ANNEXURE A-5 (Refer Clause 13.4.2 and Clause 13.4.3) TESTS ON MILD STEEL AND CORRUGATED HDPE SHEATHING DUCTS 1.0 FOR MILD STEEL SHEATHING DUCTS, AIll tests specified below shall be carried out on’ the same sample in the order given below. At least 3 samples for one lot of supply (not exceeding 7000 metre length) shall be tested. 1.1. Workability Test A test sample 1100 mm long is soldered to a fixed base plate with a soft solder (Fig. AS-U).The sample is then bent to a radius of 1800 mm altemately on either side to complete 3 cycles. ‘Thereafter, the sealing joints will be visually inspected to verify that no failure or opening has taken place. Fig. AS-1, Workabilty Test 1.2 Transverse Load Rating Test The test ensures that stiffness of the sheathing is sufficient to prevent permanent distortion during site handling ‘The sample is placed on a horizontal support 500 mm long so that the sample is supported at all points of outward corrugations. 44 INDIAN HIGHWAYS, aucust 2017A load as specified. in Table-A5-1 below is applied gradually at the centre of the supported portion through a circular contract surface of 12 mm dia. Couplers shall be placed so that the load is applied approximately at the centre of two corrugations, Fig. A5-2, The load as specified below is applied in increments. oes La Be Fig. A5-2, Transverse Load Rating Test ble showing Duct Diam« Between morethan more than more than morethan more than more than : Dia: 25mm 35mm = 45mm = SSmm = 65mm 75mm 85mm to Upto “Upto. — Upto. Upto Upto Upto 35mm, 45mm = $Smm = 6Smm = 75mm 85mm = 90mm Load: _250N 400N___500N___600N___700N 800 N 1000 N ‘The sample is considered acceptable if the permanent deformation is less than 5 per cent. 1.3 Tension Load Test The test specimen is subjected to a tensile load. The hollow core is filled with a wooden circular piece having a diameter of 95 per cent of the inner dia of the sample to ensure circular profile during test loading, Fig. A5-3. INDIAN HIGHWAYS, ausust 2017 45,Fig. AS-3 : Tension Load Test A coupler is screwed on and the sample loaded in increments, till specified load. If no deformation of the joints nor slippage of couplers is noticed, the test shall be considered satisfactory : Dia in mm Load 25 upto 35 300N More than 35 upto 45 500N More than 45 upto 55 800 N More than 55 upto 65 1100N ‘More than 65 upto 75 1400N More than 75 upto 85 1600N More than 85 upto 90 1800N 1.4 Water Loss Test ‘The sample is sealed at one end. The sample is filled with water and after sealing, the end is connected toa system capable of applying a pressure of 0.05 MPa, Fig. AS-4 and kept constant for $ minutes, hand pump and pressure gauge or stand pipe system can be used. ==} t—aa ee Fig, AS-4: Water Loss Test The sample is acceptable if the water loss does not exceed 1.5 per cent of the volume . The volume is worked out as follows: Another sample 500 mm long is sealed at one end and the volume of hallow space arrived at by pouring water from a measuring cylinder, 46 INDIAN HIGHWAYS, AuGust 2017DMENTS ‘The computation of relative profile volume is worked out as follows: Va ~ — Premeasured quantity of water in measuring cylinder Vo - Balance quantity of water left in the eylinder after completly filling of the test sample Actual Volume ‘V,"=V, -V, Relative Profile Volume = V, - 3; em’/ cat? Where / is length of specimen and @ internal nominal dia. of sheathing. 1.5 Specification for Sheathing Duct Joints ‘The sheathing ducts shall be of the spiral corrugated type. For major projects, the sheathing ducts should preferably be manufactured at the project site utilising appropriate machines. With such an arrangement, Jong lengths of sheathing ducts may be used with consequent reduction in the number of joints and couplers. Where sheathing duct joints are unavoidable, such joints shall be made cement slurry tight by the use of corrugated threaded sleeve couplers which can be tightly screwed on to the outer side of the sheathing ducts, A heat-shrink coupler could also be used if suitable. ‘Typical details of a sleeve coupler is shown in Fig.AS-5, The length of the coupler should not be less than 150 mm but should be increased upto 200 mm wherever practicable. The joints between the ends of the coupler and the duct shall be sealed with adhesive sealing tape to prevent penetration of cement slurry during concreting. The couplers of adjacent ducts should be staggered wherever practicable, As far as possible, couplers should not be located in curved zones. The corrugated sleeve couplers are being conveniently manufactured using the sheath making machine with the next higher size of die set. Fig. AS-S : Typical details of « sleeve coupler ‘The inear-shrink coupler Fig.AS-6 is supplied in the form of bandage rolls which can be used for all diameters of sheathing ducts. The bandage is coated on the underside with a heat sensitive adhesive so that after heating the bandage material shrinks in to the sheathing and ensures formation of a leak proof joint, without the need for extra taping or support in the form of corrugated sleeve couplers. The heating is effected by means of a soft gas flame. Fig. AS-6 : Typical details of a Shrink coupler 2.0 FOR CORRUGATED HDPE SHEATHING DUCTS A summary of all the requirements, methods of verification, and acceptance criteria for the polymer duct, system together with the components and material is given in Table AS-2 below. The Table is in line with the technical report Bulletin 75 published by fid titled “Polymer — duct systems for internal bonded post-tensioning”. 