Important Bridge No.

77
(Mahanadi River)
in
BLSN – ANMD Section
of
R-TIG Project
11 x 30.458m Open Web Steel Girder
+ 15 x 24.4m PSC (Box-Girder)
+ 2 x 12.2m PSC (I-Girder)
Total length: 787.5 meter
 Index
Sl. No. Description Page No.
1. SPANS ARRANGEMENT 1
2. HYDRAULIC DATA 1
3. FOUNDATION DETAILED 2
4. PIER AND ABUTMENT DETAILED 3
5. SUPER STRUCTURE DETAILED 4
6. CONCRETE QUALITY CONTROL 4
7. DEVIATION FROM GAD 5
8. BEARING DETAILED 6
9. BEARING TEST AND RESULT 6
10. TRACK STRUCTURE 7
11. SPAN LOAD TEST 8
12. LOAD TEST ON SPAN NO. 28, P27 to A2 (12.2m 8-9
PSC-I Girder)
13. LOAD TEST ON SPAN NO. 27, P26 to P27 (24.1m 9-10
PSC- Box Girder)
14. REASONS FOR NOT REQUIRED LOAD TEST ON 10
STEEL GIRDER (30.458m)
15. CAMBER READING 11-13
16. BEARING POSITION PHOTOS 14-15
17. BRIDGE PHOTOS 16-25
 SPAN ARRANGEMENT
New line (doubling) is proposed 30 m from the existing Railway line on the downstream side.

1. Loading Standard : 25 T loading -2008

2. Total Nos of Span : 28 nos

3. Total Length of Bridge : 787.50 m

4. Span Arrangement : 1 x 12.2m PSC I-Girder (A1 – P1)

+ 1 x 24.4m PSC Box-Girder (P1-P2)
+ 11 x 30.458m Open web Steel Girder (P2-P13)
+ 14 x 24.4m PSC Box Girder (P13-P27)
+ 1 x 12.2m PSC (I Girder) (P27-A2)

RDSO drawings reference

12.2 m Span PSC I Girder : RDSO/B -10258
24.4m PSC Box Girder : RDSO/B -10270
30.458m Open web Steel Girder : RDSO/B -11678-11695

7. Rail Level : 276.422 m

8. Trolley refuse provided : 19 Nos. (P2 to P13, P15, P17, P19, P21, P23, P25 & P27)

9. Bottom level of PSC – I Girder : 274.014m (Depth of Girder is 1.750m incl. camber & Deck Slab)

10. Bottom level of PSC – BOX Girder : 273.534m (Depth of Girder is 2.230m incl. camber & Deck Slab)

11. Bottom level of Steel Girder : 275.226m

12. Inspection Platform provided : 900 mm

13. Pathway provided : 1. Steel Girder : 0.9m, 2. Box Girder : 1m

HYDRAULIC DATA
1. Discharge : 5397.6 m3/s, Flow velocity: 3 m/s

2. H. F.L. : 268.810 m

3. L.W.L. : 259.839 m

4. Max. Scour Level (MSL) : 9.055m for Abutment & 7.96m for Pier
However, MSL Limited, due to the presence of
Rock.

5. Lowest Bed Level : 258.225 m at Pier P-14

6. Linear Waterway : 787.50 m

7. Waterway Provided : 787.50 m

9. Vertical Clearance of PSC–I-Girder (VC) : 5.204 m

10. Vertical Clearance of PSC–BOX-Girder (VC) : 4.724 m

11. Vertical Clearance of Steel Girder (VC) : 6.416m

12. Cut water level :269.810 m

 FOUNDATION DETAILED
1 Type of foundation : All Abutment and Pier's open foundation with MCC M-25 Grade of
concrete. However, Foundation rests on hard rock with socketing length.

2 Levelling Course : M-10 grade of concrete

TECHNICAL DATA
Sl. Description Result
No.
1 Type of soil : Clayey sand mixed with gravel, Silt Sand, Silt & Clay, Clayey gravel, Rock.
Rock level found from OGL to Top of rock level: 0 (Min.) to 6.979 (Max.)
2 Bearing capacity :

3 Bearing Pressure :

foundation data
S. No. Structure Av. OGL Bottom of Top of Top of R (Depth in Total Depth of
Name Footing Footing Rock Level Rock) in Foundation
Mtr.

