Rational Highways Authority of Indio Schedule -D 1A. Lo Annexure: D— 11 ‘gmental Co jelines for Precast s struction GUIDELINES POR SEGMENT PRODUCTION Following guidelines are presented to explair the + arious detailed procedures involved in Precast seamental construction These are explanacory in ature but not bindiaw. Zor this projet Concessiontite needs to go into all there details before fiaming his specific construction method and site conirals CASTING YARDS, ein bringing factor © maior advantages of making segments in precasting vand controlled production techmgues, efficiency y contol and ume savings to Construction, removing casting operations itom the critical path for eansteuction ar Feducig the overall construction perind The essentia! features of a casting yard as shown in Fugure A} include + Delivery aad storage pains for all materials, ageregates, sane! cement einforcement, post-tensioning hiadware, etc + Concrete bateh plant and delivery system + Rebst cage assembly areas, jigs ard templates + One oF more casting cells for superstructure segments + An area for the production of any specisl segments such as pier segments oF expansion joint segruents . or sprinkles curing faciities + Segment lifting and handing equine 6 ent storage areas + Segment loading and delivery facil:ties 5 and concrete testing facilities The size of the yard depends on the size of the job and rate of segment production Fequited Allowing for typical production problems, a realistic production rate is about SIX segments per 6 day week per casting cell/hed For St or * SOMA-NCC-SAYTAS-CoNSoRTOy Fer SOMA. omer -CONSORTIONés — (avsharived Sigoatof Find Highway ow NH? gad Finascial Meakeh Ll Highs Aushority of Indie Schedule =i? LONG LINE AND SHORT LINE FORMS Long Line Casting Bed All sevments ae cast on a satin wich as as. hull span upto coupling section in 3 shod The Sofie must ae with profile of the st worrectons for short and lung terry deliecnions One or more forms and the bulkhea travel alone tus long line y contol as done when constructing he production and avoiding errors in * Is requives a large 3 © Tr must he burton 9 fim, noneset © The soffit eannan be ress, c . he soffit cam be made onis for one casting curve Short Line Casting Bed With this method the form is stationary while the segments move frm the casti position te the match casting positan and then to storage Auvantages of this method are + Sp are much less compared to the long line method -e requi + The entire manufacturing process 1s centralized +The system is excremely adaptable to geometry vacbarions such as hosizontal ard ertical curvature and superelevation transition which are offaiies withgue ? rer ease in costs fi +The fooms are reusable for other projects \ RN The disadvantage of the system is that the match casting segment Mwai be very rately placed. This requires high skills in surveying and equipment capable of geonietry measuring elevations with a 1/1000-foot (03 mm) tolerance Else the finished of the assembled segments will not be correct RENOMA-NCC AN er. eau. For SOMA-NCC-U.AYTAS-CONSORTIUM *IAS-C9, ee , woe ‘ORTICM,Natiomal Highvoys Authority of India Scheduie PD. 40 Flevated Highway on NIT MATCH CASTING Fresh concrete of the new segment 1s cast against the already. hardened concrete of the od segment A bond breaker (usually 4 mixture of wa. soap and talcum powder, but there are aiso chemical compounds) is applied to the hardened concrete surface in orde: © ensure thal the seaments will com match casting technique as applied now epan Th fon several projects ¢s based on the fact that, provided proper precautions are taken, the segments will come apart cleanly and upon erection. will join tog er perfectly with the out being almost invisible The precautions are merely the careful application of the bond breaker and the swoidance of Jamming protrusions which make .t physically impossible to S:cak the Sond For correct tit at the ume of erection the j must noi have been altered, except 1 @ light sand blasting This generatiy means the: ao work caa ine dors an the joint ces and that segments must be stressed in such w2y ties c:terentia! deformation cannot occ CASTING CURVE made up of 1.0 important components (1) The required geometric profile, which is actuzlly the Aorzonsal and vertical curvature and superelevation shown on the plans and (2) The compensation of deflections. Both u € ceflections which occur during construction and the long term deflections FABRICATION OF REBAR CAGE WITH POST-TENSIONING DUCTS: HARDWARE [ofoor Prefabrication of the rebar cage preferably with post-tensioning ducts and as possible of the hardware installed a5 needed in order 10 achieve the requiced prodmetiad: fate This is readily accomplished by means of custom built jigs and templates. A possible jig for « complete typical segment is illustrated in Figure A2 Sometimes itis more conven another one for the top slab By having seve hsBue MNO He CBR GRFib ra well an advance for segment production \ For SOMA-NCC-MAYTAS-CONSORTIUM fs “Ay 4: Bi fc 2 oa Siznatory) SAatd Tachaicsl Besber an) i 10 use partial jigs, for example, one for the bottom slab and webs and ~__hatsited Sipeatary) Ney s Lead Fiasacial MemberNational Highwuye Authority of India Sehedute Pp 6 Elevated Highs on WH. The essential features for a pe are * Walls and Moors, ef stect plate of otiir suitable material, held vevdly by a frame te accurately define the main concrete surfaces (outside webs and Siab softs) * Bulkhead templates cut andor marked to the proper seetici size with stane ar