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REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING

CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112


REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

REQUIREMENT OF TESTING DETAILS OF PRESTRESSING SYSTEM


(ANCHORAGES , DUCT , STEEL , GROUT) AS PER IRC:112

Jatinder Singh Pahuja


Senior Principal Consultant , Tandon Consultant Pvt Ltd

Jatinder Singh Pahuja received his Mtech degree in Structural


Engineering from IIT Delhi. He has experience of 28 years in designing
flyovers & long span bridges in India and overseas. He is also a guest
faculty in Indian Academy Of Highway Engineers. He is also a part of
bridge committee, B-9 of IRC, responsible for formulating guidelines
for special bridges such as Cable Stayed bridges, Extradosed bridges,
Sea Link Bridges.

Email address:- js_tcpl@yahoo.com


jspahuja@yahoo.com
TESTING OF PRESTRESSING SYSTEM
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

• Prestressing Anchorage Assembly

• Prestressing Sheathing / Duct


• Mild Steel sheeting
• HDPE Sheeting

• Prestressing Steel

• Prestressing Grout
PRESTRESSING ANCHORAGES
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Freyssinet System

Dywidag System

VSL System
PRESTRESSING ANCHORAGES
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA
TRANSFER OF STRAND PRSTRESS FORCE TO
WEDGES/ BEARING PLATE
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

BEARING PLATE
TESTING OF PRESTRESSING ANCHORAGES ASSEMBLY
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

FIP –June 1993


RECOMMENDATIONS FOR THE ACCEPTANCE OF
POST-TENSIONING SYSTEMS
FIP COMMISION ON PRACTICAL CONSTRUCTION
TESTS FOR ANCHORAGES (FULLY EMBEDDED) –TENDON ASSEMBLY
(cl 13.2.4 of IRC:112)
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

• LOAD TRANSFER TEST

• ANCHORAGE EFFICIENCY TEST (STATIC LOAD TEST WITH TENDON ANCHORAGE)

• DYNAMIC LOAD TEST WITH TENDON –ANCHORAGE ASSEMBLY


LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST OBJECTIVES
• TO STUDY THE PERFORMANCE OF CONCRETE TEST SPECIMEN, UNDER THE APPLICATION OF
PRESTRESSING FORCE (1.1 TIMES THE ULTIMATE STRENGTH) THROUGH THE MECHANICAL
ANCHORAGE AND ITS COMPONENTS.

• TO MEASURE THE LONGITUDINAL AND TRANSVERSE CONCRETE STRAINS AT THE MAX. STRESS
(MAX. BURSTING EFFECT) AREA.

• TO IDENTIFY THE CRACK FORMATION AND TO MEASURE ITS WIDTH, UNDER EACH LOADING.

• TO INSPECT FOR ANY DAMAGE TO THE ANCHORAGE COMPONENT EMBEDDED IN THE CONCRETE.

• TO CHECK FOR THE STABILITY OF STRAIN AND CRACK READINGS

• TO CHECK FOR ANY ABNORMAL BEHAVIOUR OF PRE-MATURE FAILURE OF THE TEST BLOCK.
LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

VIEW B-B

SEC TION A-A

TEST BLOCK TO BE CASTED (With Concrete Actually Used At Site) FOR LOAD TRANSFER TEST
LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST BLOCK BEFORE CONCRETING


LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST SET UP F OR 2 7 K 1 3 LOAD TRAN SF ER TEST


LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

INSTRUMENTATION FOR OBSERVATION OF


TRANSVERSE AND LONGITUDINAL STRAIN
LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ARRANGEMENT FOR LOAD TRANSFER TEST


LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ARRANGEMENT FOR LOAD TRANSFER TEST


LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEN CHANNEL DIGITAL STRAIN INDICATOR FOR MEASURING TRANSVERSE


AND LONGITUDINAL STRAIN ON ALL FOUR SIDES OF TEST BLOCK
LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

MAPPING OF CRACK PATTERN


AND MEASURING CRACK WIDTH
ON ALL FOUR SIDES OF TEST
BLOCK USING CRACK DETECTION
MICROSCOPE
LOAD TRANSFER TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA
• Crack width upon first attainment of upper force
0.8 (load point 4) should be ≤ 0.10mm
• Crack width upon last attainment of lower force
0.12 (load point n-1) should be ≤ 0.10mm