1 A1 265.200 257.420 259.570 261.458 4.038 7.780

2 P1 264.338 257.570 260.440 261.338 3.768 6.768
3 P2 263.538 257.157 260.442 259.662 2.505 6.381
4 P3 259.258 257.642 260.792 258.583 0.941 1.616
5 P4 259.654 256.392 259.542 258.581 2.189 3.262
6 P5 259.350 256.392 259.542 258.600 2.208 2.958
7 P6 260.857 254.921 258.071 256.802 1.881 5.936
8 P7 260.912 253.885 257.035 255.400 1.515 7.027
9 P8 261.028 253.589 257.040 255.016 1.427 7.439
10 P9 261.078 252.262 255.792 254.099 1.837 8.816
11 P10 260.813 253.887 257.037 255.248 1.361 6.926
12 P11 259.826 254.240 257.540 256.011 1.771 5.586
13 P12 259.840 253.883 257.033 256.821 2.938 5.957
14 P13 259.082 254.791 257.941 257.416 2.625 4.291
15 P14 258.225 255.792 257.942 257.225 1.433 2.433
16 P15 258.515 255.942 258.092 258.515 2.573 2.573
17 P16 258.908 255.792 257.942 258.908 3.116 3.116
18 P17 259.313 257.042 259.192 259.313 2.271 2.271
19 P18 259.618 257.042 259.192 259.618 2.576 2.576
20 P19 260.114 258.292 260.442 260.114 1.822 1.822
21 P20 260.682 258.292 260.442 260.060 1.768 2.390
22 P21 262.299 258.292 260.442 260.424 2.132 4.007
23 P22 264.029 258.292 260.442 261.491 3.199 5.737
24 P23 263.655 257.042 259.192 261.607 4.565 6.613
25 P24 262.826 259.542 261.692 261.942 2.400 3.284
26 P25 262.519 259.542 261.692 261.953 2.411 2.977
27 P26 262.745 259.542 261.692 261.902 2.360 3.203
28 P27 264.463 259.542 261.692 262.776 3.234 4.921
29 A2 265.111 260.042 262.942 263.227 3.185 5.069
 PIER AND ABUTMENT DETAILED
1 Abutment and Pier : MCC M-25 grade of concrete

2 Bed Block : RCC M-35 grade of concrete

Abutment and Pier data

S. Structure Rail Level Top of RL-BF RL-TF Top of Bottom of Abutment /
No. Name (m) Foundation Depth Depth Bed Bed Pier Height
(m) (m) (m) Block (m) Block (m) (m)

1 A1 276.447 259.570 19.027 16.887 273.784 272.784 13.214

2 P1 276.447 260.440 18.877 16.007 273.104 271.604 11.164
3 P2 276.447 260.442 19.290 16.005 273.104 271.604 11.162
4 P3 276.447 260.792 18.805 15.655 273.304 271.804 11.012
5 P4 276.447 259.542 20.055 16.905 273.304 271.804 12.262
6 P5 276.447 259.542 20.055 16.905 273.304 271.804 12.262
7 P6 276.447 258.071 21.526 18.376 273.304 271.804 13.733
8 P7 276.447 257.035 22.562 19.412 273.304 271.804 14.769
9 P8 276.447 257.040 22.858 19.407 273.304 271.804 14.764
10 P9 276.447 255.792 24.185 20.655 273.304 271.804 16.012
11 P10 276.447 257.037 22.560 19.410 273.304 271.804 14.767
12 P11 276.447 257.540 22.207 18.907 273.304 271.804 14.264
13 P12 276.447 257.033 22.564 19.414 273.304 271.804 14.771
14 P13 276.447 257.941 21.656 18.506 273.304 271.804 13.863
15 P14 276.447 257.942 20.655 18.505 273.104 271.604 13.662
16 P15 276.447 258.092 20.505 18.355 273.104 271.604 13.512
17 P16 276.447 257.942 20.655 18.505 273.104 271.604 13.662
18 P17 276.447 259.192 19.405 17.255 273.104 271.604 12.412
19 P18 276.447 259.192 19.405 17.255 273.104 271.604 12.412
20 P19 276.447 260.442 18.155 16.005 273.104 271.604 11.162
21 P20 276.447 260.442 18.155 16.005 273.104 271.604 11.162
22 P21 276.447 260.442 18.155 16.005 273.104 271.604 11.162
23 P22 276.447 260.442 18.155 16.005 273.104 271.604 11.162
24 P23 276.447 259.192 19.405 17.255 273.104 271.604 12.412
25 P24 276.447 261.692 16.905 14.755 273.104 271.604 9.912
26 P25 276.447 261.692 16.905 14.755 273.104 271.604 9.912
27 P26 276.447 261.692 16.905 14.755 273.104 271.604 9.912
28 P27 276.447 261.692 16.905 14.755 273.104 271.604 9.912
29 A2 276.447 262.942 16.405 13.505 273.784 272.784 9.842
 SUPER STRUCTURE DETAILED
Pier and Abutment bed block:

Sl. No. Structure Width Length Depth

1 Abutment A1 & A2 3.47 m 6.85 m 1m
2 Pier P1 & P27 3.8 m 10.0 m 1.5 m
3 Pier P2 & P13 3.25 m 10.0 m 1.5 m
4 Pier P3 & P12 2.15 m 10.0 m 1.5 m
5 Pier P14 & P26 3.8 m 10.0 m 1.5 m
6 Pier P4 to P11 2.15 m 10.0 m 1.5 m
7 Pier P15 to P25 3.8 m 10.0 m 1.5 m

Bearing Positioning:

Sl. No. Structure Along the track Across the track

1 12.2m PSC-I-Girder 2.30 m 2.52 m
2 24.1m PSC-Box-Girder 2.30 m 2.52 m
3 30.458m Steel open web Girder 0.996 m 5.28 m

Grade of Concrete Used:

Sl. No. STRUCTURE CONC. GRADE USED

1 Bed Block : RCC M-35 grade of concrete

2 Deck Slab : RCC M-30 grade of concrete

3 PSC Box and I Girder : M-45 grade of concrete

CONCRETE QUALITY CONTROL

SL. NO. STRUCTURE D.O.C. D.O.T. GRADE COMP. AVG. CPM.