post-tensioning duct Ines*ions accurately defined + Wing cantilever and iemplates marked and fitted with locaruns fo ransverse post-ensionine ducts, ete * Spacer pars laced 10 the walls snd floors t provide correct concrete cove vw # ttg OF Fis type also permits rebar post-teasioning, duct pos tiv-s and any arvet urstely fixed and marked up for repe te Dect protite \d Soon Senin hardware locations to b van ne traced onto the walls to vase ass Febar cover and duct positions :rom open surfaces other, contain different po: fe will deform shape from tension et and anchorage arrangements, and because the reba s; ortation from the jig to the casting cells, inal adjustments must be made after plac g the cage in the castiny ceil before stant of concrete poutina tn she wo. For pier segments, abutmert segments ead expansion joint segments, the typicel segment j and expansion could be modified or a separate jig made Sometimes the pie Joins segments are cast in separate casting cells. In such cases it might be convenient to fabricate the cage directly in the casting cell itself 1h is advisable (o periodically check the accuracy of jigs and templates as they ean deteriorate with repeated use and adjustments INSTALLATION OF POST-TENSIONING DUCTS As mentioned above, most of she post-tensioning hardware an. ‘bar cage An exception o this ate the anchorage and coupling heads themselves which because of their weight, are usually installed in the form Aa accurate and smooth alignment is essential for all post-tensioniny ducts This will ensure that the required concrete compressive stress level is obtained Variations from i read shemne wl ase ode spengy te sl all incase SANG ENE 48 Aah ! i 2 Yi sthstined Sse SI et Seouidy Lead Fisagcial Mea 7 Mand Tachaicl thea, sare insta artes emYao at eighonays Authority of Inde “and strands and may lead 1 wite failures Suck kinks are verefore not acceptable Post tensioning ducts should be sect rely coaay d 10 their respective anchorages Duct Eations and abenments must be e- hed (Figure A 4) Curved post-tens nine ducts should ‘smtervals of 06 t0 09 m and there should be a9 kinks or ‘misalignments ot connections wth anchorages and between duets The pas 100 of post Srstoning dicts should be set correctly 9 preference to the position of rei forcing bars “isi should Ue locally adjusted in case of conflict (Figure AS) If itis necessary to nove the ‘cing bars, the IC shold be consulted Hons should be made to soid contlicts between the reinforcing bast and post wonine ucts Loregrated shop dressings showing the particular pr st-teusionine sensare system duets, reinforcing bars special constuction desztls are very ‘ ¢ Soule be prepsted by the Concessionaice tna! achustmierts of ducts ang ceinforcivg bars shoule be made and inspected be simenis eng inspection of aucts and t bar in slabs can be made any time befare casting of the corerere (Figure A 6) Poste oud be 56 which on usa must tened tw the rebar Fs In order 10 avoid © firm aginst the forms by chaits and. spa ‘splacerient during concrete giacemen: and c¢ ypaction Flexible post-tensioniag ducts siaily are likely to move when = Fi Our O3 mor so Dr zts in slabs, such as uransverse deck prestre jected to the pressure of moving concrete, and buvyan: his reason. flexible ducts are fastened at closer spacings of susceptible to move but should be fastened at no more than 0.6 m intervals. Poste tensioning ducts can be secured with several layers of tying wire and/or auxiliary Feinforcing, support bars laced firwwly 10 the rebar o. we AT © The laner is preferable as it avoids distortion of the rebar cave (Fi HANDLING THE PREFABRICATED REBAR CAGE ay * (3 / frm Transportation of the rebar eage from jig to casting cell should be done caretiy a4 avoid excessive disionion It is eustontary to use @ special frame (strong back}-with clkear suppom the cage at many poings (Eigyce A § * Sola HEC aiAY TAS. consonog™ Set Ree hana (three Sonne ted Finaacial Mendis f-National Highsoays Authority of India Scheduie-D The rebar cage should be securely fabricated with adequate tie wire to enainiain as mach rigidity as possible 8.0 REBAR CAGE IN CASTING CELL (MOULDS) Afier the form has been thoroughly cleaned out and oiled and afier placement of the 4s, the post-tensioning anchors are installed The important items to watch for in case of enchos vnstallation are orientation of the distribution plate, conection of pla trumpet and of trumpet to duct and also the position of bursting reinforcine Ensure that the congested anchor zone can be concreted properly without feat of honescom bine © oflentation of the distnbution plate is provided on the shop providing angle offsets to the plane of the form Based on it pockets are to be 81 ¢33¢ of many repetitive uses of the fo: <8 pockets will be made of steel p.sies Once ¢ steel recess pocket has been checked for dimensional scouraes il will consiscently provide the correct orientation W kets are for one ime use only and these need to always be check lation of nchor and the proper alignment The trumpet is sometimes an integ | part of the distribution platen wiich ease there as no installation problem IF plate and trumpet consist of 2 pieces. she joint « tight by means O° a seal ‘The connection of trumpet and cuct must be watertisht and be within a 2.3 Wweved sith heat shrink tapes. The alignment of irampet and cuct should jegree colerance (Figure A.D) The required by forcement is shown on the shop drawings to be submited by the Concessionaire The location of the bars should be stcictly adhe ed lo Spirals should be centered properly in respect of the ducts and begin right at the distribution plate of the anchor. Dimensio: for placement of hairpins are important and these should he within and show all 25 mm Particularly at the anchors, drawings should be intcer: 1s be reinforcing should be resolved on the drawing board. Spirals are spp! These should be stretched out to the proper pitch as shown on the shop drawings reinforcing, tendons and hardware present in the area. All conf ven tendons and Since anchor zones are densely reinforced, judgment should be made beforehand whether or not concreting will cause problems. If problems are anticipated, the IC should be consulted se Wee After placing the anchors. the rebar cage is placed in the cell Al post tensionypaiets are securely connect Ear SOMAr NEGRAVE A8.cboraR Eee lores ané-> For SOMA.