‘Quality Control tests for Minor Bridges/

Culverts including of non-destructive tests in

Concrete

satander50@yahoo.co.in
Structures:

Means anything that is constructed, whether

fixed or moveable, temporary or permanent,

buildings, masts, towers, framework,

pipelines, transport infrastructure and
underground works (shafts or tunnels);
any component or part of a structure.
Stem wall
Support wall
Length of a Bridges: Between inner faces of dirt
wall or between ends of deck joints or outer edges
of deck when there is no dirt wall.

ROW: Right of way; land acquired for development

 Quality Control
• Operational Techniques of Controlling Quality.

• An Important Requirement for Construction for

Ensuring Quality and Durable

Quality Assurance

Planned actions necessary to provide adequate

confidence, control human skills to assure
Quality.

QC of QC is Quality Assurance
 Definition of Quality Assurance
• To “assure” a person of something is to make him or her confident.

• To “ensure” that something happens is to make certain that it does,

• “Insure” is to issue an insurance policy.

• Quality Assurance
1. make certain of the Quality

2. inform positively and with certainty and confidence

3. assure somebody of truth of something,

4. give reassurance/ commitment

 CULVERT- IRC: 5 (Page3)
• Culvert is a structure having a total length of upto 6 m
between outer faces of walls, measured at right angles.

• Cross drainage:
• CD structures with pipes will be termed as culvert,
irrespective of length.

• Dirt Wall:
• Vertical wall projecting from abutment cap to prevent spill
of earth/pavement materials and also to support
approach slab.
 +
Beam Bridge -

• Bridge:
• Structure having length above 6 m for carrying traffic
or other moving load across a channel, depression,
road or railway track or any other obstruction.

• Flyover:
• A bridge over another road for allowing traffic without
interruption, with its approaches on both sides.

• Abutment:
• Substructure-supports ends of super structures and
retains part or whole of bridge approach fills
 Design and Construction of Foundation
• IRC 78-2014 : Design, construction of
foundation, Substructure.

• Foundation: Bridge in direct contact with

transmitting load to founding strata.

Pier: Intermediate Support of superstructure.

• Piles: Transmitting structure weight. to f. strata.
IRC: SP 13 - standard designs
i) Minor bridge – length upto 60 m.

ii) Small bridge - length - 30 m

iii) Individual span not > 10 m.
iv) Culvert- slab length 1-6 m

* Vent System for Escaping gases

*. De-silting system – drain
* Joining with Pipe Culverts
A minor bridge is a bridge having a total length
upto 60 m. IRC:5-2015 – ALIGNMENT ROAD

A small bridge is bridge where overall length

of the bridge between inner faces of the dirt
walls is upto 30 m and where individual span
is not more than 10 m.

Long span bridge > 150 m – APPROACHES-50m

Major Bridges > 60 m – APPROACHES- 50m
Stone slab can be used upto 2m span when
stones with 200 mm thickness are available.
 Overall width--- maximum loading of 2-lane class A.

(a) 2-lane carriageway: 7.5 m

(b) Single lane carriageway: 4.25 m for single lane IRC-5

 Minimum span and clearance

• Span of slab culvert - min. 2,0 m

• Minimum Height 1 .5 m

• Diameter of pipes 900mm PMGSY.

• avoid choke due to silting & for cleaning.

 Cross Drainage Protection Works

1. Type of CD works depends on flood

discharge, site conditions.

2. Pipe culverts, box culverts on weak soil,

RCC Slab Culverts/Causeways. on good soils

3. Discharge is more, Vented Causeway

Standard design as mentioned in IRCSP 13 may also be

precast box culverts and small bridges,

standard designs

2mX2m, 3 m X3m 4mX3m 5mX 3m, 6mX3m

2mX3m 4mX4m 5 m X 4m, 6mX4m

4mX5m 5m X 5m 6mX5m

6mX6m.
 Manual- IRC:SP:-73-2015 Two lanning
Manual- IRC:SP:84-2014 Four lanning
Manual- IRC:SP:87-2013 Six lanning
IRC:SP:106-2015 Landslides
IRC 102 RE (Reinforced Earth) Wall
In built-up sections- Minor Bridge:
• Viaduct span

• RE Wall height 7.5 m

• Transition in median 1 in 30

• Carriageway width- 0.5 m away from median side

• Load stresses IRC:6-2014

•
 Where Pipe/ or Box culvert
• Small openings- a pipes, pipe arch as
substitute where head room is
limited. Foundation erodible.

