LOAD TESTING

OF BRIDGES
VINAY GUPTA
DIRECTOR & CEO
TANDON CONSULTANTS PVT LTD
NEW DELHI
 TEST LOAD TO BE SIMULATED
(ADD FOR IMPACT, CONGESTION, ETC)

NOTE: DEFLECTION TEST IS FOR LL + IMPACT ONLY

 25m+30m+25m

EJ EJ

CAST-IN-SITU PRECAST-PRETENSIONED
DIAPHRAGM GIRDERS @3.0m SPACING

PLAN
 25m 30m 25m

(3 SPAN CONTINUOUS)
GIRDER SLAB SUPERSTRUCTURE
IRC CLASS 70R LOADING
LOAD TEST: MAXIMUM SAGGING BM
CLASS 70R LOADING, SIDL ALREADY PLACED
LOAD TEST: MAXIMUM SAGGING BM
CLASS 70R LOADING, SIDL ALREADY PLACED
LOAD TEST: MAXIMUM HOGGING BM
CLASS 70R LOADING, SIDL ALREADY PLACED
LOAD TEST: MAXIMUM HOGGING BM
CLASS 70R LOADING, SIDL ALREADY PLACED
TEMPERATURE

CORRECTION
R3: ORIGINAL LEVEL
 CAST-IN-SITU
DECK SLAB

LONGITUDINAL SECTION 25m+30m+25m

EXP JT FREE RESTRAINED EXP JT

CAST-IN-SITU
DECK SLAB

PRECAST
CRASH BARRIER
30mm DEEP RECESS
FOR AESTHETICS

PRECAST END DIAPHRAGM

PRETENSIONED
GIRDER
30mm DEEP RECESS
FOR AESTHETICS

CARRIAGEWAY WIDTH = 15m

DEPTH OF SUPERSTRUCTURE
1880+220 = 2100mm PLAN OF PIER
1500mm X 3000mm

TRANSVERSE
SECTION
DELHI GURGAON EXPRESSWAY
TEMPERATURE CORRECTION

PLOT TEMP VS DEFLECTIONS FOR 24 HRS

AND MEASURE TEMP DURING TESTING
LOAD TEST
 LOAD

TESTING

OF
LOADED TRUCKS IN POSITION

BRIDGE
INSPECTION GANTRY
TAWI BRIDGE FOR JAMMU UDHAMPUR RAIL LINK: LONGEST
CONCRETE RAILWAY SPAN IN THE COUNTRY
 FIXING
SUSPENSION
WIRE AT
SOFFIT FOR
DEFLECTION
MEASUREMENT
 DIAL GAUGE

SET-UP FOR

DEFLECTION

MEASUREMENT
 33.52 t/m A

B
DP1 DP5
DP2 DP3 DP4

SECTION A

SECTIONAL ELEVATION OF BOX GIRDER

DP DP

SECTION 1

DP1 DP2 DP3 DP4 DP5

DEFLECTIONS MEASURED AT GAUGE LOCATIONS
SHALL BE CORRECTED FOR DEFLECTION OF R4
ELASTOMERIC BEARINGS. FOR THIS, DEFLECTION OF
ELASTOMERIC BEARINGS SHALL BE MEASURED BY
DIAL GAUGES INSTALLED AT THEIR CENTRE LINE.
A
DEFLECTION VALUES GIVEN MAY VARY ± 20 % ON –
–
DP1 DP2 DP3 DP4 DP5 ACCOUNT OF VARIATION IN MATERIAL PROPERTIES.
THE ACCEPTANCE CRITERIA IS % RECOVERY.

TABLE FOR TEMPERATURE

CORRECTION (REFER NOTE 3)

SECTION B

PLAN AT TOP LEVEL

DETAILED REPORT SUBMITTED SEPARATELY.

R4
AS BUILT DRAWING

TCPL'S SCOPE OF WORKS DOES NOT INCLUDE DEDICATED FREIGHT CORRIDOR CORPORATION
SUPERVISION OF CONSTRUCTION FOR THIS LOAD TESTING OF 19.8M
OF INDIASPAN
LTD.
PROJECT. THESE DRAWINGS REPRESENT THE
`AS BUILT' STATUS OF CONSTRUCTION ON SITE
RAILWAY GIRDER
WESTERN FREIGHT CORRIDOR : MAJOR BRIDGES
AS CONFIRMED BY THE CONTRACTOR. BETWEEN VAITARNA AND UTRAN ON VASAI -
BHARUCH SECTION
LO

STRUCTURAL
SOMA MERIT, 9, VENKATESWAMY NAIDU STREET, TASKER TOWN,
COMMON DRAWING (BRIDGE NO.125)
SHIVAJI NAGAR, BANGALORE - 560 051, KARNATAKA, INDIA.
TEL. NO. : +91-80-4025 4545, FAX NO. : +91-80-2286 4545
E-mail : smablr@somaenterprise.com LOAD TESTING SCHEME OF PSC BOX GIRDER FOR
SPAN 19.800m (c/c OF PIER)
17, LINK ROAD, JANGPURA EXTN. NEW DELHI - 110014.
Tel : 24317684, 24310509, 24319288 Fax : 24316057
E-mail : tandon@tcpl.com & tcpl_123@yahoo.com SOMA-DFCC-CD-C-1801
4 AS SHOWN AS BUILT
OFF SITE TESTING
 HAMMER SUSPENDED SPAN
HEAD