-NCC-AYTAS-CONSORTIUM Q ‘o oe lel 5 Las Creel mh AAG Floated fighwason epee oii — AS Lesd Tachaical Member, | 7 Leadational Highs Authority of india SchediateP Hiunments are checked Firat inspection of the tendons should be pertivmed after the banection with anctors and match cast sevments are made 9.0 SELTINGS THE MATCH CAST SEGMENT © as possible to its desired position prior to placement erly adjusted, all inserts five €s bolted up t0 the forms, and the ducts taped with fn of the rebar case, ten the rebar eage and ducts are prop tapes Ir order to ensure that there will be 20 momar leakage. the i Le checked and its p form secusely around the (oh Cast seamen: Reter 10 PLACING CONCRETE ep icuce will ensure a ge duct Some of the importat re aligned end secuie and mi should be ightly oiled for sinpping and the face bond breakin, c Place the oon 1 the specified sequence 31 Use skips. chutes, or pu 0 deliver concrete and eo not let it Fall fiom 2 great relight. 25 sis causes segregation and the impact cai damage ducts end disp corset placement should be in accoreanee with procedure specifications approved by the IC ble avoid holdups which can allo already placed to teke on an inatial set. Sometimes deliber (1 Keep as continuous a delivery shox waits afe necessary especially afier placing the boom slab and web corner concreie so ‘hat it can stiffen just enough to take ‘eight of the rest of the web consrete bur be careiul that this waiting is nov averdane and avoid eld joints C Fesarders in the concrete mis to simplify tie casting operation ©) Make pro use of imemst “poker” itrators to thoroughly egptfae-we Concrete These spe of iro shouldbe pushed int the concen ere than 0 6 m or so and should slowly be withdrawn from the same Keb Dist move the sibrators sideways while still in the conc rete Do not ust Gite-snversieh poker” vibrators 12 move cor crete around oF to drag his will Fer SOMA-NCC-MAYTAS-CONSORTION/ fiom the webSumot bottom siab, for evample, bonescombing CONSORTI . Elevated Tigh’sar on Nhs A eTiCd Sig Lead Finacial Member 1) 3National Highovays Authority af Indie Le. 12.0 void contact of the vibrator with rebar and post-tensioning ducts as tifis can ause damave or displacement (Figure A 10) (0) Make sure concrete is thoroughly compacted, especially in awkward areas such # the comets around heavily reinforced anchorage zones and within spirals Souad compaction is essential as for every 1% air void content, the concrete strenpti reduces by approximately 9% 1 The finish on the top surface should be good As this is usually the aiding surface, in fimshing In spite of this be should not be hurried he last job for the day, it CONCRETE PLACING SEQUENCES, 4 vod placing pr ‘dure should prevent the concrete placed in the bottom of the web nto the bottom slab This movement of the web concrete can easily displace # ducts and can pull concrete away tom heavily reinforced bottom anchorases hunevecmbing Some such flow of the concrete is unaveidzble ¥ the following procedure, which is considered good Place the first ennierete in the mide 1 15010 304 portion of the bottom slab, leaving, f the 5) at the bottom of tie wes It is possible to do this dy a ery chute through = trap in the top slab § pulk te: Place the nd concrete in the webs and compact it around the bottom comers Complete the bottom slab Compact the concrese in any bottom anchorage blister through Nincows in their top forms Place the nest co te in the webs working up to the top. sla Linally place the concrete in the top slzb working from the center and outside edges towards the web Strike off the top surface snd finish as described below FINISHING THE TOP SURFACE * sood quality finish of the top surface is essential, a5 this, is also the riding surface. The nls one opportunity to achieve this p: operly is in the casting operation (Figure A.1)) Grinding unevenness out of the top surface after construction is never very satisfactory anyore #8 it reduces the concrete cover, takes time and costs money In adgitdon, itis ef then usually necessary so improve the skid resistance by grooving tas possible to leve 2 good finish by mechanical means providing that the 7 sed properly by tained and experienced operators, Care is needed to make sure tl depressions are filled and all high areas rem (taried Sigonery pty Lead Financial Member Re aS ee YP (Aathorived Sigoatory) = Lead Tachaical MemberNational Highwoasy Authority Schedule -D_ applying the riding surface « ment, the sucface must still be even mid accurate Undulation should not be permitted Hand finishing has been used essfully on many segmental structures in the past Hand finishing requires that a good strong, straight screeding board o¢ used extend fro: 1 the top of the bulkhead to