OF CONC. STRENGTH STRENGTH

32.89
RAFT 3RD
1 10.03.2017 07.04.2017 M-25 32 32.44
STAGE (P6)
32.44
44.3
2 PIER CAP (P11) 12.01.2018 09.02.2018 M-35 43.56 43.8
43.56
57.33
PSC I GIRDER
3 12.11.2017 10.12.2017 M-45 58.22 57.77
(P27-A2) D/S
57.77
 DEVIATION FROM GAD
Sl.
DESCRIPTION AS PER GAD AS PER COMPLETION REMARKS
No.
1 Pier Cap (P1 & P27) (6.85mX3.35mX1.2m) (10.0mX3.8mX1.5m) As per site requirement,
2 all deviations from the
Pier Cap (P2 & P13) (8.72mX3.445mX1.2m) (10.0mX3.25mX1.5m)
GAD so far adopted during
3 Pier Cap (P3 & P12) (8.72mX2.59mX1.2m) 10.0mX2.15mX1.5m) construction are on safer
4 side. Higher section
Pier Cap (P14 & P26) (10.0X3.8mX3.35mX1.5m) 10.0mX3.80mX1.5m)
adopted. The design
5 Bearing Positioning (2.10m & 2.10m) (2.30m & 2.52m) - span document was approved
Along & Across the (12.20m & 24.4m) from IIT, Delhi ( for Proof
track checking)
(1.20 m & 5.40m) (0.996m & 5.28m) -span
(30.5m)
 BEARING TEST
Bearing has been tested by third party labs.
Sl. DESCRIPTION TYPE OF BEARING SIZE COMPANY
No.
1 Bearing For PSC – I Elastomeric bearing 450 mm X 390 mm X 80 M/s. Uttam Con infra.
Girder pads mm Company Pvt. Ltd., Raipur
2 Bearing For PSC BOX Elastomeric bearing 750 mm X 600 mm X 120 M/s. Uttam Con infra.
Girder pads mm Company Pvt. Ltd., Raipur
Expansion Bearing 450mm X 850mm X 397mm
3 Bearing For open web
Roller cum rocker 650mm X 1000mm X
Steel girder
bearing 397mm

BEARING TEST RESULT

1. Bearing size (mm) : 750 x 600 x 120 mm
Quantity : 60+2 Nos.
Tested As per UIC : 772-2R
SL. TYPE OF TEST TEST RESULT PERMISSIBLE RANGE REMARKS
No.
1 Hardness (IRHD) 60 60 ± 5 Satisfactory
2 Elastic Modulus Record in Test Not Specified -
Report
3 Shear Modulus (G) Kg./cm2 7.77 8.16 Kg./cm2 ± 15% Satisfactory
(i.e. 6.94 TO 9.384)
4 Bond Test No Bond failure Shall not cause any bond failure Satisfactory
5 Ultimate Compressive > 62.00 61.78 (Minimum) Satisfactory
Strength (MPa) 6 x working stress of Bearing

2. Bearing size (mm) : 450 x 390 x 80 mm

Quantity : 8+2 Nos.
Tested As per UIC : 772-2R
SL. TYPE OF TEST TEST RESULT PERMISSIBLE RANGE REMARKS
No.
1 Hardness (IRHD) 60 60 ± 5 Satisfactory
2 Elastic Modulus Record in Test Not Specified -
Report
3 Shear Modulus (G) Kg./cm2 8.03 8.16 Kg./cm2 ± 15% Satisfactory
(i.e. 6.94 TO 9.384)
4 Bond Test No Bond failure Shall not cause any bond failure Satisfactory
5 Ultimate Compressive > 62.00 61.78 (Minimum) Satisfactory
Strength (MPa) 6 x working stress of Bearing

3. Physical Properties:
Bearing size (mm) : 1) 750 x 600 x 120 mm : 60+2 Nos. 2) 450 x 390 x 80 mm : 8+2 Nos.

Sl. PHYSICAL (UNAGED) SPECIFIED OBSERVATION

No.
1 Hardness 60 ± 5 60

2 Tensile strength MPa 17 (Min.) 18.58

 3 % Elongation at Break 400 (Min.) 650

4 Adhesive Strength kN/m 7 (Min.) 17.50

TRACK STRUCTURE
SL. NO. DESCRIPTION WORK DONE
Steel Girder
1 Rail track details :26 m rail + 6 bolts with 1m fish plate (SWR)

