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    1

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

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

    Post tensioning and LaunchingBeams in New Kallady BridgePost tensioning and LaunchingBeams in New Kallady Bridge

    Project ProfileProject Profile

    1) Project Name: Pro-Poor Eastern Infrastructure Development

    2) Finance: Special Projects Management Unit (SPMU)

    3) L/A : SL-P87, 28th March 2006

    4) Employer: Road Development Authority, MOP& Highways5) Consultant: Oriental Consultants Co., Nippon Koei Co., ECL

    6) Scope of the Work

    : Construction of New Kallady Bridge : L= 288.35 m

    7) Contractor: State Development & Construction Corporation

    (MAGA and UTRACON)

    8) Total Estimation Rs. 813,469,566 (Original Contract Amount)

    Rs. 1,389,500,000 (Amended Contract Amount)

    9) Date of Commencement 19thApri l 2010

    10) Completion Date Original : 8th January 2012

    Amended: 31st December 2012

    Bridge Length 288.35 m

    Span Arrangement 6 x 48.05 + 0.05 m

    Bridge Width Carriageway : 3.70m x 2 = 7.40mCycle Lane: 1.50m x 2 = 3.00m

    Side Walk: 1.80m x 2 = 3.60m

    Total 14.00m

    Superstructure 6 Spans Simple PC Box Beam

    Substructure Abutments RC Reversed T Type

    Piers RC T Type

    Foundation Cast-in-situ RC pileD=1,200mm, (A1:D=1,500mm)

    Approach Roads 196m (Kalmunai) + 95m (Batticaloa)

    3

    General InformationGeneral Information

    Bridge Type and DimensionsBridge Type and Dimensions

    Bridge Length and WidthBridge Length and Width

    6 x 48.05 + 0.50 = 288.35 m

    C

    SIDE

    WALK

    CYCLE

    LANE

    CYCLE

    LANE

    SIDE

    WALK

    CARRIAGEWAY CARRIAGEWAY

    1800 1500 2@3700=7400 1500 1800

    14000

    6 x 1485 = 8910 16451645900 900

    2050

    4

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    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

    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

    of bentonite or sand in the pile.

    y Reinforcement cage is kept in the bore with careful attention, with the

    bottom covers (150 mm preferred)

    5

    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.

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

    theoretical height filled and actual height filled.

    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

    the removal of bentonite slurry mixed concrete or hacked for further

    construction.

    6

    IIustration for the comparison of

    theoretical and actual concrete volume

    7

    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

    8

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    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. Longerbeams are with higher self weight and bending moment. So, boxsection satisfies the section criteria.

    B. Box beams are good torsion resistant sections. Launching is

    easier and safer for less torsion structure.

    9

    Box Girder Section Detail

    10

    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-Balance 50%.

    Strands Wires Details

    y Nominal tensile strength 1860 N/mm2

    y

    Modulus of Elasticity 200 kN/mm2y Nominal steel area 139 mm2

    11

    Losses

    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

    GleniumAdmix B233-3220ml

    Water-147 kg (W/C 0.32)

    13

    From Lab records

    3-days - 52 N/mm2

    7-days - 57 N/mm2

    28-days 58 N/mm2

    Elongation = FL/AE

    Elongation Stress

    Data Sheet for Post Tensioning

    14

    Grouting

    Tests to be performed

    1. Fluidity test < 25 sec

    2. Expansion test - (-1) to 5%

    3. Bleeding test < 2% (3-Hours)

    4. 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

    Old Beams- Glenium B233 & Flow cabley New Beams - STROAEG

    15

    Grouting test sample sheet

    16

    Grouting Test Sample Sheet

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    Current Status of Beams and Launched Beams

    17

    Yard Total NotStarted

    In

    Progress

    Re-bar

    Concreted Stressed Grout ed

    Make Up

    (Edge)Concrete

    Launched

    A1 48 3 2 0 2 3 7 31

    A2 6 - 0 2 0 4 0 0

    Total 54 2 3 2 2 7 7 31

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

    Total Number of Beams : 54

    Total number of beams launched from A1 side: 48

    Total number of beams launched from A2 side: 6

    General View (From Left Side)General View (From Left Side)General View (From Left Side)

    Batticaloa Side

    (A2 Side)

    Kallady Side

    (A1 Side)

    P4 A1P1A2 P5 P2P3

    PhotographsPhotographs

    KalladyKallady Side (A1 Side)Side (A1 Side)

    P2P3

    P1

    Batticaloa Side (A2 Side)Batticaloa Side (A2 Side)

    A2

    P5

    P4

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    21

    Approach RoadApproach RoadApproach Road

    a.a. KalladyKallady Side (A1 Side)Side (A1 Side)

    22

    b. Batticaloa Side (A2 Side)b. Batticaloa Side (A2 Side)

    SubstructureSubstructureSubstructure

    Capping Beam

    Stem

    Pile Cap

    AbutmentAbutment

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    Beam Casting WorksBeam Casting WorksBeam Casting Works

    a. Rebar Fabrication Worksa. Rebar Fabrication Worksb. Inner Shutter Fixingb. Inner Shutter Fixing

    20 Nov 201220 Nov 2012

    c. Duct Sheathes Fixingc. Duct Sheathes Fixing d. Outer Shutter Fixingd. Outer Shutter Fixing

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    e. Beam Concretinge. Beam Concreting f. Stressing Workf. Stressing Work

    g. Grouting Workg. Grouting Work h. After End makeup competed (Ready for Launching)h. After End makeup competed (Ready for Launching)

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    Beam Launching WorksBeam Launching WorksBeam Launching Works

    34

    DURING ASSEMBLING OF LUANCHING GIRDERDURING ASSEMBLING OF LUANCHING GIRDER

    35

    DURING ASSEMBLING OF LUANCHING GIRDER contd.DURING ASSEMBLING OF LUANCHING GIRDER contd.