eas: seumient tw sinke off the suisace to an accurate level samcal screeds also work very well Good results have been achieved with both former are a little more efficient rolling and vibratory screeds. The Mechanical screeding shoul? be followed by a straight edge ~ usually a substantial, sti worked oy hand and used so check and correct any low and high 4 straight surface trom the bulkhead to the match cast Ser surtace wees fas appeared, the surface mae be very buhtly “vouched uf floats produce a tine: and smoother surface Floats should not be used in such 2 way as 1d mow 1 Sisturb the accuracy of +e straighs surface When finishing 2 concrete surface it 1s impostant 2 keep the concrete live for working Y proper vibration, tamping and floating and uct to add water to wet any suff areas This eaker surface materiz! which will dust and wear badly in use In order t0 take F workable concre‘e, the sntial leveling and finishing Should Follow imimeviately a“ier placement, This is sRe best time to get the surface level Be carefull rot to spoil te tap surface when and if the concrete Je to be covered fur curing (Use means to suppor taps and prevent contact with top surfaces, ete ) ‘The top surface of the bottom slab should be finished in a similar menner akhough the appearance of the surface finish is not so enitic-’ it should, nevertheless, be accut Mech we tical screeds need no: be used on the bottom slab 13.0 CURING In order to achieve & production rate of one segment per day from one casting cel i@ essential to ensure that curing is proper and sufficient to provide the necessary strength and control of shrinkage etc Curing, procedures depend upon the type of conerese, its chemical hardening processes, temperature and exposure conditions It is com Practice to cover the segment wi tarpeuins and apply steam so maintain a controled ugmyerature and humidity Other Ao a corsontiem g) 2 aay J S (aatioriied Sigeateep) Lead Tachaical Member FievateNational Highwavs Authority of India Schedule al nile, the slower the conciete's heat of hydration and loss of moisture is he better With a production rate of one segment oer day Irom one casting the curing process in the casting cell cannot be more than a few hours trom he completion of the casting in the evening ¢o the start of sur ey and stripping the next norning This is why a controlled environment is essential )he segment must remain vill require covered with moist o be submitted by Concessionaire for IC's approval P even after stripping the form Preci-e procedures 14.0 STRIKING FORMS iKing of forms should not start until the concrete has reacaed the required strength MP2} At this strengil: it is normally possible to ually specified at 2500 psi (2 cast 5 the side forms, remove the core form and pull back the m nea sement could also be engch the jereine provided +3 incapable of that the top slab is self-supporting At this, dut not Irfied In ease she F the weight of the unsupported top slab at 2500 psi, then transverse post strength ig must be stressed in full or im part This would require a highe: 4000 psi Iv is customary to break cylinders in order to verify that wenaths are in fact obtained hg the forms should be done with care as it is vers easy tw cause spalling and other damage when the concrete is young Most casting cell forms are removable in vole pieces (Figure A 12) but it is advisable to leave removal of any special blockout forms for as long as possible as it is very easy to break the edges wf blackouts Stnking and pulling back the match cast seement should be done with particular care If the bond breaker has not been properly applied, portions can be broken off either went The shear Keys are especially vulnerable Also, the movement mechanism on the pallets must be examined and understood by the stripping crew Sometimes, the looseniay of jocks and tilting of the palle: can be done in such a way as to “lift” the pews cast segment (see Figure A 13) This motion can easily damage the shear keys and sldoesodhor mnie smh psi Te sae aps en nian new segment away from the bulkhead cS Altho at rook srised Signatory) Catpertied Sy nates te ¢ Tacheral Membesso 1 Pauaucial Membed 45: 2 Elevated Highwav-on MHFNotional Highways Authority of India _Schetute D 11 B. GUIDELINES FOR HANDLING SEGMENTS 1.0 HANDLING SEGMENTS Lifting of the segments should onl be done when the concrete 1s at a suitable strength (BO MP2) concrete and afer any transverse mally thes means at least 4000p siressing has been carriet out (if this is specitied to take place pric to handling) the inside Most methods of segmner tal erection use lifing holes through the top slab ne: oF outside of the webs Special insests or fitting Ioops cast into the concrete are als possible, but these require approval of the ICA bfing frame secured with pos ensioning bars through holes in the so} close to the webs 1s a good technique (Figure B1(2)i. By adjusting the lateral position of she local where the hars are attached othe frame. the segmens can be made to harg at the eressfall required for ereetic not always necessary te use a fling Tame for musi the segment in the castes vard Slings may sometimes be used ( (hy) Hesever, great care musi be take hardwood shoes, et lo avoid damage to the comer of ¢ using p With span by spar construction © ona truss hefore jointing. at sible (0 use slings for erection is po STORING AND STACKING OF SEGMENTS Segments should be stored wsi a) inp order to ave ee-point support (igure b ping with time in storage Double stacking 1s usually possible (figure B 2 (b)) providing three