• For openings of moderate size a pipe

and box culverts.
 Where Pipe/ or Box culvert
• For larger opening a single or multiple
span box culverts or more large
diameter pipe.

• Slab culverts replace box

culverts where foundation is
non-erodable
 Culverts
• It is a transverse and totally enclosed drain
under a road or railway.
• OR
• A water course totally enclosed and usually of a
size through which a man can pass
• OR
• An opening through an embankment for
conveyance of water by mean of pipe or an
enclosed channel.

aboutcivil.org/geometric-design-of-
highways.html
 DESIGN
IRC:6 -2017 Standard Specification and Code of
Practice for Road Bridges:
Section 1:
Section 2: Load and Load Combinations

Bridges Design for 70 R Loading should be

checked for Class A loading for bridges and
culverts
 Class 70 R Wheeled Load IRC: Loading

0.61 3.960 m
M m 55555555
 Design part - similar to IRC:SP:13-2014.
• Catchment area <1 sq km, a culvert

• Catchment a. > 1 km sq, small bridge

• Length of span =

1.5 times height

of abutment
or piers from the bottom of its
foundation to its

top in metre .
Vertical clearance above water level + Depth of Foundatio
 SIMPLY SUPPORTED/ CANTILVER
• Simply supported beam is • Cantilever =beam
supported at both ends anchored at only one
end.
 Beam Bridge
• Horizontal beam supported at each end by piers.

• Weight of beam pushes straight down on piers.

• Farther apart its piers, weaker beam becomes.

 Continuous Span Beam Bridge

• several beam bridges

Chesapeake Bay Bridge-Tunnel

 Truss Bridge: Forces
• Every bar - pushing or pulling force.

• bars rarely bend.

• span more than beam bridges.

 Arch Bridge:
• Arch is squeezed together,
Abutments,
 IS CODE: 13920
Clause 1001 MORD

Near Loha Mandi DElhi CONVENTION IN SITU METHOD

.
 Application in India
• Chandikhole- Jagatpur Bhubneshwar Cuttack Orissa -
 clause 1101

NP 3 or 4 Pipe less than 500 mm buried not culvert

600 mm fill

NP 3 or NP 4 RCC ----- FOR BOX CULVERT

Minimum dia 900 mm

In exceptional cases600 mm
NP 1 Un reinforced Drainage/irrigation

(0.07 Mpa 7 m head)

NP 2 Reinforced , Light duty Drainage/irrigation/CD/Culverts

(0.07 Mpa 7 m head)

NP 3 UnRein./Reinforced, medium duty Drainage/irrigation/CD/Culverts

(0.07 Mpa 7 m head)

NP 4 UnRein./Reinforced, heavy duty Drainage/irrigation/CD/Culverts

(0.07 Mpa 7 m head)

PRESSURE and Non Pressure Pipe- Very Severe

 PRESSURE PIPES
P1 Reinforced, medium duty, Pressure Gravity mains, site 0.6* 0.2 MPa

Pressure 0.2 Mpa (20 m head)

P2 Reinforced, medium duty, Pressure Pumping main 0.5* 0.4 MPa

Pressure 0.4 Mpa (40 m head)

P3 Reinforced, medium duty, Pressure Pumping mains, site 0.5* 0.6 MPa

Pressure 0.6 Mpa (60 m head)

PRESSURE and Non Pressure Pipe

Very Severe
450 mmdia, Web = 35 mm, caulking 19 mm, Length collar= 200 mm M 45 Mpa
 LIFTING SYSTEM
Causeway:
Paved submersible structure which allows
flood to pass through and /or over it.
Atleast for two lanes

ASTM C-1504
Bally Bd
Clearance over Roads – IRC:5-2015 General
Features of Design Minor Bridges
• Minimum vertical clearance provided 5 m for non
urban areas.