    36

    General Data for Launching

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    37

    Lunching Girder CapacityLunching Girder Capacity

    38

    39 40

    Beam Launching Sequences

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    41

    Progress of Launching Works

    42

    Launching EquipmentsLaunching Equipments

    Launching Beam

    PSC Beam Casting Yard

    PSC Beam

    Front Support

    A1 Abu tment

    Rear Support

    P1 Pier

    Rear CraneFront Crane

    Front Trolley

    Rear Trolley

    Platform

    Platform

    Gantry Crane

    43

    Launching Beam

    PSC Beam Casting Yard

    PSC Beam

    Front Support

    A1 Abu tmen t

    Rear Support

    P1 Pier

    Rear CraneFront CraneFront Trolley

    Rear Trolley

    Platform

    Gantry Crane

    1. Loading PSC Beam on Trolley using Gantry Crane

    Gantry Crane

    Platform

    Trolley

    44

    Launching Beam

    PSC Beam Casting Yard

    PSC Beam

    Front Support

    A1 Abu tment

    Rear Support

    P1 Pier

    Rear Crane Front Crane

    Front TrolleyRear Trolley

    Platform

    Gantry Crane

    2. Moving PSC Beam to Front Crane using Trolley

    PlatformTrolley

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    45

    Launching Beam

    PSC Beam Casting Yard

    PSC Beam

    Front Support

    A1 Abu tmen t

    Rear Support

    P1 Pier

    Rear CraneFront Crane

    Front TrolleyRear Trolley

    Gantry Crane

    3. Hanging PSC Beam by Front Crane from Trolley

    Platform Trolley

    PSC Beam

    A1 Abu tment 46

    Launching Beam

    PSC Beam Casting Yard

    PSC Beam

    Front Support

    A1 Abu tment

    Rear Support

    P1 Pier

    Rear Crane

    Front TrolleyRear TrolleyGantry Crane

    4. Launching PSC Beam by Front Crane and Rear Trolley

    PlatformTrolley

    PSC Beam

    A1 Abu tment

    Front Crane

    47

    Launching Beam

    PSC Beam Casting Yard

    PSC Beam

    Front Support

    A1 Abu tmen t

    Rear Support

    P1 Pier

    Rear Crane

    Front TrolleyRear Trolley

    Gantry Crane

    5. Hanging PSC Beam by Rear Crane from Rear Trolley

    PlatformTrolley

    PSC Beam

    A1 Abu tmen t

    Front Crane

    Rear Trolley

    Rear Crane

    48

    Launching Beam

    PSC Beam Casting Yard

    PSC Beam

    Front Support

    A1 Abu tment

    Rear Support

    P1 Pier

    Rear Crane

    Front TrolleyRear Trolley

    Gantry Crane

    6. Moving PSC Beam by Front Crane & Rear Crane

    Platform

    PSC Beam

    A1 Abu tmen t

    Front Crane

    P1 Pier

    PSC Beam

    Front Crane

    Rear Crane

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    49

    Launching Beam

    Front Support

    A1 Abu tmen t P1 Pier

    Rear Crane

    Gantry Crane

    7. Lateral Shift ing and Moving Down PSC Beam

    by Front Crane & Rear Crane

    Platform PSC BeamA1 Abu tmen t

    Front Crane

    P1 Pier

    PSC Beam

    Front CraneRear Crane

    P1 Pier

    Front Support

    Front Support

    v

    50

    v

    PSC Beam Casting Yard

    Front Support

    A1 Abu tment

    Rear Support

    P1 Pier

    Rear Crane

    Front TrolleyRear TrolleyGantry Crane

    8. Moving PSC Beam by Front Crane & Rear Crane

    Platform

    PSC Beam

    A1 Abu tmen t

    Front Crane

    P2 Pier

    Front Crane

    Rear Crane

    P2 Pier

    P1 Pier

    Launched Beams

    Span-1

    Platform

    Rail Line

    P3 Pier

    Beam Lif ting Work on A1 SideBeam Lif ting Work on A1 Side Setting Beam on TrolleySetting Beam on Trolley

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    Moving Beam by TrolleyMoving Beam by TrolleyHanging up Beam by Front Crane from FrontHanging up Beam by Front Crane from Front

    TrolleyTrolley

    Beam Launching WorksBeam Launching WorksBeam Launching Works Launching Beam by Front Crane and RearLaunching Beam by Front Crane and Rear

    Trolley (1)Trolley (1)

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    Launching Beam by Front Crane and RearLaunching Beam by Front Crane and Rear

    Trolley (2)Trolley (2)

    Hanging up Beam by Rear Crane from RearHanging up Beam by Rear Crane from Rear

    TrolleyTrolley

    Launching Beam by Front Crane and RearLaunching Beam by Front Crane and Rear

    CraneCrane Moving Down and Lateral Shifting BeamMoving Down and Lateral Shift ing Beam

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    Launched 9 Nos. of Beams 3rd SpanLaunched 9 Nos. of Beams 3rd Span Problems Faced at SiteProblems Faced at Site

    After RectificationAfter RectificationAfter Rectification

    1.1.1.

    After RectificationAfter RectificationAfter Rectification

    2.2.2.

    After RectificationAfter RectificationAfter Rectification

    3.3.3.

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    After RectificationAfter RectificationAfter Rectification

    4.4.4.

    66

    Double Bailey Girder Arrangement for

    Launching Beam by SD &CC

    Double Bailey Girder Arrangement forDouble Bailey Girder Arrangement for

    Launching Beam by SD &CCLaunching Beam by SD &CC5.5.5.