• Crack width upon final attainment of upper force


0.8
 (load point n) should be ≤ 0.25mm
• Readings of longitudinal and transverse strains
should have stabilized during cyclic loading. The
strains can be assumed to have stabilized if the
increase of strains in the last two load cycles is
less than 5%
• Readings of crack widths should have stabilized
Wmax

during cyclic loading. The crack widths can be


(mm)

assumed to have stabilized if the crack width does


not increase by more than 0.02 mm in the last two
load cycles
• The measured failure load Fu must meet each of
the following requirements:

.
    1.1

.
ANCHORAGE EFFICIENCY TEST
(STATIC LOAD TEST WITH MECHANICAL ANCHORAGES)
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST OBJECTIVES:
• TO STUDY THE PERFORMANCE OF TENDON ANCHORAGE ASSEMBLY UNDER THE
APPLICATION OF PRESTRESSING FORCE.

• TO OBSERVE FOR ANY PRE-MATURE FAILURE, ANY PERMANENT DEFORMATION AND


ABNORMAL BEHAVIOUR DURING APPLICATION OF LOAD.

• TO MEASURE THE ELONGATION OF TENDONS DURING LOADING.

• TO EVALUATE ANCHORAGE EFFICIENCY.


ANCHORAGE EFFICIENCY TEST
(STATIC LOAD TEST WITH MECHANICAL ANCHORAGES)
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST SET UP FOR ANCHORAGE EFFICIENCY TEST


ANCHORAGE EFFICIENCY TEST
(STATIC LOAD TEST WITH MECHANICAL ANCHORAGES)
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

DEAD END ANCHORAGE (MEASURING SLIP IF ANY AT DEAD END OF CABLE)


ANCHORAGE EFFICIENCY TEST
(STATIC LOAD TEST WITH MECHANICAL ANCHORAGES)
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA

• Residual deformations of anchorage components after the test should


confirm the reliability of the anchorage
• The increase in the displacements between the anchorage components as
well as between the prestressing steel and anchorage components should
not be disproportionate to the increase in tendon force

• The measured anchorage efficiency should be:



  0.95


• The total elongation  in free length of the tendon under the load 
should be  2 %
DYNAMIC LOAD TEST WITH TENDON-ANCHORAGE ASSEMBLY
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST OBJECTIVES:
• TO DETERMINE THE CAPACITY OF THE TENDON-ANCHORAGE ASSEMBLY UNDER LOAD
FLUCTUATIONS AS AN INDICATION OF RELIABILITY AND DURABILITY OF THE ASSEMBLY.
DYNAMIC LOAD TEST WITH TENDON-ANCHORAGE ASSEMBLY
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST PROCEDURE:
• TEST TO BE PERFORMED IN TENSILE TESTING MACHINE WITH A PULSATOR AT A
CONSTANT FREQUENCY FORCE OF NOT MORE THAN 500 LOAD CYCLES PER MINUTE.

• UPPER LIMIT OF FORCE- Fmax = 0.65 Fpk


LOWER LIMIT OF FORCE- Fmin = 0.60 Fpk

• NOS OF CYCLES- 2million

ACCEPTANCE CRITERIA:
• NOT MORE THAN 5.0% OF WIRE /STRANDS SHALL BREAK
TESTS FOR MILD STEEL SHEATHING DUCTS
( ANNEXURE-A-5 Of IRC: 112)

REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

• WORKABILITY TEST

• TRANSVERSE LOAD RATING TEST

• TENSION LOAD TEST

• WATER LOSS TEST


TESTS FOR MILD STEEL SHEATHING DUCTS
( ANNEXURE-A-5 Of IRC: 112)

WORKABILITY TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

A TEST SAMPLE OF
1100mm LONG FIXED
WITH BASE PLATE USING
SOFT SOLDER

TEST PROCEDURE SAMPLE IS BENT TO A


RADIUS OF 1800mm ALTERNATIVELY ON
EITHER SIDE TO COMPLETE 3 CYCLES
ACCEPTANCE CRITERIA
THEREAFTER THE SEALING JOINTS WILL
BE VISUALLY INSPECTED TO VERIFY NO
FAILURE OR OPENING HAS TAKEN PLACE
TESTS FOR MILD STEEL SHEATHING DUCTS
( ANNEXURE-A-5 Of IRC: 112)

TRANSVERSE LOAD RATING TEST


REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST PROCEDURE:
SAMPLE IS PLACED ON A HORIZONTAL
SUPPORT OF 500mm LONG SO THAT
THE SAMPLE IS SUPPORTED AT ALL
POINTS OF OUTWARD
CORRUGATIONS.
LOAD OF 1000N IS GRADUALLY
APPLIED AT THE CENTER OF
SUPPORTED PORTION THROUGH A
CIRCULAR CONTACT SURFACE OF
12mm DIA.

