastomer + 20%, max of
layer 2mm
Thickness of individual outer layer -0, + 1 mm
5. Plan dimensions of laminates -3 mm, +0
Thickness of laminate + 10 %
Parallelism of laminate with respect to 1 in 100
bearing base as datum
 FABRICATION (917)
• Bearing with steel laminates shall be cast as
single unit in a mould and vulcanized under
heat and pressure
– Vulcanising equipment/ press shall be such that
between platens constant pressure/ temperature
can be maintained
• Mould shall be kept at uniform temperature and pressure
for uniform vulcanisation
 FABRICATION (917)
– All bearings shall preferably be fabricated in
one lot
– Steel plates for laminates shall be sand
blasted clean of all mill scale and
contaminants
– Rusted plates with pitting shall not be used
– Edges of plates shall be rounded
 FABRICATION (917)
– Spacers shall be used in moulds to ensure cover
and location of laminates
• Hole in surface or in edge cover shall be filled in
subsequently
– Raw material to be put in metal dies for
vulcanisation shall be weighed accurately
• Homogeneous and compact bearing
• No spongyness or deficiency of material shall be there
– Before any batch, test pieces shall be made to
monitor quality
 ACCEPTANCE (918)
• Manufacturer shall have facilities for testing
• Testing at manufacturer’s cost except under
special conditions
• Prior submittal of testing program
• Any acceptance testing delayed beyond 180
days require special approval
• Lot by lot inspection
 TESTING & ACCEPTANCE
LOT SIZE(918)
• A lot under acceptance shall comprise all bearings
including the pair of extra bearings where ever
applicable
• A lot size of 24 or larger number of bearings shall be
defined as LARGE LOT
• A lot size of less than 24 bearings shall be defined as
SMALL LOT
– When the number of bearings for a project is large and
phased production/ acceptance is permitted then number of
bearings supplied in any phase of supply shall be considered
as LARGE LOT for the purpose of testing
 LEVELS OF ACCEPTANCE
(918.3)
• LEVEL-1 acceptance testing
– For large lots only
– Two extra bearings to be manufactured,
consumed in destructive testing
• LEVEL-2 acceptance testing
– For small lots only
– No destructive testing unless otherwise
specified
 TYPES OF TESTING (918.4.1)
LEVEL 1
1. General Inspection
2. Tests On Specially Moulded Test
Piece
3. Test On Complete Bearings Or
Sections for Measurement of Various
Quality Parameters
 LEVEL-1 TESTING (918.4.1)
• General inspection
– All bearings visually inspected for defects in surface
finish, shape or any discernible defects
– All bearings checked for dimensional tolerances
– Application of an axial load equal to 15 MPA and visual
examination for
• Misalignment of laminates
• Poor bond at interface
• Variation in hi , he
• Any surface defects
• Low stiffness
 LEVEL-1 TESTING (918.4.1)
• Tests on specially moulded test piece
– Identical compounds and vulcanizing conditions as used for
bearing
• Check for
– Composition
– Hardness
– Tensile strength
– Elongation at break
– Compression set
– Accelerated ageing
– Adhesion strength
– Ozone test
 TESTS ON MOULDED PIECES
(918.4.1.2)
• For acceptance testing level 1, the
ash content and specific gravity of
specially moulded test pieces and test
bearings shall be compared
• Variation acceptable
– Specific gravity ±0.2
– Ash content ±0.5%
 TESTS ON MOULDED PIECES
(918.4.1.2)
• Ozone resistance may be waived off when the
satisfactory results of tests are available from
process control record or development test data
• Ozone test may not be insisted for bearings not
located under adverse conditions of exposure
• Process and acceptance tests for ozone by
independent testing agency shall be acceptable
 LEVEL-1 TESTING (918.4.1)
• Tests on complete bearings
– Randomly select two bearings from the lot
– These bearings shall be excluded from the lot
• Tests to be conducted
– Shear modulus
– Elastic modulus
– Adhesion strength
– Ultimate compressive strength
• Bearings are not accepted (destroyed during
test).
 LEVEL-2 ACCEPTANCE
TESTING (918.4.2)
• General inspection
• Tests on specially moulded test pieces
– Same as level 1 inspections
• Test on complete bearings
– Tests for shear modulus only on two
bearings
• These bearing shall be part of the lot accepted.
 SPECIAL TEST (918.5)
• As per special conditions or evidence
of improper process/ quality control
– Level 1 inspection for small lots
– External agency to do acceptance testing
– Tests on pieces prepared from surface/
body of test bearings instead of specially
moulded pieces.
 TESTING
• On random sample
• At room temperature
• Skilled person
• Not before 1 week after vulcanisation
• Test for finding Ec shall precede test for G if
done on same bearing
ELASTIC MODULUS TEST
 ELASTIC MODULUS TEST
1. Two bearings taken
2. Preload vertical load upto Ntest. Keep for 10
minutes and unload upto 2 MPA
3. Increase vertical load @ 0.5MPA TO 1 MPA
per minute
4. Max test load corresponds to σm= 20 MPA
5. Load and deflection shall be measured at
equal intervals (min 5)
 ELASTIC MODULUS TEST
• Deflection measured at four edges and mean
value taken
• Separate for both the bearings
6. Graph shall be plotted stress vs strain
7. Determine the slope which is ‘Ec’
8. Bearing shall not show signs of defect or
damage
SHEAR MODULUS
SHEAR MODULUS
N=5 MPA RIGID CONCRETE
SLAB (FIXED)