2 Sleeper spacing : Bridge Approach sleeper <60cm

Joint sleeper (Clear spacing) 20cm

3 Channel sleeper : < 60 cm c/c spacing

Spacing at joint -20cm (Clear spacing)

4 Pathway of Steel girder : 900 mm

Concrete Girder
1 Ballast Cushion on deck :350 mm

2. Pathway of Box Bridge : 1000 mm

3. Expansion joint : Expansion joint has been provided as per RDSO drawing
no.RDSO/ B – 1757 R.
Manufactured by M/s. Vigyashree Sharoda Infrastructure Ltd.,
Bhopal.
MTC dated on 08.01.2018.
Total 18 nos of expansion joints are provided both 12.2m span
PSC I Girder & 24.4m PSC Box Girder.
1. 4.8m x 2 nos = 9.60 RMT
2. 5.8m x 15 nos = 81.2 RMT

Bridge Approach
1 Bridge Approach Ballast : 350mm
Cushion
 SPAN LOAD TEST
ACCEPTANCE CRITERIA FOR CONCRETE BRIDGE:
The acceptance criteria of the load test is based on IRC-SP-51.
i. Increase and decrease in deflections at a point shall follow a linear relation, with actual
deflections not exceeding the theoretically estimated ones by more than 10%.
ii. The maximum crack width in reinforced concrete shall not exceed 0.25mm to 0.3mm
(but no crack in prestressed concrete).
iii. The deflection at the end of the 24 hours of maintaining the test load shall not exceed
the corresponding values at the start of this 24 hour period by 5%.
iv. The residual deflection at any point 24 hours after complete unloading shall not exceed
10% of the maximum observation deflection at that point ( i.e. recovery : 85% or more.)

1. LOAD TEST ON SPAN NO. 28, P27 to A2 (12.2m PSC-I Girder)

LOAD CALCULATIONS

LENGTH OF GIRDER = 12.2 m

Effective Span = 11.69 m
Complete = 13.40 m

COEFFICIENT OF DYNAMIC AUGMENT (CDA)

From bridge rule Appendix-XXIII
EUDL of 11.00 m span=130.75 MT
EUDL of 12.00 m span=140.40 MT
Now, value of X
=9.65/X=l/0.69
X=0.69x9.65=6.65 MT

Hence EUDL of 11.69 m girder=130.75 MT+6.65 MT=137.40 .................................(A)

For single track span (as per bridge rule 2.4.1.1)

CDA=0.15+8/ (6+L)
=0.15+8/ (6+11.69)
=0.60
For 350 mm ballast cushion, from 2.4.2.1 for all gauges
={[2-(d/0.9)]x1/2xCDA}
={[2-(0.35/0.9)]x1/2x0.6}
= {[2-(0.39)] x0.3}
= {[2-(0.39]] x0.3}
=0.483 ................................................................................ (B)
 EUDL with CDA for 11.69 m span
=0.48x137.4+137.4
=65.95+137.4
=203.35
Characteristic imposed load 203.35 MT ................................... (C)

DEAD LOAD
Weight of ballast and track =5.67 T/mtr
For 11.69 mtr span = 66.2823 MT
(Weight of girder already present and need not be taken)
Characteristic Dead load= 66.28 MT ..................................................... (D)

Test load for limit state of deflection

= [D + (1.25*C)]
= [66.28 + (1.25x203.35)]
=320.47 MT (as per 18.2.3 of barcode)
Maximum Bending Moment with test load
M= w x L /B
=WL/8=320.47x11.69/8
= 468.29 MT

Required loading for center half of span

M= (WL2/32)
W= (32xM)/L2
W= (32x (m/3)]/L2 W= (32xm)/3L2
= (32x468.29)/(3x11.69x11.69)
=14985.28/409.97 =36.55
W=36.55x11.69/2
=213.63 MT (mid span loading in 5 increments)

LOADING STAGE:

Sl. No. LOAD INCREMENT CUMULATIVE LOAD

PER STAGE
1 42.72 T 42.73 T

2 42.72 T 85.46 T

3 42.72 T 128.19 T

4 42.72 T 170.92 T

5 42.72 T 213.63 T

Increasing load each stage is 20%.

100% Load on Span @ 213.63 MT.

OBSERVED SETTLEMENT AT FULL LOAD FOR CENTRE SPAN:

 D5 D6

6.08 mm 5.54 mm

OBSERVED SETTLEMENT AFTER COMPLETION OF UNLOADING FOR CENTRE

SPAN:
D5 D6

0.18 mm 0.83 mm

1. % of Recovery for D5 = 97.04%

2. % of Recovery for D6 = 85.02%

Maximum settlement as per IRS concrete bridge

(Cl. No. 18.2.5.2)
Max. Settlement = L/500 (Where L is effective span = 11.69m)
= 11690/500 = 23.38 mm

Maximum settlement to avoid recovery as per IRS concrete bridge

(Cl. No. 18.2.5.3)

Max. Settlement to avoid recovery = 40 x L2/h (Where L is effective span = 11.69m, h=2180)
= 40 x 11.69 x 11.69/2180= 2.51mm

CONCLUSIONS:

At 100 % load (213.63MT) settlement observed at the centre is 6.08 mm and 5.54 mm, hence the
bridge is in good condition and recovery required as centre displacement is more than 2.51
mm ( As per Cl. No. 18.2.5.3 of IRS concrete bridge code : 1997)

Recovery is more than 85% and no cracks were observed during the time of testing, hence the
span is found to be Okay.