2.9m 24.39m 2.9m

W A T E R

WELL FOUNDATION

SPAN ARRANGEMENT
DETAILS OF SHARAVATHI BRIDGE, KARNATAKA
 WEARING COURSE GAP SLAB

CAST IN SITU PART

OF DIAPHRAGM

SECTION OF SUSPENDED SPAN

DETAILS OF SHARAVATHI BRIDGE,

KARNATAKA
 TESTING AND REHABILITATION OF SHARAVATHI
BRIDGE, KARNATAKA
DETAILS • 25 years old at the time of testing; 30.175mx34 spans.
• 2 lanes +2 footpaths.
• 2.9m cantilever hammer head on either side, monolithic
with pier.
• Hammer heads: PSC girder, 4 cross girders.
• Suspended spans 24.39m long.
• 5 nos. parallel precast post- tensioned I-girders with
1.264m wide top flange, 0.603m wide gap slab, cross
prestressed.
• Three intermediate diaphragms in additions to two end
diaphragms, all prestressed.
• Twin dumb bell shaped well foundation.
 TESTING AND REHABILITATION OF SHARAVATHI
BRIDGE, KARNATAKA

OBSERATIONS

• Regular breaking and falling of footpath s

precast planks.
• Improper functioning, leakage of expansion
joints.
• Corrosion of reinforcement.
• Corrosion and snapping of prestressing wires.
• Intermittent patch repairs already carried out.
• Gap slab and wearing course damaged.
 TESTING AND REHABILITATION OF SHARAVATHI
BRIDGE, KARNATAKA

OVERALL PLANNING OF REHABILITATION

• Establish details of the as built structure.

• Checks for present day design loadings.
• Original structure based on 1971 codes, deficient
estimation of relaxation losses.
• Three representative spans selected for detailed
investigations.
• NDT, physical & chemical testing.
• Repairs and rehabilitation.
 TESTING AND REHABILITATION OF SHARAVATHI
BRIDGE, KARNATAKA
DIAGNOSTIC TESTS
• Exposed cable ducts showing hollow
portions were selected.
• Photography using Endoscope: cables
and ducts found corroded.
• Penetration of clean water under gravity
revealed large quantity intake.
• Very ineffective grouting almost implied
unbonded prestressing due to no bond
existence.
• Chemical tests of grout samples revealed
excessive chloride penetration.
 TESTING AND REHABILITATION OF SHARAVATHI
BRIDGE, KARNATAKA

LOAD TEST

• Load testing before repairs to ascertain level of

prestressing when cracks start appearing at bottom.
• Electric Resistance Strain gauges (ERS) of 120mm length
fitted externally to observe strain behaviour.
• Ten nos. of wires from two cables each in all five girders
were exposed 1500mm length and instrumented with ERS
gauges and Mechanical Strain gauges.
• Wires cut to measure actual UTS also, results were
generally ok.
 TESTING AND REHABILITATION OF SHARAVATHI
BRIDGE, KARNATAKA

REHABILITATION SCHEME

• Additional steel bracket to give partial support to the

suspended span and relieve the hammer head.
• Regrout the cables.
• Lay additional RCC deck slab- 150mm thick.
• Jacketting (150mm thick RCC) of pier and pier cap- also to
support the steel bracket over elastomeric bearings.
• Lay bituminous waterproofing (Mastic Asphalt).
 ++ ++
++ ++

SUSPENDED
SPAN

STEEL BRACKET BEARING

PIER JACKET

SCHEMATIC ARRANGEMENT OF STEEL BRACKETS

SHARAVATHI BRIDGE, KARNATAKA
 TESTING AND REHABILITATION OF SHARAVATHI
BRIDGE, KARNATAKA
REHABILITATION SCHEME
• Analysis of stresses made assuming different levels of
existing prestress and additional external prestressing
imparted.
• External prestressing of diaphragms.
• Grouting of cracks with epoxy.
• Anti corrosive treatment to all exposed reinforcement
before laying patch up mortars.
• Painting of concrete surfaces with asphaltic acrylate
coating for chloride/ carbonation protection.
• Replacement of expansion joints.
• Fixing drainage spouts at pier and suspended span
locations.
LOAD TESTING OF PRTENSIONED GIRDER TO FAILURE
 DESTRUCTIVE

L T
O E
A S
D T

DEFLECTION MEASUREMENT TEMPERATURE CORRECTION

 VINAY GUPTA
DIRECTOR & CEO
M/S TANDON CONSULTANTS PVT LTD
NEW DELHI

SAR 4 Y2k