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Rob PSC1
Rob PSC1
Cement
Reinforcement Steel
Coarse Aggregate
Fine Aggregate
Admixture
HT Strands
Sheathing Strip
Pre-stressing Hardware
Cement:
Source: 53 Grade L&T / Grasim / Ambuja
Material shall be tested at the manufacturing source and Test certificate shall be
collected for each lot. In every batch the following test shall be conducted at Q.C.
Lab (Subarnarekha site) to ensure that Manufacturers Test certificate results are
matching Q.C. Lab results.
Consistency
Initial Setting Time
Final Setting Time
Fineness Of Cement
Compressive Strength
Soundness Test.
Acceptance Criteria: Test results shall conform to IS 8112.
Reinforcement Steel:
Source: TISCO / SAIL / RINL / SRMB/ IISCO
Chemical and Mechanical properties shall be tested as per IS 1786 at the
manufacturing source & test certificates shall be collected along with the every
consignment of steel. Also steel samples shall be tested randomly in outside
laboratories to check whether the test certificate results match the laboratory test
result.
Acceptance Criteria: Test result shall conform to IS 1786.
Coarse Aggregate:
Source: Durga crusher/ Tarini crusher
Material 40mm / 20mm / 10mm shall be received at ROB sites. Samples shall be
collected for every 200 m3 of aggregate or for any change of source, the following
test shall be conducted in Q.C. Lab as per IS 2386
Fine Aggregate:
Source: Gobarghata
Material shall be received and screened at the stacking yard of the respective
ROB site. Sample shall be collected for every 200 m 3 of aggregate or any
change of source, the following test shall be conducted in Q.C. Lab
Gradation
Silt content shall be estimated as per IS 2386 & ensured less
than 3%.
Admixture:
Source: Chembond, Sika
Admixtures required for different mix grades shall be procured from approved
agencies. Test certificates shall also be collected along with the every
consignment. The following tests are conducted in Q.C. Lab to verify with Test
certificate result
HT Strands:
Source: M/s Indore Wire & Tata SSL
12.7mm dia low relaxation 7 ply strands of class II conforming to IS 14268 1995
Random inspection of the materials shall be done by consultants engineer at
factory.
Pre-stressing Hardware
Source: M/s Freyssinet Pre-Stressing Concrete Company Ltd., Mumbai
12 T 13 & 19 K 13 anchorage cone & cir clip
FPCC will supply 19K13 and 12T13 anchorage cones which will be as per
specifications and drawings.
For ROB-1, 19K13 and for all other ROBs 12T13 shall be used.
CONSTRUCTION METHODOLOGY:
SALIENT FEATURES OF PSC BEAM OVER OBLIGATORY
SPAN
DETAILS OF SECTION OF PSC GIRDERS FOR
4 ROBS
f
e
c
d
t
175
175
b
a
175
175
115
DETAILS
a
b
c
d
e
f
t
g
Span length
ROB-1
ROB-2
ROB-3
ROB-4
240
200
100
1530
180
1100
275
680
40.50
240
200
100
1080
180
1100
275
680
23.14
240
200
100
1330
180
1100
275
680
29.17
240
200
100
1080
180
1100
275
680
23.80
4 ROBS
DETAILS
ROB-1
ROB-2
ROB-3
ROB-4
Concrete
quantity (cum)
Span length
Grade of
concrete
Pre stressing
type
Dia of
sheathing pipe
Bearing type
Nos of girders
per span
42.2
18.25
31.30
20.60
40.50
M40
23.14
M40
29.17
M40
23.80
M40
19K13
12T13
12T13
12T13
85mm dia
75mm dia
75mm dia
75mm dia
Elastomeric
6nos.
Elastomeric
6nos.
Elastomeric
6nos.
12.
Description
ROB-1
ROB-4
14.445m
980mm
32.410m
980mm
8.145m
14.837m
14.934m
7.845m
17.349m
26.26m
32.799 m
32.879 m
26.000 m
34.870 m
9.201m
8.61 m
480mm
600 mm
8.060m
1.92m
7.35 m
1.480 m
2.415m
1.99 m
02 Set
01Set
01 No
02 Nos
06&02Nos
03 Nos
04 Nos
02 each
01No
Manpower:
Project engineer
Junior engineer
Foreman
Supervisor
Surveyor
Skilled/ Unskilled Labor:
Carpenter
Fitter
Khalasis
Concrete pump operator
TM Driver
Male Coolie
01
01
01
01
01
35
35
50
02
04
15
CONSTRUCTION METHODOLOGY:
The procedure as described below is for ROB-1, PSC girders. For other ROBs
similar arrangements and methods shall be adopted during the time of
construction as per respective drawing.