2. LOAD TEST ON SPAN NO. 27, P26 to P27 (24.1m PSC- Box Girder)

LOAD CALCULATIONS

LENGTH OF GIRDER = 25.20 m

Effective Span- 24.10 m
Complete = 26.10 m

COEFFICIENT OF DYNAMIC AUGMENT (CDA)

From bridge rule Appendix-XXIII
EUDL of 24.00 m span=245.18 MT
EUDL of 25.00 m span= 253.66 MT
Now, value of X
=8.48/X=l/0.10
X=0.10x8.48=0.848 MT
 Hence EUDL of 24.10 m girder=245.18 MT+0.848 MT=246.03 .................................(A)

For single track span (as per bridge rule 2.4.1.1)

CDA=0.15+8/ (6+L)
=0.15+8/ (6+24.10)
=0.416
For 350 mm ballast cushion, from 2.4.2.1 for all gauges
={[2-(d/0.9)]xl/2xCDA}
={|2-(0.35/0.9)]x1/2x0.416}
= {[2-(0.39)] x0.208}
= {[2-(0.39]] x0.208}
=0.34 ................................................................................ (B)

EUDL with CDA for 24.10 m span

=0.34x246.03+246.03
=83.65+246.03
=329.68 MT
Characteristic imposed load 329.68 MT ................................... (C)

DEAD LOAD
Weight of ballast and track =5.67 T/mtr
For 24.1 span = 136.65 MT
(Weight of girder already present and need not be taken)
Characteristic Dead load= 136.65 MT ..................................................... (D)
Test load for limit state of deflection
= [D+ (1.25*C)]
= [136.65+ (1.25x329.68)]
=548.75 MT (as per 18.2.3 of barcode)
Maximum Bending Moment with test load
M= w x L /B
=WL/8=548.75x24.10/8
= 1653.11 MT

Required loading for center half of span

M= (WL2/32)
W= (32xM)/L2
W= (32x (m/3)]/L2 W=(32xm)/3L2
= (32x1653.11)/3x24.10x24.10
=52899.52/1742.43 =30.36
W=30.36x24.10/2
=365.838 MT (mid span loading in 5 increments)

LOADING STAGE:

Sl. No. LOAD INCREMENT CUMULATIVE LOAD

PER STAGE
1 73.17 T 73.17 T

2 73.17 T 146.34 T
 3 73.17 T 219.51 T

4 73.17 T 292.68 T

5 73.17 T 365.85 T

Increasing load each stage is 20%.

100% Load on Span @ 365.85 MT.

OBSERVED SETTLEMENT AT FULL LOAD FOR CENTRE SPAN:

D5 D6

6.88 mm 6.78 mm

OBSERVED SETTLEMENT AFTER COMPLETION OF UNLOADING FOR CENTRE

SPAN:
D5 D6

0.60 mm 0.58 mm

3. % of Recovery for D5 = 91.28%

4. % of Recovery for D6 = 91.45%

Maximum settlement as per IRS concrete bridge

(Cl. No. 18.2.5.2)
Max. Settlement = L/500 (Where L is effective span = 24.1m)
= 24100/500 = 48.2 mm

Maximum settlement to avoid recovery as per IRS concrete bridge

(Cl. No. 18.2.5.3)

Max. Settlement to avoid recovery = 40 x L2/h (Where L is effective span = 24.1m, h=2150)
= 40 x 24.1 x 24.1/2150= 10.83mm

CONCLUSIONS:

At 100 % load (365.85MT) settlement observed at the centre is 6.88 mm and 6.78 mm, hence the
bridge is in good condition and recovery is not required as centre displacement is less than
10.83 mm ( As per Cl. No. 18.2.5.3 of IRS concrete bridge code : 1997)

Recovery is more than 85% and no cracks were observed during the time of testing, hence the
span is found to be Okay.

3. LOAD TEST FOR STEEL GIRDER (30.458m)

 NOT REQUIRED

AS PER CLAUSE -3(A) OF GUIDELINES FOR CARRYING OUT LOAD DEFLECTION TEST
OF PLATE, OPEN WEB & COMPOSITE GIRDER (BS-128):
“For RDSO standard spans of steel Plate & Open Web Girder Bridges, whose fabrication work
is also inspected & passed by RDSO officials or RDSO certified fabrication inspection unit under
CBE of Zonal Railways or any other inspecting agency, load deflection testing is not required”.