ACCEPTANCE CRITERTIA
THE SAMPLE IS CONSIDERED
ACCEPTABLE IF THE PERMANENT
DEFORMATION IS LESS THEN 5
PERCENT.
TESTS FOR MILD STEEL SHEATHING DUCTS
( ANNEXURE-A-5 Of IRC: 112)

TENSION LOAD TEST


REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST PROCEDURE
A COUPLER IS SCREWED ON AND THE
SAMPLE IS LOADED IN INCREMENT TILL
LOAD OF 1800N.
ACCEPTANCE CRITERIA
IF NO DEFORMATION OF THE JOINT NOR
SLIPPAGE OF COUPLERS IS NOTICED, THE
TEST SHALL BE CONSIDERED
SATISFACTORY.
TESTS FOR MILD STEEL SHEATHING DUCTS
( ANNEXURE-A-5 Of IRC: 112)

WATER LOSS TEST


REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TEST PROCEDURE
SAMPLE IS SEALED AT ONE END.
THE SAMPLE IS FILLED WITH WATER
AND AFTER SEALING THE END IS
CONNECTED TO A SYSTEM CAPABLE
OF APPLYING A PRESSURE 0.05 MPA
AND KEPT CONSTANT FOR 5
MINUTES.
ACCEPTANCE CRITERIA:
THE SAMPLE IS ACCEPTABLE IF THE
WATER LOSS DOES NOT EXCEED 1.5
PERCENT OF VOLUME.
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
DIMENSION REQUIREMENT TOLERANCES
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)

TO DETERMINE EFFECTIVE STIFFNESS OF DUCT


REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

OBJECTIVE

Determine Feff Corresponding to ∆=5mm


EFFECTIVE STIFFNESS OF DUCT=
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)

TO DETERMINE EFFECTIVE STIFFNESS OF DUCT


REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA
Max Support Spacing < Calculated Supported Spacing
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
LATERAL LOAD RESISTANCE OF HDPE DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

OBJECTIVE
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
LATERAL LOAD RESISTANCE OF HDPE DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA
No transverse deformation exceeding 35% at specified transverse load for
immediate duct deformation.
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
FLEXIBILITY OF DUCT SYSTEM
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

OBJECTIVE
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
FLEXIBILITY OF DUCT SYSTEM
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
LEAK TIGHTNESS OF DUCT SYSTEM
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

OBJECTIVE
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
LEAK TIGHTNESS OF DUCT SYSTEM
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

OBSERVATIONS

ACCEPTANCE CRITERIA
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
CONCRETE PRESSURE ON DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

OBJECTIVE

TEST PROCEDURE
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
CONCRETE PRESSURE ON DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
WEAR RESISTANCE OF DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA
OBJECTIVE

Strand (1m free length)


stressed to a
value of 0.7U.T.S 15.2mm
Or
12.7mm Dia
Strand
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
WEAR RESISTANCE OF DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
WEAR RESISTANCE OF DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
WEAR RESISTANCE OF DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA
Minimum wall thickness of duct >1.5mm
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
WEAR RESISTANCE OF DUCT UNDER SUSTAINED LOAD
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

OBJECTIVE
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
WEAR RESISTANCE OF DUCT UNDER SUSTAINED LOAD
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA

Minimum wall thickness of duct >1.0mm


TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
BOND BEHAVIOUR OF DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

OBJECTIVE
TESTS FOR HDPE DUCTS
(Annexure A-5 of IRC:112)
BOND BEHAVIOUR OF DUCT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

ACCEPTANCE CRITERIA
TESTS FOR PRESTRESSING STEEL
(CL 18.3 of IRC:112)

REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

TYPE BIS STANDARD

Plain cold drawn stress-relieved wire IS : 1785 (Part-I)


Indented hard-drawn stress-relieved wires IS : 6003
Stress relieved multiply strands of normal relaxation IS : 6006
Stress-relieved multiply strands of low relaxation IS : 14268
High tensile steel bars IS : 2090

