SIX LANING OF

CHANDIKHOLE-JAGATPUR-BHUBANESWER (NH-5)

SIX LANING OF CHANDIKHOLE-JAGATPUR-

JOB NAME
BHUBANESWER (NH-5)
DOCUMENT METHODOLOGY FOR LOAD TEST OF 25 M SPAN FOR
NAME KHAPURIA FLYOVER

SIMPLEX DOCUMENT NO. 02/DD/2608/NH-5/KHAPURIA-FLY/LT/DOC/002

CUSTOMER NATIONAL HIGHWAY AUTHORITY OF INDIA

CONSULTANTS STUP CONSULTANTS P.LTD

CIVIL EPC CONTRACTOR SIMPLEX INFRASTRUCTURES LIMITED,NEW DELHI

DATE REV. NO. MODIFICATION / PURPOSE OF ISSUE PREPARED CHECKED APPROVED

Name Signature Name Signature Name Signature

27.08.15 R0 ISSUED FOR APPROVAL SUNIL SKB SKB

 SIMPLEX INFRASTRUCTURES LIMITED
(Formerly SIMPLEX CONCRETE PILES (INDIA) LIMITED) DESIGN CALCULATION SHEET
PROJECT: SIX LANING OF CHANDIKHOLE-JAGATPUR-BHUBANESWER (NH-5)
TITLE : METHODOLOGY FOR LOAD TEST OF 25 M SPAN FOR KHAPURIA FLYOVER

Table of Contents

1. Introduction
2. Vehicles for Testing
3. Preparations for Testing
4. Procedure for testing
5. Observations of Load testing
6. Procedure for temperature correction
7. Acceptance Criteria
8. Precautions to be taken

This document should be read in conjunction with drg no. 02/DD/2608/NH-5/KHAPURIA-FLY/LT/02-R0

Date :27.08.2015 PREPARED BY: SUNIL.

 SIMPLEX INFRASTRUCTURES LIMITED
(Formerly SIMPLEX CONCRETE PILES (INDIA) LIMITED) DESIGN CALCULATION SHEET
PROJECT: SIX LANING OF CHANDIKHOLE-JAGATPUR-BHUBANESWER (NH-5)
TITLE : METHODOLOGY FOR LOAD TEST OF 25 M SPAN FOR KHAPURIA FLYOVER

1. Introduction:

This note presents a procedure for load testing of Single lane flyover superstructure for flyover in the
stretch between Bhubneswar and Chandikhole section of NH-5. Load testing is useful in assessing the
flexural capacity of the structure, where in deformations due to applied loading can be measured and
checked with the acceptable limit criteria. The span of the proposed span is 30m.
Load test is planned according to the guidelines given in IRC SP: 51 “Guidelines for load testing of
bridges”
2. Vehicles for Testing:
In view of difficulty in simulating the IRC standard vehicle loads exactly in the field, it proposed to
produce a loading which will give the maximum bending moment same or slightly more than the
theoretical values computed with IRC vehicles at Mid span. The configuration of commercial vehicle
available for load testing is as follows.
The vehicle is having a gross load of 29 ton. Axle load distribution assumed as per the testing load
requirement is as shown in the attached figure. The vehicle shall be loaded such that the assumed axle
distribution as above is simulated. The number of vehicles, their positions and loading of each vehicle
are as per the design live load bending moments. Design live load bending moments and deflections in
comparison with test load generated forces are as follows.

Entity @ Section Resultant of IRC Vehicle ( with Resultant of 6 test Vehicles of 29

Impact factor & considering ton each as per drg no.
reduction for 3 lane) 02/DD/2608/NH-5/KHAPURIA-
FLY/LT/02-R0