Here, QAP and WPSS are approved by RDSO. And also inspected & passed by RDSO and RDSO
approved agency (Third party lab).

CAMBER READING
30.5m span steel girder camber required as per RDSO drawing no. RDSO/B-11678

SL. NO. CAMBER POINT REQUIRED

CAMBER (mm)
1 L-0 0
2 L-1 9.59
3 L-2 16.21
4 L-3 20.72
5 L-4 16.21
6 L-5 9.59
7 L-6 0

READING AT SITE:

Camber reading on steel Girder

BR. NO. - 77 STEEL GIRDER CAMBER CHECKED (AFTER GROUTING)

SPAN NO:- 1 FROM (P3-P2)

SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 0 0
2 L-1 9.59 10 15
3 L-2 16.21 16 16
4 L-3 20.72 21 24
5 L-4 16.21 16 16
6 L-5 9.59 11 8
7 L-6 0 -1 0

SPAN NO:- 2 FROM (P4-P3)

SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 0 -1
2 L-1 9.59 10 8
3 L-2 16.21 19 20
 4 L-3 20.72 29 26
5 L-4 16.21 18 18
6 L-5 9.59 11 12
7 L-6 0 0 -1

SPAN NO:- 3 FROM (P5-P4)

SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 -1 0
2 L-1 9.59 10 13
3 L-2 16.21 20 23
4 L-3 20.72 24 27
5 L-4 16.21 18 21
6 L-5 9.59 13 11
7 L-6 0 0 0

SPAN NO:- 4 FROM (P6-P5)

SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 0 0
2 L-1 9.59 9 9
3 L-2 16.21 18 17
4 L-3 20.72 22 20
5 L-4 16.21 18 18
6 L-5 9.59 11 11
7 L-6 0 1 0

SPAN NO:- 5 FROM (P7-P6)

SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 -1 0
2 L-1 9.59 10 9
3 L-2 16.21 14 16
4 L-3 20.72 15 17
5 L-4 16.21 15 15
6 L-5 9.59 8 7
7 L-6 0 -1 -1

SPAN NO:- 6 FROM (P8-P7)

SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 0 0
2 L-1 9.59 12 10
3 L-2 16.21 18 14
4 L-3 20.72 22 22
5 L-4 16.21 17 15
6 L-5 9.59 8 8
7 L-6 0 0 -1
 SPAN NO:- 7 FROM (P9-P8)
SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 0 -1
2 L-1 9.59 10 7
3 L-2 16.21 22 17
4 L-3 20.72 27 17
5 L-4 16.21 27 18
6 L-5 9.59 17 8
7 L-6 0 0 -2

SPAN NO:- 8 FROM (P10-P9)

SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 -1 0
2 L-1 9.59 8 12
3 L-2 16.21 16 19
4 L-3 20.72 16 22
5 L-4 16.21 15 19
6 L-5 9.59 9 10
7 L-6 0 0 0

SPAN NO:- 9 FROM (P11-P10)

SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 0 -1
2 L-1 9.59 8 12
3 L-2 16.21 17 21
4 L-3 20.72 18 21
5 L-4 16.21 15 15
6 L-5 9.59 8 11
7 L-6 0 -1 0

SPAN NO:- 10 FROM (P12-P11)

SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 -1 -1
2 L-1 9.59 9 11
3 L-2 16.21 14 14
4 L-3 20.72 19 21
5 L-4 16.21 17 18
6 L-5 9.59 10 13

7 L-6 0 0 0

SPAN NO:- 11 FROM (P13-P12)

 SL. CAMBER Required (mm) as CAMBER READING
REMARKS
NO. POINT per RDSO U/S D/S
1 L-0 0 0 0
2 L-1 9.59 14 13
3 L-2 16.21 17 13
4 L-3 20.72 20 19
5 L-4 16.21 16 13
6 L-5 9.59 11 8
7 L-6 0 -1 -2

GIRDER STRESSING

24.4 M SPAN PRESTRESSED CONCRETE BOX GIRDER

Girder stressing has been done as per table-3 of RDSO drawing no. RDSO/B-10270/1

CABLE TOTAL CABLE INITIAL THEORETICAL

NOS. LENGTH PS FORCE AT JACKING ELONGATION AT EACH STAGE OF
(mm.) END(kN) END BEFORE SLIP (mm) PRESTRESSING
*
1 24999.2 1653.3 87.83 1st stage
2 24970.7 1653.3 87.96 2nd stage
3 24947.0 1653.3 88.11 1st stage
4 24927.3 1653.3 87.61 2nd stage
5 24902.2 1653.3 88.29 1st stage
6 16042.9 1653.3 56.77 2nd stage
7 16042.9 1653.3 56.77 1st stage
E 24902.2 As per requirement 2nd stage
* Excluding 0.75m extra length required at each side for jack attachment.