TESTS TO BE CONDUCTED ON STRANDS AS PER IS : 14268-1995


• PHYSICAL TESTS ON STRANDS

• CHEMICAL TESTS ON STRANDS

• ELONGATION TEST

• RELAXATION TEST
TESTS FOR PRESTRESSING STEEL
(CL 18.3 of IRC:112)
PHYSICAL TEST ON STRANDS
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

1. DIAMETER OF STRAND – TOLERANCE ARE DEFINED BASED ON DIAMETER OF STRAND


TO BE MEASURED BY VERNIER CALIPER.
2. DIA OF ALL SEVEN WIRES OF STAND ARE MEASURED (AS PER CL. 4.2 OF IS: 14268-1995)
CENTRAL WIRE SURROUNDING WIRES
4.36mm 4.22mm
4.23mm
4.22mm
4.23mm
4.23mm
4.23mm
CENTRAL WIRE AT LEAST 1.5% GREATER IN DIAMETER THAN THE SURROUNDING WIRE AND
TOTAL AREA SHALL BE MORE THAN 98.7mm2
TESTS FOR PRESTRESSING STEEL
(CL 18.3 of IRC:112)
PHYSICAL TEST ON STRANDS
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

3. MASS WIRE - 0.775kg/m


(AS PER TABLE-2 OF IS: 14268-1995)

4. LAY LENGTH IN BETWEEN 12 TIMES OF STRAND DIA AND 16 TIMES OF


STRAND DIA i.e.157.4mm AND 203.2mm
(AS PER CL.4.2 OF IS:14268-1995)
TESTS FOR PRESTRESSING STEEL
(CL 18.3 of IRC:112)
CHEMICAL TESTS ON STRANDS
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

SULPHUR AND PHOSPHOROUS SHALL NOT BE MORE THAN 0.05%


(AS PER CLAUSE 4.1.2 OF IS:14268-1995)
TESTS FOR PRESTRESSING STEEL
(CL 18.3 of IRC:112)
0.2% OF PROOF STRESS
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

LOAD EXTENSION GRAPH (AS PER CL.6.2.2 OF IS: 14268-1995)

20000
LOAD TO BE CALCULATED FOR EVERY 0.1%
18000
ELONGATION
LOADS ( IN kGS)

16000
14000
12000 LOAD VS % ELONGATION IS PLOTTED UPTO
10000
8000
1.0% OF ELONGATION
6000
4000 LOAD CORRESPONDING TO 1%
2000
0
ELONGATION SHALL NOT BE LESS THAN
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1
0.2% PROOF LOAD (90% OF BREAKING
EXTENSION %
LOAD) AS DEFINED IN TABLE - 1 OF IS:
14268-1995
TESTS FOR PRESTRESSING STEEL
(CL 18.3 of IRC:112)

ULTIMATE STRENGTH TEST


REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

LOAD EXTENSION GRAPH


TOTAL ELONGATION (AS PER CL.6.3
20000 OF IS: 14268-1995) FOLLOWING
18000
AN EXTENSION OF 1.0%, LOAD
LOADS ( IN kGS)

16000
14000
12000
SHOULD BE CONTINUED TILL
10000 ULTIMATE FAILURE. THE TOTAL
8000
6000 ELONGATION UNDER ULTIMATE
4000
2000
LOAD SHALL NOT BE LESS THAN
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1
3.5%
EXTENSION %
TESTS FOR PRESTRESSING STEEL
(CL 18.3 of IRC:112)

RELAXATION TEST
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

(CL.6.4 AS PER IS CODE 14268-1995) LOW RELAXATION STRAND, WHEN INITIALLY


LOADED TO 70% OF SPECIFIED BREAKING STRENGTH OF THE STRAND SHALL HAVE
RELAXATION LOSS OF NOT MORE THAN 1.8% AFTER 100hrs AND NOT MORE THAN
2.5% AFTER 1000hrs.
TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)

REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

• Provide an alkaline environment around cables to inhibit corrosion

• Primary protection to cables from corrosion

• Material & Process largely effect the long term durability of cables &
thereby structure

• Develops bond between prestressing steel and surrounding concrete


TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)