Bending Moment (T-m) Mid span 249.9 -251.8

Deflection, mm Mid span 6.66 7.35

Deflection, mm Quarter span 4.7 5.3

3. Preparations for Testing:

1. Specific locations of the loading computed (As shown in the drawing) should be exactly marked
on the carriageway.
2. Load test should be planned in such a time when the variation in temperature is low. if it is not
possible suitable temperature correction shall be made accordingly.
3. Expansion gaps, joints should be cleared of all debris, so that the movement if any shall be free.
4. Functionality of the bearings should be ensure.
Date :27.08.2015 PREPARED BY: SUNIL.
 SIMPLEX INFRASTRUCTURES LIMITED
(Formerly SIMPLEX CONCRETE PILES (INDIA) LIMITED) DESIGN CALCULATION SHEET
PROJECT: SIX LANING OF CHANDIKHOLE-JAGATPUR-BHUBANESWER (NH-5)
TITLE : METHODOLOGY FOR LOAD TEST OF 25 M SPAN FOR KHAPURIA FLYOVER

5. Settlement of bearings shall be ensured by measuring deflections below the girder at bearing
locations.
6. Contact of the dial gauge shall be ensured during the course of testing as the structure is likely to
hog/sag due to temperature variation.
7. Staging for dial gauges and any other instrumentation shall be stable, independent and rigid.

4. Procedure for testing:

1. The test load shall be applied in stages following the given values 0.4W, 0.5W, 0.7W, 0.8W, 0.9W,
1.0 W. Where “W” is the gross loading weight of the test vehicles.
2. For first stage, the corresponding loaded test vehicle shall be brought to the intended/marked
position and observation of deflections shall be made instantaneously and after each hour of loading.
3. The next incremental loading at any stage of testing shall only be added after the deflections under
the previous loading have stabilized and all the stipulated observations are completed.
4. The final test load shall be retained for 24 hours and deflection after each hour of loading shall be
measured and noted.
5. During the testing operations, the load-deflection diagram should be plotted at site at every stage of
loading. if the deflection observed at any stage exceeds the limit prescribed or abnormal the further
loading shall be stopped.
6. After 24 hours of retention period, the unloading should be done in same stages as it was applied
(One after other) and next stage of unloading should be proceeded to only after deflections have
stabilized. Instantaneous deflection recovery and deflection recovery after each hour of removal of
load should be noted at each stage and till 24 hours after final removal of loads.

5. Observations of load testing:

1. It is proposed to observe the deflections at mid span and quarter spans below the girder.
2. Dial gauge reading below the girder at the prescribed locations shall be measured continuously as
mentioned above.
3. The Dial gauge reading shall be tabulated as follows.

S.No Time Loading Time Unloading

(Hrs) (Hrs)
Dial gauge 1 Dial gauge 1

Date :27.08.2015 PREPARED BY: SUNIL.

 SIMPLEX INFRASTRUCTURES LIMITED
(Formerly SIMPLEX CONCRETE PILES (INDIA) LIMITED) DESIGN CALCULATION SHEET
PROJECT: SIX LANING OF CHANDIKHOLE-JAGATPUR-BHUBANESWER (NH-5)
TITLE : METHODOLOGY FOR LOAD TEST OF 25 M SPAN FOR KHAPURIA FLYOVER

Initial value on dial gauge - R1

Final Value after placement of test load - R2
Value at 24 hours after placement of test load - R3
Value immediately after removal of test load - R4
Value at 24 hours after removal of test load - R5
Percentage recovery of deflection 24 hrs after removal of test load - (R3-R5)/(R3-R1)*100

6. Procedure for temperature correction:

Temperature correction due to the variation in temperature shall be appropriately accounted for during
the testing. For the same, reference shall made to Cl. 4.8 of IRC:SP-51-1999.

7. Acceptance Criteria:

Percentage recovery the deflection at 24 hours after removal of test load shall be at least 85%.

8. Precautions to be taken:

1. Staging for measuring deflections and for observation should be independent so that the observer
movement can not affect the deflection measurements.
2. Staging for dial gauge measurement should be rigid and safe.
3. Ensure that there is sufficient lever available for deflections in both directions.
4. Surface preparation should be carried out at all dial gauge locations.
5. The vehicles shall be brought to the test position slowly without any vibrations.
6. As far as possible there shall not much traction due to movement of vehicles over the structure.

Date :27.08.2015 PREPARED BY: SUNIL.