points suppor is used However, segments should periodically checked for any evidence of detriay effects resulting fom double stacking the effects of localized loadings so that cracking Itis essential thar the designer check will be avoided. Double stacking, therefore. requires that approval af the designer Afier placing the seyments in storage, ciher routine tasks ace performed, such as transverse post-tensioning and grouting, light sand blasting of the joint faces, and repa: of small defects 11. GUIDELINES FOR ERECTION METHODS, 1.0 GENERAL, The different PO SGM NEE RAYS Car Garatete i Pata akCoerctowine saat . ne ON Z 340 2 tiesd Si sh a BR! Seas goat Fievcied Highway on Ni ead Pencat mete fad Tochaical Meath! aSchedule 19 Natiomat Highwns Authorayof ka 2.0 SPAN-BY-SPAN ERECTION This metnod, uilized a custom made thuss co temporary suppor all the segavent complete span The cuss, which 1s normally longer than twice tie span is usua!ls smpered an the pier footines or. in case ofa higher pies. on brackets attached 1.1 ely used sn a variecy of conditions, in urbar The method has been exten: Sw Honmeatally sensitive areas The meshed! has also been applied to eonsenict Bical tereain’ The teuss ean move fivhs pier to pier and sevments can be transporter pver the completed bridge Alternatively, if there are no restrictions posed bv the wre trucks can deliver se. adjacent to the tnuss ard a erare can place then eased @ contest alignment enturs made during production or erection of the seurien< The sequence of erection is usually a follows + Fifting, rotating the seuments by 80 dearces and ascerubhig she seaments by the overhead launching girder including dry matching viz checkin all tines and alignment + Separation of the segments by some distance for applying ond * Bringing the segments together snd joining by appiving stressing force though the temporary PT bars * Threading in HT strands, coupling and applying about 2/3 of the specie stressing force in the permancat PT tendons a= per approved sequence The ‘ssembied span shall be supported by the launching girder with a small vert en {4p above the top plate of the POT bearing on pier cap * Lowering the span on the POT bearing afte appving a thin cos! of epoxy om the top plate of the bearing Concessioraire to work out fixing procedere fer the upward Fixing bolts (iP any) of the POT bearings in the vier seement 2. recommendation of the bearing supotier . Carry out balance M/3rd of PT stressing and remove temporary PT bars (Ay 5 * Move Launching Girder to next span and repeat the sequence, . . ‘ typical erection rate from one launching girder shall be not more thing 0.5% days per span. Initially this cycle time may be somewhat longer Howeve GH arsine contpes and ih the leaming curve a sabe wide Nae For SQHA SSCA PEAS consdiMM ARMA MACE 64 vBu BQN CORT. Kt 0 1 ww Aalberived Signatory) Patri Spaiagh BOS Froud Tighosa nE7 O Lead Finaacial Member Lead Tachnical Member ©National Highvnys Authority of India Schedule - D 3.0 BALANCED CANTILEVER ERECTION B 3 construction stants by placing 2 pier segment on top of the pier This 1s followed by erection of the 1we next segments, one on either side ct Ine pier he structure grows by placing one sey-nent on each side of the pier seztent fortis @ cantilever which, because of the fect that an equal number of s added on each side is “balanced " after each comsleted eycle th side of the pier, are sible, it seléom happens that two segment, one on cued svn uttaneously Usually there is oaly one ane ave able which will first place went on the one side and then the sezmen en the ster Because of this there usually “sa temporary unbalance This unbalance “equires scsi strutting, placed on the lize the cantilever (figures BS 12 and (While most segments are stilever, some segments, Usually the “es ia ts end span 2) The layout of the permanent PT tendons in this ~ethod siall be torally different thom pan erection method. This “sill corzrise for a combinatio: for the spam né continnity tendons cantilever tendons in os middie of ali che int e cantilevers are ss casting and curing of the nese ty each ile ning is applied c2\ 2d cant vaity post-tensioning second stage post ten 11D. GUIDELINES FOR ERECTION DETAILS 1.0 POST-TENSIONING LLL Temporary Post-Tensioning nental construction, it is comamen practice to use temporary With most forms of se ents betore the main longitudina’ post-tensionning to secure the erected segment 0 tensioning is installed (figures D1) the purpose is (1) to provide a rapid means of transferring che weigat of the segment from the «to the structure within the alloweole setting time called “open lifing equipm time” of the epoxy jointing material (2) Tooaliow afaty even ses 0 be apps gage tbe shole jit face in order 10 bed down che epoxy and let it set ury a saga For SOMA-NCC-MAYTAS- ae totsb RTI St Cte Hevated High on NIE sea Td Sipsatoryy 1 (\apketived Sigoatory), 7 Sdad Tachaie Lead Financial Member st emberNational Highways Authority of India Schedule =D 13 Flevaued Highway on Nit- Provide 30-50 psi (0 21 to 0.35 MPa) averave compression for this pufpose If the compression 1s significantly non-uniform from top to bottom, especially in cantilever construction, then the epoxy joint thicaness tends to vary whieh, alter several segurcuis, can afTect the di od alignment ©) Temporary post-tenstoning bars are used to cantiol a temporary stress condition in the structure Fos ds case the bars can only be removed after carry ermanent PT The temporary post-tensioning should be designed by the Concessionaire and approved