• 5.5 m in case of urban areas

• Minimum Vertical clearance footways 2.25 m

 Clause 1803.21 – Culverts and Minor
Bridges page 535 MORD
• TABLE 1800.41, 42, 43
• TESTS ON RCC SLAB CULVERTS AND MINOR BRIDGES.
Prior and during construction.
• Table 1800.37 and 38 QC Steel reinforcement
• Table 1800.46- causeways
• Table 1800.39 Tests on Pipe Culverts
• IRC: 83 Bearings
• IRC: 87 Form works
• IRC: 78 Foundation and sub structures
• IRC: 5 and 6- General Design Features, stresses, Loads
Soil and Type of
Foundation
 Reasons of Pile/Deep Foundation

• Soil at depth is too soft for required loads

• Large lateral loads

• Uplift loads- negative friction

• Open foundation, well foundation not feasible

Sub soil Investigation- IS:1892, IRC:SP:73 clause 7.6

Standard Penetration Test (SPT) - Bore Hole Test

SPT- IS: 2131
• Bore location SPT-

• One bore at each foundation Sample splitter IS:9640

Function of Pile
• Load transfer mechanism :

• Transfer axial loads by friction

along its shaft or end-bearing.
 SPT Videos
IS: 1892- Soil Investigation for Foundation
Standard Penetration Test (SPT)

69
Cone Penetration Test (CPT)

70
71
 Foundation
• IRC 78-2014 : Design, construction of
Pile foundation, Substructure

• IS: 2911- Part 4-2013 Design, construction of (Load Capacity)

Pile foundation.
(High strain I.)
• IS: 1904-1986 : All types of Foundation
ASTM Pile Integrity Test

(Low Strain Integrity)

 Basics- Pile Foundation
• Load from structure transmitted settlement
(>12mm)- may result in structural damage.

• IS: 2974 for Adjacent structures Distance/vicinity

 NEGATIVE SKIN FRICTION AND SETTLEMENT OF PILES
• A relative movement between a pile and a soil produces:
• Swelling soils, when soil moves upward in relation to pile.
• _______________________________________________
• If movement of pile is downward, i.e., soil shear stress
induced in pile is upward, direction of shear is positive.

• ________________________________________________

• If movement of pile is upward,

shear stress direction is negative;
 A telescopic Kelly bar
• Drilling large excavations.

• Lower outer bar section,

• One middle bar sections

• An upper inner bar

• High Tensile Steel

Pile Construction at NCB Haryana NH2
 Cased
Driven
Cast-in-situ Pile

Uncased
Driven
Cast-in-situ
Pile
Concreting -
Tremie Pipe
Pre Cast Pre-stressed Concrete Piles- Less
requirement for coffer dam
Quality of Density of Bentonite Slurry = 1.05 gm/ cm3 Min.
Marsh Cone Viscosity of Bento. Slurry 30-40 Sec
 Bentonite slurry
• Silt Content < 1%, LL > 400 %

Quality Check of pH = 9.5-12

Welding of Bar = ?
Placing of Pumpable Concrete Through Boom/Tremie Pipe

Polymer alternate to bentonite ?

Cut-Off Level - Level where installed pile is cut-off to
support pile caps or beams or any other structural
components at that level.

