NATIONAL HIGHWAY

AUTHORITY OF INDIA
(NHAI)

METHOD STATEMENT FOR I GIRDERS

REPAIRING OF VOIDED END BLOCK
RESULTING IN CRUSHING OF ANCHOR
CONE DURING STRESSING

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 NATIONAL HIGHWAY
AUTHORITY OF INDIA
(NHAI)

Scope:

This method statement outlines the procedure for repairing the voided end
block of I girders resulting in the crushing of the anchor cone during stressing.
The repair process will involve de-stressing the failed cable, removing loose
concrete and crushed anchor cone casting, and filling the cavity with high-
strength micro concrete. The repaired structure will then be subjected to
inspection and testing to ensure its integrity and compliance with relevant
standards.

Reference Documents:

 IRS Concrete Bridge Code

 IS 456:2000 - Code of Practice for Plain and Reinforced Concrete
 IS 2502:1963 - Code of Practice for Bending and Fixing of Bars for
Concrete Reinforcement
 IS 1786:1985 - Specification for High Strength Deformed Steel Bars
and Wires for Concrete Reinforcement
 IS 12269:1987 - Specification for 53 Grade Ordinary Portland Cement
 IS 516:1959 - Method of Tests for Strength of Concrete
 IS 383:1970 - Specification for Coarse and Fine Aggregates from
Natural Sources for Concrete

Repairing Methodology:

1. The failed cable shall be de-stressed first by using a multi-pull or mono-

pull jack.
2. The loose pieces of the crushed anchor cone casting and concrete shall
be removed.
3. Manual chipping with sharp chisels and a hammer to remove the loose
concrete wherever present at the location.

Prepared By Checked By Approved By

 NATIONAL HIGHWAY
AUTHORITY OF INDIA
(NHAI)

4. This should be done to the extent of the hardened concrete and allow for
inspection by the client.
5. Upon satisfactory compliance, the new anchor cone casting and HS
eating duct shall be fixed with holding arrangements by means of spot
welding or tying the same with the existing reinforcement using binding
wires. The cavity formed due to the removal of crushed pieces of anchor
cone casting an concrete shall be filled with high-strength micro
concrete (10mm aggregate & Conbextra GP2 with a 1:1 ratio) or a
suitable material.
6. This can be done without a pressure grouting device or instrument, in
such a way to match the shape of the anchor cone casting.
7. Special attention shall be given for proper compaction to remove any air
entrapped in the micro concrete.
8. Ensure that the micro concrete develops strength equal to or greater than
the strength of the surrounding concrete.
9. An MS plate size 300x300x20mm with a central hole equal to the
central hole of the 19T13 anchor cone casting (±1 mm) in diameter shall
be placed in the pocket provided for the cable as shown in the annexed
sketch.
10.A grout of 3/4” shall be provided as shown in the sketch.
11.The 19T13 anchor head will be on the MS plate and strands shall be
fixed by permanent wedges as done in a normal stressing operation.
12.The stressing operation of the cable shall be carried out as per the
specified methodology.
13.After stressing, the cable shall be grouted as per the specifications.
14.The calibration of the pressure gauge shall be renewed every three
months.
15.Ensure the hydraulic pump can be operated only by an authorized
person and the operator's name details shall be displayed in the stressing
area.
16.Compressive strength tests shall be carried out for 7 days and 28 days.

Prepared By Checked By Approved By

 NATIONAL HIGHWAY
AUTHORITY OF INDIA
(NHAI)

17.NDT tests shall be performed after casting of the micro concrete.

18.After micro concrete, the duration of stressing shall be after achieving
50 MPa of compressive strength or 7 days of casting, whichever is later.

Quality Control and Documentation:

1. Work shall be executed as per the method statement.
2. Inspection checklist shall be maintained for each work.

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