Methodology for super structure minor bridge

The super structure work will be started once the abutment /pier
caps are completed and sufficient cured

The major activities of superstructure are.

1. Ground preparation.
2. Erecting of staging and shuttering.
3. Reinforcement.
4. Balance shuttering.
5. Concreting.
6. Expansion joint and wearing coat.

Ground preparation:-

The ground for erection of staging will be prepared to the

required level and size of the staging it will be ensure that no loose spots
are on the ground that may cause settlement.

Erection:-
The centering for the support of the superstructure formwork
is proposed to be placed on dry level ground. Therefore each span in
turn shall be leveled to the required elevation above the water level
and the stream shall be diverted by suitable arrangement as per site
conditions. Cribs of 450 mm X 450 mm X 1500 mm, 600 mm X 600
mm X 1800 mm, 600 mm X 600 mm X 1000 mm and other suitable
sizes or pipes with cup lock system or any suitable type of centering
shall be used to support the super structure form work. The design of
the formwork shall be furnished and got approved by the Engineer
before starting formwork and shuttering.

In minor bridges, Elastomeric bearings shall be kept in

position with epoxy mortar on top of pedestals, just before the casting of
the superstructure girders, as per approved drawings.
The line and levels have to be got approved from the Engineers
representatives.
Reinforcement:-
The staging /shuttering will be get checked by the
engineer and reinforcement binding will be commenced.
 Drainage spouts shall be laid in the form work, Formwork and
reinforcement shall be got approved by the Engineer, prior to pouring of
concrete.
The slab shall be cast in one operation. In the case of minor bridges, the
sequence shall be as follows.
The base plates of girder formwork shall be placed in position in true
line and level.
Prefabricated girder reinforcement shall be placed on base plates
manually or with the help of crane.
Side shuttering around girders and cross girders shall be closed and
deck slab shuttering shall be laid. Shuttering oil or suitable
formwork releasing formulation or plastic sheeting shall be applied
to all inside faces of the formwork.
Lines, levels, dimensions, formwork, centering and reinforcement of
main girder and cross girders shall be got checked and approved by
the Engineer. Concreting shall be carried out to the bottom of the
haunch at the junction of the girders and slab.
The reinforcement for deck slab, foot path kerb and hand rail beams
shall be laid in position as per the approved bar bending schedules
and drawings. Also the drainage spouts shall be laid in true position.
All necessary approvals shall be taken for lines and levels in the
deck slab form work held in place firmly, reinforcement and other
accessories such as drainage spouts from the Engineer.
Concreting: -
Concreting will be done with help of concrete pump.
A stand by crane with bucket will be arranged for emergency
situation.
Concreting will be commenced from the far end.
1St stage concrete of about 1/3 rd height will be commenced to a
length of about 6 to 8 meters.
The pipe will be taken back again and the second stage will be
commenced to complete the 2/3 rd height of the slab in the same
distance.
 The process is once again repeated to finish the pour to the top
level in the length.
During the process care will be taken to ensure that the concrete
forms the green joints and is not set completely before
commencement of the next stage.
Once the concrete has finished to the planned distance the pipe of
the concrete pump will be removed to suitable distance and the
process is finish.
Care will be taken to ensure that there is no leakage in the joints of
the voids
Parapet / crash barriers and wearing course shall be laid after the
deck.

In minor bridges, the sequence of taking up the remaining

items shall be as under.

(i) Construction of dirt-wall and return walls. When the curing

period is over, placing back filling in specified layers behind
abutments with filter media and selected fill using rising
separators to prevent contamination and compacting in
accordance with Technical Specifications of the Contract.
(ii) Box cutting for approach slabs, laying lean concrete base
layer, placing reinforcement and formwork for approach
slab and concreting to the required level.
(iii) Construction of cross barrier in cast-in-situ after completion
of deck slab

Expansion joints and wearing coat:-

Expansion joints will be fabricated according to profile of the
deck slab will be procured from the approved manufacturer.
Fixing the expansion joints in a position in deck slab under the
supervision of the manufacturers representative.
 Compression seal expansion joints with total movement f 40 mm
( 20mm ) will be installed to the finished levels and profile f the
carriageway
6 mm thick mastic asphalt over 50mm thick one layer of BC will be
paved accurately so that does not gives jerk at the joint location

Curing & Formwork stripping

Methods of curing concrete and to prevent evaporation will be
(i) Pounding of water over the concrete surface after it has set.
(ii) Sprinkling of water.
(iii) Covering the surface with wet Hessian cloth.
Curing shall be done for a minimum period of 14 days continuously. Water
to be used in concreting and curing shall be confirming to Clause 302.4 of
IRC 21-2000.
When the cube compressive strengths attain the specified value at the
period indicated in the Specifications, the formwork shall be released and
taken for re-use. Additional cubes shall be cast for ascertaining the cube
strengths at times before 28 days and if the strengths are achieved as per
the requirements, it shall be proposed for early de-shuttering or de-
staging in order that subsequent similar work can be advanced
appropriately.

QUALITY CONTROL

Routine testing shall be carried out as stipulated within relevant IS

codes and any errors reduced to acceptable levels during
continuous production.
Cube compressive strength shall be used for determination for
strength achieved.

Test Frequency (Minimum)

(i) Quality of cement Two samples per lot to be subjected
to setting time, Consistency, Mortar
Cube compressive strength tests,
(ii) Aggregate Impact Value One test for each source of supply
and subsequently on monthly basis
as required and as and when Source
is changed
(iii) Flakiness Index One test for each source of supply
and subsequently on monthly basis

(iv) Soundness Test
(v) Alkali aggregate reactivity
(v) Water Absorption of Aggregate
(vi) Chemical tests on water
(vi) Sand equivalent Test
(vii) Mix Grading
(viii) Slump Tests on Mix
(xi) Cube compressive test
as required and as and when source
is changed.
Before approving the aggregates and
every month subsequently.
Before approving the aggregates and
every month subsequently.
Regularly as required subject to a
minimum of one test a day for coarse
aggregate and two tests per day for
fine aggregates.
Once for approval of source of
supply, subsequently as and when
source is changed and in case of
doubt.
As required and as and when source
is changed
As required and as and when source
is changed
At regular close intervals One test
per load
As per subsection 1716.2 of MORT&H

TOLERANCES:
Cast-in-situ Superstructure:

a) Variations in thickness of top and bottom slab for

Box girders, top and bottom flange for T-girders or slabs:-5 mm to + 10
mm
b) Variations in web thickness : -5 mm to + 10 mm
c) Variations in overall depth or width : + 5 mm
d) Variations in length overall and length between bearings :shall not
exceed
+ 10 mm or + 0.1
percent of the span
length, whichever is
lesser

e) Permissible surface irregularities when measured with a 3 m

Straight edge or template : 5 mm