by the IC within the shop drawing process Ia any event, the sequence of installation, stressing and removal of the temporary post- tensioning should be clegrly shown on the shop drawings and for erection manus to be submitted by the Concessionaire I is normal practice to limit the stress in temporars post tensioning bars to of the breaking strength of the bars. This will allo many ceuses of the bar ors Sometimes, however, is '5 necessary to exceee this figure and if sa. then these bars should not be reused with out the express permission for the post tensioning bar manufactures If there is any doubs. it is safer not to reuse the bars Permanent Post-Tensioning Pern proceeds Internal tendons are located in ducts inside Plzcing, stressing a ensioning tendons are installea and sessed as erection of segments nent post nctete Slabs and web J grouting of post-easioni nental bridges 1s no tendons for se different from tendons used in other applications Lifting Segments for Erection Lifting and handling of sey ments was also discussed in earlier section Clearly the method is the Concessionaire's choice, subject to the approval of the IC ot Construction Schedule and Sequence The casting curve will reflect the various deformations the bri in accordance with the if Se schedule and sequence the Concessionaire propose: construction schedule and sequence are important Once sequence and schedule are selected as a basis for the casting curve, a change of sequence or schedule or both may require a change of the casting curve and possibiy even a design change. The schedule is ‘mporant because once cast and under stress, concrete has the tendency to deform One sees th yee ith beams, 88,00 as _pre-stressing is ccs CONSORTIUM 164 1 Sigoatory) baical Member Memberwns Authority of India Schedule 1) applied IY the camber is checked apsin after say a month it may offen increase end ay time oes by, 11 may increase even more Tus ioccease an camber 15 caused by concrete creep In seumental bridges where sp. vo be longer, this creep effect may amount to sever mas. In order to compensate for hed p effects, they are calculated based o: The bridge detlections are generally calculated by the Concessionaire and reviewed by the IC The reason is clear Only the Concessionaire, after making out his schedule cat snow fos sure when and how the structure will be constructed 2.0 GUIDELINES FOR EPONY JOINTINC 21 Purpose of Epoxy The puspose to use ait epory-resin in the joint between segiicnts are * to completely Bll any minor surface imperfections and + irreaularities between the match cast surfaces, and. 1 provide a wat right seals, and i the segments . censure that there is a ti Fit be ween the surfaces so thar stress is transmit: directly across the joint 2.2 Types of Epoxy and Applications Epoxies are formulated as two par compounds consisting of a resin and a havdene: When mixed they be setting which can take anywhere ffom a few minutes 1 over an hour depending upon the material an ambi H cemperatures For some applic: ions, sucn as the span-by-span bridge construction the setting time ean be mcreased to allow sufficient time ford rection and ad stressing of a complete span, which may lake several hours The formulati mixing, use and testing specification separately Poor to application, joint surfaces must be clean, dry and free from any loose « ete very slight surface dampness is usually acceptable u S CONORTIOM done in the can using a custom made motorized sizer yattoars For SOMA-NCC-HAYTAS-CONSOR TEE £ Ob 55 pak fis BAuborieed Sigeateryy IO We ( pe igor ed For on-site use, it is advisable to have all epoxy rote Smee ES Mixing can be wthiocined Signal Leal Financial Member Elevated Highway on NH? sMuriomal High wars Authority of India Schedule p Application is best dane by hand ising wooden spatula, using protectin, disposable rubber labour should be » gloves Since the application time is short, sulfic Joint in the time allowed Applicabon of about 16 mm thickness te one face is wsually sufficient Application to 0xu faces 1s always preferred The advantage of nwo-lace sppheation 5 vrat ouside layer of the epoxy, whicit hewins curing right after applicatinn, will not be alacey against adjacent concrete but against adjacent epoxy. which will got a chance set The str ctural function of epoxy sefers, at most, to restoring the tensile stress of concrete in ‘order to snerease the “eracking mom provide moment capacity at a location ed for safety but be good to have for durabiiny One this capacity is mot requ location is the joint between two segments in the deck. A wheel load placed on this joint wi i which, often, are not fully ress up tersile stresses across th apressi-w dug to the pre-siress Wh Consequently, the coating should be left about together and stressed, the epoxy is squeezed out © segments are broughs od siressed ing it to harden will only cause furure mm shy of the outside edges (Figures D 2) once the sepments have been jained 3 HI epcxv should be cleaned off ymmediacely Le difficultics. 