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[Leak tightness | 7.1 [Leak tightness test of “Leak tight for tendons (Sminutes) a) Initially, | 5 ofanchorage- | Annex |anchorage 'b) When there is a change in design and/ | y uct assembly duct assembly ‘or mamufacturing process of polymer 2 “at room temperature 23 °C | ducts, trumpets or connectors, i i . anchorage components, ! g ©) For each type of duct material, > 8 Szunpet and anchorage components et €) When anew anchorage or trumpet = fa Z proposed for use. S| Full scale 74 | Fall scale PT and duct Duct profile compiies with specified profile |a) Initially, 2 ‘duct system | Annex | system assembly test no apparent tendon profile kinks or 'b) When a new duct or connector or a =| assembly B4 | -at ambient temperature _| discontinuities or loss connections ‘new installation method is proposed 1 no excessive duct deformations on support or | for use. Ss ‘duct deflections between the supports spaced at 7) ‘maximum permissible support spacing as per _| Section 6. ; Leak tightness | 7.5 | Leak tightness test of -Pressure loss < 10% of initial pressure afier 5 | a) Initially, } ‘ofassembled | Annex |assembled PT and duct ‘minutes for tendons PL2 and PL3 'b) When a new duct or connector or a duct system | BS | system 1new installation method is proposed for use.ANNEXURE A-6 DESIGN CONSIDERATIONS FOR CONSTRUCTION STAGES AG-1 General (i For bridges built in stages, the design and detailing shall take into account of the construction procedure, sequence etc., as appropriate.Some situations are illustrated in the following. a) Where forces, other than those produced on the completed structure, occur in any structural section during the phases of construction (e.g. deck erection by incremental launching, bridges built by balanced cantilever, change in sections during construction, change of support conditions during construction etc.).. b) Where redistribution of forces due to Creep, shrinkage and steel relaxation is originated by changes to the structural arrangement during the construction process (e.g. continuous bridges built span by span on false work or by cantilever). ©) Where distribution of stresses due to Creep, shrinkage and stee! relaxationis originated by changes io structural sections during the construction process (c.g. decks consisting of precast beams and an insitu slab). 4) Where the erection or construction sequence may have an influence on: the stability of the structure / capacity of section during construction, the forces in the completed structure, or the geometry of the completed structure (ii) For structures in which any of the circumstances described in paragraphs (i) a) to d) apply, the serviceability limit states and ultimate limit states should be verified during various construction stages. (ii) For structures in which the circumstances described in paragraphs (i) b) or c) apply, long term values of forces or stresses should be determined from an analysis of redistribution effects, Step by step or approximate methods may be used in these calculations. (iv) For structures in which the circumstances described in paragraph (i) d) apply erection and casting sequences/procedures should be indicated on drawings or detailed in a construction procedure document along with assumed construction and equipment loads / configurations etc. A6-2 Actions & Effects to be considered during construction For the verifications of equilibrium and limit states during various construction stages following construction loads and erection effects shall be considered. A6-2.1General (a) Distributed construction live load taken as 50 kg/n? of deck area for cantilever construction, sequential/span by span construction etc. (b) Specialized construction equipment load from launching gantry, from traveler, beam and winch, ‘movement of precast segments over constructed portion etc. (©) Dynamic load of equipment may be taken as 10% of the lifting load INDIAN HIGHWAYS, AuGust 2017 51(@) Longitudinal forces arising from construction equipment loads. according to the type of the machinery. (©) Unbalanced load resulting from sequence /construction stage. () Horizontal wind load on structure shall be taken in accordance with the provisions of IRC:6 for construction stages. (g) Effects arising from imposed deformations shallbe taken into account. These effects can be of permanent nature, depending upon the situation. In such situations the strains and stresses shall be algebraically superimposed as per applicable section at various construction stages. (h) The support restraints during all construction stages shall be ensured tor stability against sliding and overturning. The situation may arise when restraint, particularly in longitudinal direction, may be absent during construction stage. Need of temporary restraint for this situation shall be either accounted for in suggested sequence & detailing or constructor shall be instructed to provide appropriate restraint. : A6-2.2For cantilever construction (a) Differential Dead Load of 2 % on one side of cantilever on unfavorable side. (b) For verification of equilibrium under the accidental combination, dynamic response due to accidental release of precast segment taken as equivalent to additional static load as 100% of the ~ weight of the precast segment. A6-3 Verification criteria AG-3.1 Verification for static equilibrium ‘The equilibrium of the structure shall be verified for the combinations as per Table 3.1 of IRC:6. AG- 3.2 Ultimate Limit States ULS verifications required for design during construction are the same as those given in sections 8, 9,10 & 11. A6- 3.3 Serviceability limit states (@) Serviceability criteria for the completed structure need not be applied to intermediate construction stages, provided that durability and final appearance of the completed structure are not affected (e.g. crack width and deformations) and comply with applicable provisions of the Code. (b) The idea of frequent combination does not exist during construction and also limit states related to durability are not pertinent for short term-phases as such limiting stresses in concrete to 0.48 fag and steel to 0. 8f,, under rare combination during constructionis adequate. (©) For bridges or clement of bridges in which limit state of decompression is checked on the completed structure, tensile stresses less than fy under the quasi permanent combination during construction is permitted. (@) Prestressing effects may be taken as r,, = r,,= 1.0 during the construction 52 INDIAN HIGHWAYS, aucust 2017 re