Project Profile

Post tensioning and Launching Beams in New Kallady Bridge

1) 2) 3) 4) 5) 6) Project Name: Pro-Poor Eastern Infrastructure Development Finance: Special Projects Management Unit (SPMU) L/A : SL-P87, 28th March 2006 Employer: Road Development Authority, MOP& Highways Consultant: Oriental Consultants Co., Nippon Koei Co., ECL Scope of the Work : Construction of New Kallady Bridge : L= 288.35 m Contractor: State Development & Construction Corporation (MAGA and UTRACON) Total Estimation Rs. 813,469,566 (Original Contract Amount) Rs. 1,389,500,000 (Amended Contract Amount)

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8)

T.Ranjithhumar, Project Engineer, Special Project Management Unit, RDA,Batticaloa.

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Date of Commencement 19th April 2010 Original : 8th January 2012 Amended: 31st December 2012

10) Completion Date

General Information
Bridge Type and Dimensions
Bridge Length Span Arrangement Bridge Width 288.35 m 6 x 48.05 + 0.05 m Carriageway : 3.70m x 2 = 7.40m Cycle Lane: 1.50m x 2 = 3.00m Side Walk: 1.80m x 2 = 3.60m Total 14.00m 6 Spans Simple PC Box Beam Abutments RC Reversed T Type Piers Foundation Approach Roads RC T Type Cast-in-situ RC pile D=1,200mm, (A1:D=1,500mm) 196m (Kalmunai) + 95m (Batticaloa)
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900 1645 1800 SIDE WALK

Bridge Length and Width

C 14000 1500 CYCLE LANE CARRIAGEWAY 2@3700=7400 CARRIAGEWAY 1500 CYCLE LANE 1800 SIDE WALK

Superstructure Substructure

6 x 1485 = 8910

1645

900

6 x 48.05 + 0.50 = 288.35 m

2050

Sub-structure : R/C Bored Pile Construction

y Rotary drilling and percussion type drilling machines used. y During the boring time continuous boring record to be maintained

Sub-Structure : R/C Bored Pile Construction Contd.

y The slump of the concrete is kept in the range of 150 225 mm to

ensure the concrete is smoothly flowing for the construction of piles.

y The concrete is casted by using the tremie pipe.

and level of finding hard rock to be noted.

y Socketing for the Piers and Abutment piles : 1.2 m (Similar to the

diameter of the piles)

y The sand concentration to be kept at minimum to avoid the intrusion

y Casting records should consist the volume of concrete casted, the

theoretical height filled and actual height filled. of bentonite or sand in the pile.
y Reinforcement cage is kept in the bore with careful attention, with the y The length of tremie to be removed should be decided accordingly. y At the cut-off level, either additional concrete casted and flushed for

bottom covers (150 mm preferred)

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the removal of bentonite slurry mixed concrete or hacked for further construction.
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IIustration for the comparison of theoretical and actual concrete volume

Methods to test the piles

y Pile Dynamic Analysis Test (PDA) : Load Bearing capacity of the pile

could be analyzed and the settlement also could be measured Abutment -12200kN & Pier-9500kN (1m height)
y Pile Integrity Test (PIT): Consistency of the casted concrete could be

verified from the generated wave pattern

y Cross Sonic Log Test (CSL/SLT) : Consistency of the casted

concrete could be verified

Box Girder Section Detail Super Structures Post Tensioning Beam

| 48m Box girder beam | Length of the beam > 25 m, normally post tensioning is preferred | Reinforcements provided to resist shear and torsion | Why box beam?

A. I -girders is suitable for beam length around 35 m. Longer beams are with higher self weight and bending moment. So, box section satisfies the section criteria. B. Box beams are good torsion resistant sections. Launching is easier and safer for less torsion structure.
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Data for Post-Tensioning (General Data-Kallady Bridge)

For 48 m Box beams.(Grade-50 concrete)
y Initial Pre-Stressing force per strand is 205 kN (79% of Breaking Load) y Tentative average pre-stress elongation of the cable is 350 mm y Cube strength for transfer condition is 36 N/mm2 (After 3 days) y Expected pre-camber after stressing is 21 mm upwards y Strength of cement grout to be 30 N/mm2 at 7 days y Stressing sequence C-C,B-B,D-D,A-A and E-50%,E-100% &E-

Losses

Balance 50%.

Strands Wires Details

y Nominal tensile strength y Modulus of Elasticity y Nominal steel area

1860 N/mm2 200 kN/mm2 139 mm2

All allowable loss

- 25% for Post tension - 20% for Pretension

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Mix Design Details and Strength Details

Grade 50 for 1cum. Cement-460kg Aggregate-1133 kg Sand -719kg Glenium Admix B2333220ml Water-147 kg (W/C 0.32)
From Lab records 3-days - 52 N/mm2 7-days - 57 N/mm2 28-days 58 N/mm2

Data Sheet for Post Tensioning

Elongation = FL/AE Elongation

Stress

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Grouting Test Sample Sheet Grouting

Tests to be performed
1. 2. 3. 4.

Grouting test sample sheet

Fluidity test < 25 sec Expansion test - (-1) to 5% Bleeding test < 2% (3-Hours) Casting cubes (4 4) to determine the strength as per desired to suit the construction. Normally for this kind of work 30N/mm2 in 28 days is desired.