11 is important to rod out all ducts so that any epoxy squeezed into them does not form an clstiuctioa of high spot for the tendons to pass 3.0 GEOMETRY CONTROL 3.1 General The geometry control of segmental bridge is achieved in the cesting yard The “shom-ine’ djustiments te each match east segment in the casting system is based on making very fi and therefore requizes high precision, more so than the “long hiewe wher builds casting he soffit in the casting yard where the geometry contrat is mainly (on the * short-Lin commonty The following discussion concentrat system since itis mor Used although the principles apply to both systems: he Precision geometry contol has nothing to do withthe sizes, thickness variation dx wiefenves de / ‘of the component pieces of the segments, important though as these are to the overajiaaty of the finished produ. The precision is required Farm lative cast position oF ene sepmesin elon 95 ae ean Beene yl eer OMALKCE RAVTAS CON ENTE Hl 4g pee BR ne ie ft? WH orsaayy 2 Lebd Financial Member Tochareat tember 166 Elevated Highway on NH?Rutionol Highways Autharity of Inca Schedule B “The alignment 15 controlled by an instrument on a permanent tase and 4 permanent tactet Neither instrument nor target should be disturbed throushour the production, otherwise control must be reestablished Tor this adequate benchmarks should be maintained The vd usually squate so the ge motes conteal is estabhis 1s always plumb, level ‘ositioning the old serments prescribed by the castine curvy As the first segment is cast and the top slab has teen Prished. elevauon bolts A, BEC an D_ as well as two centerline markers, & and F aicy be installed The followine mornin the clevations of the tops of the bolts are recosde and the certerline as senhed ante Centerline markers Now the sezment can be rolled forward casting Afier the first segment is maved to the match casting positicn «is reset to the lasteuctix Provided by the casting curve The centerline wil be as it was Sefore, unless the bri cuned i the bri fo agus! th: she detections. witteh oce pnstruction. AS mentioned, the amount of adjustmer de is determined ‘he casting curve, which is part of the shop drawings by Concessionsire If the seamert sould be posiboned in such @ way that both centerline markers are in line wich instrame and the bolt elevations are the same as those measured before the segment wa aad tangs moved, the seement would line up exactly with the next segme: poured Geometry control for segmental bridges requires highly skilled anc experienced surveyor He should be om the job deily aad Keep accurate recorcs. In spite of his conip work should be meticulously checked by the inspector since extors are expensive and time consuming to correct After the old segment is properly reset and the setup for the rew seyment is complete, che new segment can be cast The following moming the surveyor marks the centerlines the elevations of the new segment In addition, be ecords cle b egment is moved the elevations of its bolts and its centerline position are checked to determine if the old @ the new segment It is often noted thet position ch segment has moved during eastir of the “old segment” oceur due to set it of the soffit rails by the seeme! eight, duc ae “ibrating of fesh concrete egninst it oF due te forces applied to s while closing the forms} that in order to obtain the required erection tolerance (1/100 feet of 3 rim) thé prison SS) within any pair of segments must be proportionately greater For example, if there aft-tO™ segments tn a cantilever. Then the precision in the casting cell should be to 1/10 of I/1 feet (0 3 mm) or 1/1000 feet, Direct reading to 1/1000 feet on elevations and offsets in the casting cell i at the limit of normal survey 2 peasoring devices Centin equipment enhancements, however, oye “Ain @Noonau trained For SOMA-NCC-MAYTAS- CONSORTIUM /* : 5 a5 \ ah_ 13 = aa Hivated Highs NAT bathed Sip STP S ~ A aeNational Highways Authority of India Schedule D ig kort surveyors can consistently obtain reading with an eccuracy of this osder As accuracy depend upon consistency. itis important that the same individuals make the critical “as cass observations at the same time each day prior to stnppiag the forns of both the new and the the daily crews fold match cast segment Usually, this is the first thing each morning b ve and when weather conditions are must stable from day to day ote that all the critical readings are those afler casting While it is impostant sw have a-curate setup before casting, this 1s unlikely to remain so during the casting operation, Some movement, however slight will occur, $0 the true achieved geometry is recorded af feasting [1 is possible to compensate for casting errors by adjusting the position ef the nest Setup and so on In fact, the major tnck on geometry control Les in Keeping trach of casting is very imporsant thar all the information fron the casting operations and the calculated is cast” actual relative positions ef the segments rough the field erect process as well This difficulties because it is by no means as easy 0 obtain the same ses some pr cy in the field as in dl gard However. the field setting 1s only required at each pier segment or start of @ successive run and it as worthwhile doine Placing a large chunk of concrete with @ erane to an of a few thousands of fot may not be practical, Tn practice it 1s possible to use shims, packs and wedges ta mareuver the segments to within an acceprable accuracy. Also, by installing supplementary transverse -gment can alignment marker while in the casting cell, the horizontal adjustment of the pte: be set in the field using the base line of the full segment width, thereby not relying solely upon the shorter, front 10 back, longitudinal centerline marks (figure D3) During erection, elevations anc horizontal alignment should be checked to see if they are in surement with the calculated, as-cast position If not, then adjustments may be necessary Such compensations include. reorienting of rot ting the cantilever afler erection, calculating # compensatory setting for the