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INDIAN RAILWAY STANDARD CODE OF PRACTICE FOR PLAIN, REINFORCED AND PRESTRESSED CONCRETE FOR GENERAL BRIDGE CONSTRUCTION

(CONCRETE BRIDGE CODE) APPENDIX-BI ( Clause 7.2.6.4.2.) ADDITIONALTESTS FOR CORRUGATED HDPE SHEATHING B1-2 COMPRESSION TEST FOR THE LOSS OF WALL THICKNESS B1-2.1 Objective: To establish the wear and tear of the sheathing material and the rigidity of sheathing surface against indentation and abrasion under concentrated line loading from the tendon constituents. B1-2.2 Equipment 1. 3 nos. of concrete blocks. B1-1.2 Equipment 1. 3 nos. similar reinforced concrete beams with a HDPE sheathing of length equal to 40 times the sheathing diameter. 2. Prestressing tendon of adequate length for stressing and for embedding in the beam. 3. Tendon anchorage system 4. Load cells and meters 5. Grout constituents B1-1.3 Methods: Cast an adequately reinforced beam to withstand the prestressing operation and of length to embed 40 times the dia. of sheathing to suit the tendon to be adopted. Introduce the strands of the tendon by spacing them parallel by means of ply spacers as shown in Fig. B1-1 and fill the sheathing with grout of strength not less than 27N/mm2 . When the grout has attained the necessary strength, stress the tendon slowly increasing the load to the failure capacity. The failure capacity of the bond shall be at least equal to the anchorage efficiency or 0.95 of failure capacity of the tendon. At least 3 nos. of tests shall be carried out to ascertain the adequacy of the sheathing. 6. A bearing plate with a mono strand jack to pull and strand under loaded condition. 7. A digital caliper B1 2-3 Method: Cast 3 nos. of concrete cubes of 300 mm size, of the same strength as of main structure, with half cut HDPE sheathing embedded in it at the top as shown in Fig. B1-2. Care shall be exercised to ensure that the sheathing surface has uniform contact with concrete all around. Place the concrete block over the press with a 1000mm length of strand forming the tendon placed in the sheathing and apply 5 kN uniform load gradually as shown in Fig. B1-2. Pull the strand under the stressed condition by 200mm across the sheathing. Repeat the test on all the 3 nos. of sheathings so embedded. Measure the indentations formed in all the 3 nos. of sheathings along the length of the strand, 2. 1 no. of 1000mm long strand forming the tendon 3. A 3 MN press 4. A loading beam of 300mm length of transmit 5KN load 5. A rubber pad for placing between the press and the beam for uniform and constant load transfer

Apart from tests specified in Appendix-B, additional acceptance tests for the prestressing systems employing corrugated HDPE sheathing shall cover the following two tests: BI-1 BOND TEST B1-1.1 Objective: To establish satisfactory bond characteristics between the tendon and concrete, in the ultimate condition.

INDIAN RAILWAY STANDARD CODE OF PRACTICE FOR PLAIN, REINFORCED AND PRESTRESSED CONCRETE FOR GENERAL BRIDGE CONSTRUCTION (CONCRETE BRIDGE CODE) by means of digital caliper. The residual thickness of the sheathing shall not be less than 1.5mm.

Fig. B1-1 BOND TEST

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Fig B1-2 COMPRESSION TEST

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