STRESSING RESULT:
MEASUREMENT IN SPAN: P14 – P15
CABLE THEORETICAL TOTAL MODIFIED SITE READING DATE OF
NO. ELONGATION AT EACH ELONGATION ELONGATION MEASUREMENT
END BEFORE SLIP (mm) (mm)
(mm)
● RAIPUR END U/S:

RAIPUR END: 92
TITLAGARH END: 92
1 87.83 89 21.02.2018
● RAIPUR END D/S:

RAIPUR END: 90
TITLAGARH END: 88
● RAIPUR END U/S:

RAIPUR END: 91
TITLAGARH END: 91
2 87.96 89 29.11.2018
● RAIPUR END D/S:

RAIPUR END: 97
TITLAGARH END: 91
● RAIPUR END U/S:
3 88.11 87 21.02.2018
RAIPUR END: 89
 TITLAGARH END: 90
● RAIPUR END D/S:

RAIPUR END: 86
TITLAGARH END: 87
● RAIPUR END U/S:

RAIPUR END: 91
TITLAGARH END: 93
4 87.61 89 29.11.2018
● RAIPUR END D/S:

RAIPUR END: 95
TITLAGARH END: 90
● RAIPUR END U/S:

RAIPUR END: 92
TITLAGARH END: 86
5 88.29 89 21.02.2018
● RAIPUR END D/S:

RAIPUR END: 91
TITLAGARH END: 92
● RAIPUR END U/S:

RAIPUR END: 63
TITLAGARH END: 62
6 56.77 59 29.11.2018
● RAIPUR END D/S:

RAIPUR END: 63
TITLAGARH END: 63
● RAIPUR END U/S:

RAIPUR END: 59
TITLAGARH END: 62
7 56.77 59 21.02.2018
● RAIPUR END D/S:

RAIPUR END: 62
TITLAGARH END: 56

TEST RESULT OF PRESTRESSING ACCESSORIES

All prestressing accessories have been tested by M/s. DYNAMIC PRESTRESS (I) PVT. LTD.

Following testing has been done by M/s. DPIPL factory. The dimensions of randomly selected
Anchorages are given here under.

1.0 REPORT ON ANCHOR CONE 6 DP 13 -16 Nos.

Sr. NO Flange size Total Length Visual

( 145.00 X 145.00 ±3.0mm) (100.00 ± Inspection
3.0mm)
1 145 X 145 100.1 Satisfactory
2 145 X 145 100.2 Satisfactory
REPORT ON ANCHOR HEAD 6 DP 13 - 16 Nos LOT NO : JZ

Sr. DIAMETER THICKNESS Hardness Visual

NO 40.00± 2.0 mm 152 - 230 BHN Inspection
100.00 ± 2.0 mm
1 100.0 40.1 160 Satisfactory
2 100.1 40.0 159 Satisfactory

REMARKS: The above test results are satisfactory & the material is confirming to manufacturers
approved drawing.

2.0 REPORT ON ANCHOR CONE 12 DP13- 242 NOS.

Sr. FLANGE SIZE TOTAL LENGTH 130.00 VISUAL

NO 190.00 ±3.0mm ± 3.0mm INSPECTION

1 191 130 SATISFACTORY

2 189.6 129.4 SATISFACTORY
3 190.9 131.8 SATISFACTORY

3.0 REPORT ON ANCHOR HEAD 12 DP13- 242 NOS LOT NO : LU

Sr. DIAMETER THICKNESS HARDNESS VISUAL

NO 130.00 ± 2.5 mm 48.00± 2.5 mm 146 - 230 BHN INSPECTION
1 131.4 48.5 198 SATISFACTORY
2 130.7 48.5 189 SATISFACTORY
3 130 48.2 189 SATISFACTORY

REMARKS: The above test results are satisfactory & the material is confirming to manufacturers
approved drawing

4. 0 REPORT ON WEDGES 12.7mm : 3328 NOS

Following testing has been done by M/s. DPIPL factory. The dimensions of randomly selected Wedges
are given here under.
RIR NO - W-113 / T-3190 , T-3191
Sr. OUTER LENGTH HARDNESS TAPER BY GAUGE VISUAL
No. DIAMETER 40.00 ± IN CHECKING
24 ± 0.50mm 1.0mm 15N SCALE 88-
93
1 24.25 40.5 91 SATISFACTORY SATISFACTORY
2 24.40 40.25 92 SATISFACTORY SATISFACTORY
3 24.30 40.26 90 SATISFACTORY SATISFACTORY
 One sample from the lot has been given a load up to 95% of UTS of strand as per
requirement Wedge set observed as follows
Strand Dia. 12.7 mm .Theoretical Breaking Load For Calculation 18737 kg Jack
Ram Area-48.5 cm2
Applied load :95% = 18737 X 95/100 = 17800.15 Kg

Applied Pressure = load / Ram Area =17800.15/48.5 =367Kg/cm2 (Say 370Kg/cm2)

APPLIED PRESSURE
% LOAD REMARK
(Kg/cm2)
95 % 370 Kg/cm2 2-3 mm SLIP

REMARKS: The above results are satisfactory. After removing the sample by visual inspection
the sample (wedge 12.7 mm) is found free from any cracks & deformation.