next cantilever or shimming the joints. The latter should only be used as 8 last resort a5 it can unpredictably lead te “correction of corrections” afd so on Moreover it is not effective for short cantilever or deep girders f: . \ Vr ta fa) Precision within the geometry control system is essential in order to avoid erkdad th ine gy geometry of the structure. A source of error in alignment may arise from the defo characteristics of the concrete being different from these assumed, Deformation of concrete are difficult to predic: with any degree of confidence and most attempt are at best ha.gctual deflection can differ from the haPrss eB Bid in camber aie Sgaciagy HP Lead Tacha sophisticated judgments In segmental constnic3 ‘hep se BOAR GS ih WEAR SCOTIOR BINA, ag feed Sitar \G Elevated Highway on 3 Lead Finaucial Member ircatery) ! MemberNational Highways Auhorty of India Sehedut> 1 by a few inches: However, with pre-cast segmental construction mnast af the shrinkage has ususlly occurred during storage ai fe has matured substantially by the ome of erection This helps to eliminate the significant variations likely with young concn 32 Casting Cell Geometry Control System se figure D4 A typical sample case is shown i bolts A, BLC and D are set over the webs as these are the poiats where no vertiea deflection will occur due to traasy fects Fer example bending or post-tension’n wing tips can deflect or camber by as much as 20 mn Teet of dead fo: d and Wansverse prestress This kaeation would theretore ao: fe for verucal she ime contro! bolts The horizontal alignment is established by setung the match east seuments at the nece skew and offSet, as measured on sts centerline hairpins E and F, from the casting cel centerline Likewise, vertical alignment is se, by adjusting the jacks om the match east Segments carriage until its elevation bolts ares: the calculated levels above or below thy plane defined by the top of the bulkhead of the newly cast seginent is carefully measured by canine After casting, the exact posit. jeadings on all ereht bolts and offser ceading on ail four centerline harpins ‘lary Length measurements are mace along the lines of the elevation bolts (Figure D +) The ebsecvations are made ts an accuracy of O01 feet or 3 mimi It is advisable that parallel but se essionaire and resident staff of the IC in order to parate reading be made by the C avoid any major misreading. It is likely that two sets or observation will not agree exactly but parallel reading and subsequent computations will track the geometry better and avoid © bulkhead should be checked back to remote benchmarks to puard against inadvertent ecrors due to drift of the Periodically, the aligament of the cell centerline and elevations of 1 ‘equipment through usage. Provessing of the observatians is made ether by numerical analysis or by graphical ylgeting The former it quite conveniently handled by desktop computer ot calculator for, ove tid Procedure has been established, it becomes very repetitious and automatic Desktop computer progranis are avila ef kisyfeny ot gua Practice to check by making paralel eraphical plots For SOMA-KCC-IAYTAS-CONSORTICM ake wit — ignatary) Hlovaed Hshway on M24 Fsxacial Member (hy ee__Sehedute' p Authority of Indio The above description provides the basic introduction to the techniques With emphasis on metry control Be0d practice It is not the intent here to present the full these oe Feant 1 the Comoutation as these can be extremely involved and would add nothing si object of this suide 33° Tools Normally Used for Geometry Control ' Offers: Ce: 's are measured front the casting cell Centerline using a imetsl scale fitted with a center point which sits in a punch mark on the hairpins erline off A spirit level shomld be attached t0 this scale So that its set horizontal Also. i Should be held at rigit angles to the esteline of sight in the cet ¢ igure D5) ed Os top of the fixed mounting, reading onto a levelling vod fired with scale 2 Elevations. Elevation readings on the bolts are make with a precision level pla Givided down to at feast 1 im. In order to make sure the readings are taken at Sxacily the seme point cach tine, the levelling rod should be fined with « center point which sets into a punch mark in the top of tie bolt Lengths, A steel tape may be used for length measurement. Iti ads amaveous to Ressute Tengths Between the center point marks on she hairpins, the distasce beticeen adjacent haipins and similarly along the bolt lines hers cog the levelling purca marks, Readings should be estimated at lease 0.5 mm for Day Lateral offets 0 the level bolts should be measured from the eentreline hairpins Ir 4s prefercble to have the bolt position accurately masked on she bulkhead so {et they are always atthe exact required offset from the centreline (Figure Day With care and precision, the veadings obtained wilt allow Precise processing using three- ccurate when it dimensional coordinate geometry computations which are the meer Somes to defining curved surfaces in space. Good record keeping is essertial ne mel Sve esn occasions when accidentally one er more of the seomeyy contiok. 9 halnpins or bolts were fost. This is not irrerievable. It ic usualy possibi¢<ép’ continue Construction By using known relative positions of adjacent undamatted fads Whang ‘means is merely z litte less predictable control over the ‘erection alignment! Ie the First Pier Seems SOMA- ‘NCC-M. AYTAS-CONsOR’ NRTEG™ SS, a 34 Geometry Control of For SOMA-NCC. ‘ fo Sv Aatberiied Sip, ry Elevated Highway on N= Riszactl Menber