PROJECT PRESENTATION

ON
PRESTRESS GIRDER
18.30M SPAN
UNDER THE GUIDANCE OF
Sh. RAJESH KUMAR
PROF. T/I
BY
R.C.MANDAL, AXEN/C/SILAPATHAR
K.K.KUTTY, AXEN/C/PANVEL
H.K.DAS, ADEN/HQ/LUMDING
INTREGRATED COURSE NO-813
FROM-14.07.08 TO 26.09.08
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The Br.No.63(3x18.3m span) in Construction,

under the project of Bogibeel-rail-cum-road
bridge over the river Brahmaputra has great
importance in the socio-economic matters of
Upper Assam . The people of Assam along
with Arunachal Pradesh will be benefited
with a better transport system and a better
railway communication.
 Contd.
The Bogibeel bridge is designed for road
way and broad gauge railway track. The
length of the new railway line to be
constructed on the northern bank of the
river will be 18.6 km and the southern bank
will be 23.5 km. The length of Bogibeel
bridge is 4.315 km.
System Map N.F.RLY.
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 Site snap

Two span completed

*
Drawings in connection with the Bridge

The work is in progress as per Drg.No.

1 .GAD-CE/CON/Bogi/B/162/2003.
2.ASA/POST/18.3/1 For Girder
3. ASA/POST/18.3/2 For Cable profile
4.ASA/POST/18.3/3 For Reinforcement
5. ASA/POST/18.3/4 For Bearing
 Hydraulic Data of Bridge
Pre-stressed girder bridge on pile foundation-
1.LWL-103.915M
2.HFL-107.965M
3.Silt Fector-0.8
4.Design Discharge -130Cumec
5.LBL-103.563M
6.NSL-100.496M
7.Clearance Reqd.-825mm(Provided)
8.Cut off level -104.121M (Pier)
9.Cut off level- 105.221M(Abutment)
 Proposed construction
Super structure
PSC Girder bridge (I- section) Span - 3x18.30m
Sub structure:
RCC abutment and pier
Foundation :
Pile foundation
1200 mm dia bored pile 6 nos under pier and
abutment each
Depth of pile varies 25 m to 27m from cut off level
Bearing :
Elastomeric bearing 91 mm thick (630x450mm)
 Formwork
Form work was designed for :
1.Dead load of wet concrete and reinforcement
2.Self weight of form work
3.Plant and equipment including impact
4.Construction personal
5.Water proofing
Formwork was fabricated with MS plate 8 MM
thick as per standard approved drawing of girder.
As per designed screw and jack type staging were
erected to support girder formwork. Shuttering oil
was applied before casting of girder.
 Materials for construction:
Mix Design Data
Done by Assam engineering college ,Guwahati

M-30 ( For foundation and sub structure)

TMS-38.25MPA
Water cement ratio -0.40
Cement-450kg/cum
Water-176.58 kg/cum
Sand- 487.97kg/cum
Course Agg.-1224.02kg/cum
28 days cube strength 38.50 N/sq mm
40.20N/ sq mm
39.10 N/sq mm
 Mix Design Data
M-40 (For superstructure and girder)
Done by Assam Engineering College ,Guwahati ASSAM

TMS-48.25MPA
Water cement ratio -0.38
Cement-473.68kg/cum
Water-180 kg/cum
Sand- 410.18kg/cum
Coarse Agg. -1311.55kg/cum
28 days cube strength 52.15 N/ sq mm
48.31 N/ sq mm
51.24 N/ sq mm
 Reinforcement

a) Procure HYSD steel of IS 1786 - 1985

b) After receiving satisfactory test results from
laboratory, steel was used for reinforcement
purpose.
 Pre stressing steel
Uncoated stress relieved low relaxation
strand IS 12468.
Following test for strands was conducted
1. Elongation percentage
2. Cross- section area
3. Lay length
4. Yield stress
5. Breaking load
 Sheathing
Galvanized sheathing were used for duct :

Following test were conducted :

1. Load test
2. Bend test
3. Ductility test
4. Water Leakage test
 Anchorage
The anchorage device shall be capable of holding
pre stressing tendon with out more than nominal
sleep . It should be strong enough to resist force
equal to atleast breaking strength of tendon. The
anchorage should be safe and secure both
dynamic static load as well as against impact.
The anchorage shall provision for the
introduction of neat cement grout for protection
of pre stressing tendon . Anchorage for 12T13
were used in this girder. Three split wedge were
used for locking the tendon.
 Sequence of construction

Pile boring
Pile cape casting
Abutment and pier casting
Pedestal casting
Placing of bearing
Casting of PSC girder
 Casting of girder
Bed for Erecting Staging
1. Bed for erecting pipe and jack for prop
concreting was done earlier.
2. Care was taken no settlement took place.
3. Horizontal bracing was provided.
4. Bottom girder shuttering was done.