RIGID CONCRETE
SLAB (DEFLECTED)

2H
RIGID CONCRETE
SLAB (FIXED)
 SHEAR MODULUS
(APPENDIX 2)
1. Two test bearings
2. Preload bearings with max horizontal load,
Htest and release
3. Vertical Load Of 5 MPA shall be held constant
4. H increased gradually @ 0.05 TO 0.1 MPA
per min to Htest max horizontal
5. Load and deflection shall be measured at
equal intervals (min 5)
6. Graph shall be plotted
7. Determine the slope which is ‘G’
 STRIPPING STRENGTH

BEARINGS HELD IN RECESS TO PREVENT SLIPPAGE

 STRIPPING STRENGTH
• Cut two identical test pieces from test bearing
(already tested)
– >100 mm x 200 mm in plan
– Two opposing ends of the test piece shall be leveled at an
angle of 450.
• Ntest corresponding to σm= 4 MPA to be held constant
• Horizontal load shall be increased gradually up to
max yielding τ =3 MPA
• Check the test pieces for evidence of cracking or
peeling
ULTIMATE COMPRESSIVE
STRENGTH
 ULTIMATE COMPRESSIVE
STRENGTH
• Same arrangement as for shear test may be
there OR
• Small section not less than 100 mm x 200 mm
may be cut from test bearing
• Tested to failure between plates of testing
machine
• Rate of loading < 10 MPA per minute
• If the at failure, σm > 60 MPA, then bearing is OK
 CERTIFICATION AND
MARKING (919)
• Bearings shall be accompanied by engineers
certificate regarding acceptance.
• Information card shall accompany
– Name of manufacturer
– Date of manufacture
– Bearing dimensions
– Elastomer grade used
– Production batch no
– Acceptance lot no
– Date of testing
– Specific bridge location
– Explanation of markings.
 INSTALLATION (920)
• Bearings shall be transported and stored
carefully, avoiding damage, contamination
with oil,, dust, grease, exposure to
sunlight and weather
• Multiple bearings one after the other is not
permitted
• All bearings in one line of support shall be
of identical dimensions.
 INSTALLATION (920)
• Bearings must be placed on horizontal
surface
– Tolerance 0.2% perpendicular to load
• Proper plan position
– ±3 mm
• Concrete surface shall be free from local
irregularities
– ±1 mm
ANTI SLIP DEVICES
• Required
especially for
steel girders
where load is
less
– Bearings can
slip out under
vibrations
 MAINTENANCE (921)
• Exposed surface shall be maintained clean and
free of grease, dirt etc
• Annual inspection to see surface is free from
cracking, signs of damage, distress or
deterioration
• Arrangement for lifting of bridge deck shall be
there hence better to use bed blocks/pedestals
• Rly bridges with ballasted decks should be
provided with suitable expansion joints to
prevent ballast fouling the breathing space
 Limitations of Elastomeric
Bearings
• Ordinary elastomeric bearing can’t be
used as a fixed bearing
• Translation allowed by elastomeric
bearing is restricted by its thickness – 0.5
to 0.6 of thickness
• Thick elastomeric pads are rather
unstable
• Limit of vertical load which can be placed
safely on elastomeric pads
– It causes excessive compression & bulging.
 Maintenance Aspects
• Bulging of neoprene
• Tearing of neoprene
• Tilting of bearing
• Disintegration of bearing
• Soft bearings (excess vibrations)
 General Guidelines for
Inspection
• Shear deformation more than 50% of
height of Elastomeric Pads

• Rotation leading to off loading of an edge

• Compression more than 5% of height of

the pads