Admixtures used
y y

Old Beams- Glenium B233 & Flow cable New Beams - STROAEG
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Total Number of Beams : 54

Current Status of Beams and Launched Beams
Yard Total Not Started In Progress Re-bar Concreted Stressed Grouted Make Up (Edge) Concrete Launched

General View (From Left Side)

Photographs

A1

48 6 54

2 0

0 2

2 0

3 4

7 0

31 0

A2 Total

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Only 5 Nos. Beams to be casted (3 Nos. in Progress out of 5 Nos.)

A2

P5

P4

P3

P2

P1

A1

Total number of beams launched from A1 side: 48 Total number of beams launched from A2 side: 6

Batticaloa Side (A2 Side)

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Kallady Side (A1 Side)

Kallady Side (A1 Side)

Batticaloa Side (A2 Side)

P2 P1

P3

P4 P5 A2

Approach Road a. Kallady Side (A1 Side)

b. Batticaloa Side (A2 Side)

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Substructure

Abutment

Capping Beam

Stem

Pile Cap

Beam Casting Works

a. Rebar Fabrication Works

b. Inner Shutter Fixing

20 Nov 2012

c. Duct Sheathes Fixing

d. Outer Shutter Fixing

e. Beam Concreting

f. Stressing Work

g. Grouting Work

h. After End makeup competed (Ready for Launching)

Beam Launching Works

DURING ASSEMBLING OF LUANCHING GIRDER

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DURING ASSEMBLING OF LUANCHING GIRDER contd.

General Data for Launching

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Lunching Girder Capacity

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Beam Launching Sequences

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Launching Equipments Progress of Launching Works

PSC Beam Casting Yard PSC Beam

A1 Abutment

P1 Pier

Rear Trolley

Platform Gantry Crane Rear Crane Front Trolley

Rear Support Launching Beam Front Crane

Front Support

Platform

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1. Loading PSC Beam on Trolley using Gantry Crane

PSC Beam Casting Yard

2. Moving PSC Beam to Front Crane using Trolley

PSC Beam Casting Yard

Platform PSC Beam PSC Beam A1 Abutment P1 Pier A1 Abutment P1 Pier Platform

Rear Trolley

Gantry Crane Front Trolley Rear Crane

Rear Support Launching Beam Front Crane

Front Support Rear Trolley Gantry Crane Front Trolley Rear Support Rear Crane Front Crane Launching Beam Front Support

Gantry Crane Trolley

Trolley Platform

Platform

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3. Hanging PSC Beam by Front Crane from Trolley

PSC Beam Casting Yard

4. Launching PSC Beam by Front Crane and Rear Trolley

PSC Beam Casting Yard

PSC Beam PSC Beam A1 Abutment P1 Pier A1 Abutment P1 Pier

Gantry Crane Rear Trolley Front Trolley Front Crane Rear Support Launching Beam

Front Support

Gantry Crane

Rear Trolley

Front Trolley Rear Support Front Crane

Front Support Launching Beam

Rear Crane

Rear Crane

PSC Beam PSC Beam Platform Trolley A1 Abutment Platform

Trolley A1 Abutment

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5. Hanging PSC Beam by Rear Crane from Rear Trolley

PSC Beam Casting Yard

6. Moving PSC Beam by Front Crane & Rear Crane

PSC Beam Casting Yard

PSC Beam

PSC Beam

A1 Abutment

P1 Pier

A1 Abutment Launching Beam

P1 Pier

PSC Beam Gantry Crane Rear Trolley Front Trolley Front Crane Rear Crane Rear Support Launching Beam Front Support Gantry Crane Rear Trolley Front Trolley Rear Support Rear Crane Front Crane Rear Crane Front Crane Front Support

PSC Beam Rear Crane Rear Trolley Platform Trolley A1 Abutment Platform PSC Beam

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A1 Abutment

P1 Pier

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7. Lateral Shifting and Moving Down PSC Beam by Front Crane & Rear Crane
A1 Abutment Launching Beam P1 Pier

8. Moving PSC Beam by Front Crane & Rear Crane

PSC Beam Casting Yard Rear Support A1 Abutment P1 Pier Rear Crane Front Crane P2 Pier

PSC Beam Gantry Crane Rear Crane Rear Crane Front Support Rail Line Front Support Front Crane Front Crane Platform Gantry Crane Rear Trolley Rear Crane

v
Front Support Front Crane

Front Trolley

PSC Beam Platform PSC Beam A1 Abutment P1 Pier Platform A1 Abutment Launched Beams Span-1 Front Support P1 Pier P2 Pier P3 Pier

P1 Pier

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Beam Lifting Work on A1 Side

Setting Beam on Trolley

Moving Beam by Trolley

Hanging up Beam by Front Crane from Front Trolley

Beam Launching Works

Launching Beam by Front Crane and Rear Trolley (1)

Launching Beam by Front Crane and Rear Trolley (2)

Hanging up Beam by Rear Crane from Rear Trolley

Launching Beam by Front Crane and Rear Crane

Moving Down and Lateral Shifting Beam

Launched 9 Nos. of Beams 3rd Span

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Problems Faced at Site

After Rectification

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After Rectification After Rectification

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Double Bailey Girder Arrangement for Launching Beam by SD &CC

After Rectification

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