Placing of Bearings
1. Bearing was placed truly horizontal
2. Bearing was fixed on specified surface with
adhesive material.
 Placing reinforcement

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 Placing of cable duct
. After completion of reinforcement cable duct
was fixed as per design profile.
2. 75mm dia hole have been kept for cable.
3. Care should be taken during concreting no
leakage took place.
4. PVC pipe of 60 mm dia was inserted in to the
ducts and moved to and fro to prevent
setting of slurry leaked in to the duct if any
during casting of girder.
5. Side shuttering was done.
 Cable profile
Distance of cable from bottom of girder

Cable No. Dist.(mm)

Center 2m 4m 6m 8m End
1. 120 128.7 154.80 198.20 259.20 330
2. 120 141.10 204.50 310.30 458.10 630
3. 280 306.90 3876.70 522.40 711.10 930
4. 440 472.70 570.90 734.60 963.80 1230
5. 630 638.5 754.10 946.80 121.60 1530
6. 760 804.30 937.30 1159.00 1469.40 1830
Cable position
Cable position
 Concreting of girder

Mixing

Proper mixing of concrete was done to obtain

homogenous mass and uniform colour &
consistency . Mixing was done by machine mix
with weigh batchers. Mixing time was taken 2 min.
per batch of mix ( 30 revolution ).
Transportation of mix
Transportation of concrete is an important
activity in the production of concrete. The time
taken in the transit is a design parameter, as it
depends on the initial setting time as well as
requirement of workability at the destination. We
used wheel barrow four sets for transportation of
concrete mix . Concrete was carried out
continuously up to construction joint.
 Compaction
1. Bottom layer ,for haunch internal and external
vibrator was used.
2. External surface vibrator provided at haunch
after interval of 2m.
3. Needle vibrator was used for compaction.
4. Over vibration and under vibration are harmful
hence avoided.
Curing of concrete
1. Concrete was kept constantly wet for a period of
28 days.
2. Concrete surface was covered with Hessian cloth
or similar absorbent materials.
 Stressing
1. Duct was cleaned of any foreign materials using
high pressure water jet.
2. Strand cut in required length was treaded in the
duct and in anchorage
3. The anchorage was rotated so that the strand
wire become straight.
4. Jacking arrangement was made with help of
chain pulley
5. Before fixing jacks , the pressure dial gauge was
calibrated
6. Wedge and master key was fixed
 Contd.
7. Now stress was applied with incremental load
8. The designed elongation was 135.56 mm and was
measured
9. The jack pressure was also verified compatible with
elongation
10. During measuring elongation zero correction was
taken .
11. There are six cables provided in each girder,cable-
1,2,3,4,5 and 6.Cable are to stressed one by one .Each
cables are to be stressed from one end. Cable no- 1,6,4
should be stressed left end. Cable no-2,5,3 from the
right end. Here only cable no-1 and 2 stressed shown
in the chart. Balance cable will be stressed (3,4,5,6)
after casting diaphragm slab attaining full strength.
Post tensioning

View of stressing
 Grouting of cable
After one day of stressing the slip in cable was
measured and if found ok cable duct was
grouted with net cement slurry (1:1) with
grouting pump . Non shrinkage compound
(conbex 100) was mixed with cement slurry.
Cement used was fresh and sieve through 75
micron. Grouting carried out under pressure of 5
kg /sqcm maintained for 1minute. While injecting
the slurry from one end the density of slurry
coming out from other end should be same. In
similar way others cables were grouted.
- Elongation required =135.56mm
-Jack used multiple fressinet cable stretching
jack
 Observation of Cable No 1 Girder No 1
( A1P1)
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 Quality control was ensured as:

) Testing and inspection of the various materials

selected for use

) Clear and complete detailed working drawings

) Accurate stressing procedures

) Proper control of dimensions and tolerances

) Proper location of anchors

 Material testing at field

Sieve Analysis
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 Contd.
Fine aggregate
Sample taken -1000GM
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 Field Testing of Cement
(Quick assessing the quality of cement )
Date of manufacture
Because aging reduces the strength
Open the bags No lumps should be
present (Mean no setting)
Thrust your hand into the cement
There should be cool feeling (means no
heat of hydration no setting)
Pinch of cement between fingers-It
should give smooth feeling (means no
setting).
 Contd.
Handful of cement thrown on water It
should float initially before finally
settling
Take 100 gm of cement, make stiff
paste, prepare cake with sharp edges,
put on glass plate and Immerse in water
Shape shouldnt be disturbed
It should set and attain strength.
Period of storage %age of strength

Fresh 100%
3 months 80%
6 months 70%
12 months 60%
24 months 50%
 Site snap

Staging of girder under progress

 Site Snap

Measurement of
elongation and
gauge pressure