Trestle Foundation
After doing survey, trestle foundations shall be marked and shall be constructed
as per attached drawing 8007/TS/516C.
i.
ii.
iii.
Reinforcement
Treated bars shall be fabricated in advance as per approved bar bending
schedule. After fixing and checking verticality of one side shuttering,
reinforcement fixing shall be completed.
Cable Profile
Fabricated sheathing pipe shall be brought to location and shall be placed over
marked cable profile as per drg. No.ROB-1/08(R1). After necessary checking by
the Engineer, cable profiling shall be completed.
After checking of cable profiling, closing of shuttering shall be carried out. Proper
alignment of the girder shall be carried out by the help of adjustable props and
then it shall be ready for final checking before concreting.
ROB-1
ROB-2
ROB-3
ROB-4
Concrete quantity
Grade of Concrete
Time for completion
Location of Batching
Plant
42.2
M40
5 hrs
Existing
Haldipada
Batching plant
18.25
M40
2 hrs
ROB-2
Batching plant
31.30
M40
4 hrs
Existing Belda
Batching plant
20.60
M40
3 hrs
Existing Belda
Batching plant
(yet to be installed)
3. Concreting shall be done up to a depth of 400 mm and the same layer will
be continued till completion of the beam.
4. Compaction of concreting at bottom flange, web shall be done by using
shutter vibrator and also with immersion vibrator simultaneously.
5. Proper care shall be taken to ensure all the cables are free from concrete.
6. During concreting and up to 3 to 4hrs after completion of concreting, the
cables shall be checked manually for free movement.
7. Finally surface hacking shall be done at the beam top surface for proper
construction joint with deck slab.
PRE-STRESSING
1. 1ST Stage stressing will be done when the concrete achieves strength of
32 MPa and total 3nos. cables (i.e. cable no.1, 2&3) in each girder shall
be stressed in 1st stage by the help of K-350 FPCC make jack.
2. 2nd Stage stressing will be done after completion of diaphragms and
deck slabs and attains specified strength of 40MPa. 3nos. (i.e. cable no.4,
5&dummy) of cables shall be stressed in each beam in 2nd stage.
3. Extension at each end during stressing operation should be equal as far
as possible, max. Difference should not exceed 5% of the prescribed
extensions at each end. In case the required extensions are not obtained
at the specified pressure stressing should be continued till the required
extensions are obtained subjected to jack pressures not exceeding
585kg/cm2
4. difference between calculated and observed tension and elongations
during the pre-stressing operations shall be regulated as per MOST sec.
1807 under post tensioning head as per point a, b, c, d
Method of Stressing
1. During curing of pre-stressing beam, arrangements for pre-stressing shall
be started
2. Place the tripod on both end of PSC beam
Lowering of Girder
J Bolt shall be fixed over pier as per drg. No.TS/112 at the time of casting of
pier cap and then girder shal be lowered with the help of hydraulic jack and
pre-fabricated stool as per drg. No. TS/570 by removing the stools one by
one.
Cube Test:
Cubes of size 150x150x150mm shall be taken. Number of cubes shall be taken
as per Table No.1700 in MOST specification.
The same shall be tested at the Q.C.lab for 2 to 3 days strength and 28 days
strength and it will be entered in the cube test register. 30% of concrete cube
shall be placed at top of PSC Beam for checking of periodical strength to ensure
minimum strength specifications for Pre-Stressing..
RECORDS:
Documents/Records
SAFETY MEASURES:
SAFETY ARRANGEMENTS FOR CASTING PSC GIRDER IN ROBs.
GENERAL:
Materials:
Equipment:
Mixing of Grout:
Grouting Operations:
Injection of Grout
Records
Annexure-1
METHOD STATEMENT FOR CASTING PSC GIRDERS IN ROBS/Page 16
of 16
FIG: OBLIGATORY SPAN SUPPORTING ARRANGEMENTS AT ROB-1
17.349m
14.934 m
14.837 m
8.145m
7.845m
Annexure-2
B
A
LEGENDS:
A Overhead Railway Electrical Conductor.
B Aluminium profile both side covered with 25mm thick
Rubber sheet of adequate insulation grade.
C Adjustable Suspenders.
D - 33 KV Disc insulators.
E Overall length of the profile 4mtrs if the beams are cast
and shifted, 17mtrs if all six beams are cast simultaneously.