5.0 REPORT ON MASTERGRIP 12.7 MM (MP.TL- 30 NOS

Following testing has been done by M/s. DPIPL factory. The dimensions of randomly selected Wedges
are given here under.
RIR NO – KJ-2/ T – 3068

Sr. OUTER LENGTH HARDNESS TAPER BY GAUGE VISUAL

No. DIAMETER 50.00 ± 15N SCALE 88- CHECKING
29.50 ±2.Omni 2.0mm 93
1 29.58 50.18 90.7 SATISFACTORY SATISFACTORY
2 29.52 50.20 91.2 SATISFACTORY SATISFACTORY
3 29.64 50.14 92.3 SATISFACTORY SATISFACTORY

One sample from the lot has been given a load up to 85% of UTS of strand as per
requirement Wedge set observed as follows
Strand Dia. 12.7 mm .Theoretical Breaking Load For Calculation 18737 kg Jack
Ram Area-48.5 cm2
Applied load : 85% = 18737 X 85/100 = 15926.45 Kg

Applied Pressure = load / Ram Area =15926.45/48.5 =328.38 Kg/cm2(Say 330 Kg/cm2)

APPLIED PRESSURE
% LOAD REMARK
(Kg/cm2)
85 % 330 Kg/cm2 3 mm SLIP

REMARKS: The above results are satisfactory. After removing the sample by visual inspection the
sample (wedge 12.7 mm) is found free from any cracks & deformation.
6.0 C.R.C.A SHEATHING PIPE TEST REPORT

Material details: sheathing pipe bm dia.75 mm,

Thickness : 0.3mm
Code reference: IRC 18/2000
Qty.:2317.83 RMT

Test Result:

Type of Test Permissible Unit Observations Remarks

WORKABILITY TEST Failure or opening of Joints visually inspected All the samples passes
joints should not take in all the samples after the test satisfactorily.
Test sample 1100mm long place. testing and observed no
is fixed on a test opening or failure of
frame lenc co a radius joints.
of 1800 mm alternately
on either side to
complete 3 cycles.
No.of test sample(s)-
3No(s).

TRANSVERSE LOAD TEST Max. deformation should Deformation is less

be less than 5% at 700N than 5% in sample and
Discretion I II III hence passes the test
Test samples were
subjected to a % Deflection 1.4 1.2 1.6 satisfactory
Transverse load
through a circular
contact surface of
Dia.l2.0mm on a test
bed.
TENSION LOAD TEST No deformation or No slippage of coupler All the samples passes
Samples were subjected opening of joints or occurred or deformation of the test satisfactorily.
to a tensile load with slippage of coupler joints took place.
a coupler screwed at should take place at
one end, up to a 1400N
specified limit.

WATER LOSS TEST water loss should not All the samples passes
The samples are sealed exceed to a max. of the test satisfactorily.
at both the ends after 1.5% of the total Discretion I II III
fill- led with water volume of water filled % water loss NIL NIL NIL
subjected to a pressure in Sheathing pipe.
of O.05MPa with the
help of a hand Pump &
retained at that
pressure for 5 min.
 CONCRETE PERMEABILITY TEST
Concrete Permeability has been tested by third Party labs (M/s. Marshal Geo test laboratory) as
per IS : 3085.

Mahanadi Bridge no. 77

PARTICULAR OF SAMPLE (S)

'
Nature:- Concrete Permeability of M-45 Grade ( Size 200mm dia and 120mm height)
Sample No.(S) Details:- One Sample ( Set)
Quantity .:- 03 Nos. of Core
Packing Container:-Loose

RESULT OF CONCRETE PERMEABILITY

Sample No. Sample -1

Particulars / Sped. No. Speci.1 Speci.2 Speci. 3

Dt. of Casting (as reported) 12/03/18

12/04/18

Dt. of Testing

Days 30 Days

Applied Pressure ( Kg(f)/cm2) total 96 hrs.1 Bar 3 Bar7 Bar 1 Bar 3 Bar7 Bar1 Bar 3 Bar7 Bar

Test Temperature (°C ) 26 27 26

Duration ( HRS ) 48 24 24 48 24 24 48 24 24

Weight Before Test ( gm ) 9794 9671 9656

Weight After Test ( gm ) 9798 9676 9662

Penetration (mm) 24.60 25.20 26.40

Average Penetration ( mm ) 25.40

Remarks: The value of average penetration is greater than 25 mm. Result found non-satisfactory.
Bearing Restoration with 120T Jack – 4 Nos.

Span 20 - Titlagarh end (LHS)

After Restoration – 1 mm Normal

Before Restoration -10mm tilt

Span 28 - Raipur end (LHS)

Before Restoration -8mm tilt After Restoration -0mm Normal

Span 27 - Raipur end (LHS)
Before restoration – 5mm tilt After restoration – 0mm Normal

Span 26 -Titlagarh end (RHS)

Before Restoration -5mm tilt Before Restoration -0mm Normal

Bridge Photos