PROPERTIES OF GROUT
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

S.No Property Acceptance criteria


1 WATER CEMENT RATIO W/c < 0.45
2 DELETERIOUS MATERIALS Chloride (Cl-) < 0.1% by wt of cement
Sulphate ( SO3) < 4.0% by wt of cement
Sulphate ions (S2) < 0.01% by wt of cement
3 TEMPERATURE Tgrout < 25oc
4 FLUIDITY By cone test – Efflux time of one litre grout should be less
than 25 Sec
5 BLEEDING Bleeding < 0.3% after 3 hours
6 VOLUME CHANGE -0.5% and 5.0% of original volume after 24 hours.
7 COMPRESSIVE STRENGTH 27 MPa @ 7 days 30 MPa @ 28 days.
8 SETTING TIME 12 Hours. > TINITIAL SETTING > 3 Hours
TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)
HOMOGENEITY
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Sieve Test

The test consists of pouring a quantity(1ltr) of grout through a sieve to check for the absence of
lumps on the sieve.
Apparatus: 150mm diameter of sieve with an aperture ≤ 2mm
Results: Report the presence or absence of lumps
TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)
FLUIDITY
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Cone Method

The fluidity of grout, expressed in seconds, is measured by the time necessary for a
stated quantity of grout (1Ltr) to pass through the orifice of the cone, under stated
conditions.
Apparatus: Cone(refer Pic., all dimensions in mm and Internal diameters), stop watch
and graduated beaker.

Results : Measure efflux time

Acceptance Criteria
Efflux time of One Liter of grout should be less than 25 Secs
TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)
FLUIDITY
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Spread Method
The grout spread test measures the fluidity of thixotropic grouts. The fluidity is measured by
the diameter of the circle of grout spread on a smooth plate after a fixed period.

Apparatus: Cylinder of 39mm dia and height of 60mm, Graduated Steel ruler

Results : Measure Spread at 0sec and 30Sec.

Acceptance Criteria
Area of Spread should be more than 140mm after 30sec
TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)
BLEEDING
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Inclined tube test CONTENTS


This test serves to determine the bleed properties and volume stability of grout at full scale
and includes the filtering effect of strands. The test consists of measuring the quantity of
water and air remaining on the surface of the grout which has been allowed to stand
protected from evaporation.

Apparatus:
 2 transparent tubes, of approximately 80 mm diameter and 5 m long, equipped with
caps at each end including grout inlet at the lower end, and grout vent at the top. The
tubes and caps shall be able to sustain the proposed grout pressure.
 12 prestressing strands ø 15-16 mm per tube, i.e. a total of 24, length (approximately 5
m) to just fit between the caps on the tubes.

Results : Bleed water percentage


TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)
BLEEDING
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Inclined tube test

Acceptance Criteria
Bleeding shall be less than 0.3% after 3hrs
TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)
BLEEDING & VOLUME CHANGE
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Wick induced test CONTENTS


This test provides both volume change and bleeding measurements. Bleeding is measured
as the volume of water remaining on the surface of the grout which has been allowed to
stand protected from evaporation.
The volume change is measured as a difference in percentage of the volume of grout
between the start and the end of the test. The test measures mainly the volume change
caused by sedimentation or expansion.

Apparatus:

 One transparent tube, of approximately 60 mm to 80 mm internal diameter, and


approximately 1 m long, equipped with caps at each end.
 One 7-wire strand approximately 900 mm long which fits inside the tube.

Results : Bleed water percentage and Volume change percentage


TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)
BLEEDING & VOLUME CHANGE
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Wick induced test

Acceptance Criteria
Bleeding shall be less than 0.3% after 3hrs
Volume change shall be -1% and +5% after 24hrs
TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)
COMPRESSIVE STRENGTH
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Prisms test

The compressive strength of grout in this test (which is an adaption to grout of the
mechanical tests described in EN 196-1) is determined on the broken halves of prisms.

Apparatus: Metal moulds of 40 x 40 x 160mm, Compressive strength testing machine


TESTS FOR GROUT
(Cl 18.7.4 of IRC:112)
SETTING TIME & DENSITY
REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

Setting time is measured using Vicat apparatus similar to cement testing.

Density is measured as the ratio of mass to volume in the fluid state.


REFRESHER COURSE ON CONCRETE BRIDGE DESIGN USING IRC:112 , ORGANIZED BY IASTRUCTE, 22nd SEP 2018, DELHI- J. S . PAHUJA

THANK YOU

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