Cleaning soil around Piles

One Pile can take load of about 200 Tonnes
9 Piles *200 Tonnes= 1800 Tonnes
One Segment max 60 Tonne
5 *2 segment 5*2* 80= 800 Tonnes
Kentledge - Dead-weight used for applying a
test load’on piles.
Ultimate Load Capacity - The maximum load which a pile or
pile shaft can carry before failure of ground ( when the soil
fails by shear as evidenced from the load settlement curves )
or failure of pile.
 Lateral Load Tests- 0.1 mm per 30 minutes
• IS: 2911- Part 4-2013

• SAFE LOAD FOR INITIAL TEST

• Final load - Deflection less than 5 mm

• ROUTINE TEST - WORKING LOAD

• Safe lateral load resistance, deflection - 5 mm

 Reinforcing steel IRC 112/IS: 1876
• Grade % Minimum
Elongation
• Fe 415 IS 1786 14.5
• Fe 415 D 18
• Fe 500 12
• Fe 500 D 16
• Fe 550 10
• Fe 550 D 14.5
• Fe 600 10
 IS 1786-2008- Fe 500, 16 mm/ clause 1001.6.2.2 page 239 MORD
• Carbon Max 0.3%
• Sulpher Max 0.055
• Phosphorous Max 0.055
• Sulphur +Phorphorous Max 0.105

• Carbon Equivalent, C + Mn + Cr+ Mg+ V + Ni + Cu

(Morth 530p) IRC: 112 6 5 15
Guaranteed weldability, Carbon Equivalent, < 0.4% (For
special grade Fe 415) page 239 MORD--- 2 times bar dia, away
from bends
• Tensile Strength (8% More YS) > 545 Mpa
• Yield Strength > 500 Mpa
• % elongation 5.65 ( Area)1/2 12% minimum
• Mass / meter 1.580+/- 5%
• Rate of stressing 30 MPa/sec

• Oxy-acetelen welding
Quality Check on the Depth of Bore Hole for Pile with Chain
• Silt Content less than 1%

• LL not less than 400 %

Welding of Bar = ?
Insertion of Cage- Placement of Concrete without compaction below 4 m from Top
 Problems- solution
• Improper penetration ( Less length)
• Un-expected Hard rock
• Lateral movement of pile
• Out of alignment/location
• Pile develop cracks
• Pile spalling
• cold joints.

Remedial Measures:
i) Load test extra piles
ii) Questionable pile may be replaced
iii) Another location
 NUMBERS OF TESTS
• Initial Load test-
• Determination of Ultimate load and safe load having factor of safety 2.5

• Minimum one prior to execution of job.

• 2 upto 1000 piles less than 1000 mm dia
• 2 upto 1000 piles one for every 1000 piles for larger dia

• Routine -
• checking safe load, initial test
• any unusual - concrete, sudden drop, tremie/ boring, different depth of piles,
cold joints, fail in NDT test
• Frequency 0.5% - 2% of total piles, subject to minimum one pile.

• If higher than cut-off, remove material for skin friction, take burden pressure.
 SPECIFICATION (Rate of Compression –– 0.2 mm per hour)

• IS: 2911- Part 4-2013 max load for 24 hr.

INITIAL TEST- in terms of 20%

Safe Vertical Load -2/3rd of final load < 600 mm dia pile, deflection < 12 mm

Safe Vertical Load -2/3rd of final load > 600 mm dia pile, deflection < 18 mm
• 2 % of dia which ever is less ( say 1000 mm X 2% = 20 mm)

• ROUTINE TEST - 1.5 TIME WORKING LOAD ,

• Deflection for < 600 mm pile; < 12 mm

•
• Deflection for < 600 mm pile < 18 mm or 2%
 Lateral Load Tests- 0.1 mm per 30 minutes
• IS: 2911- Part 4-2013

• SAFE LOAD FOR INITIAL TEST

• Final load - Deflection less than 5 mm

• ROUTINE TEST - WORKING LOAD

• Safe lateral load resistance, deflection - 5 mm

 – Bi-directional pile load test
• A deep foundation pressurised by an
embedded jack assembly to perform axial
compressive load test, so that the foundation
section above the jack assembly moves
upwards and the foundation below the jack
assembly moves downwards, each section
providing reaction to the other. As such
applied test load is twice the load in the jack
assembly.
6.2 fixed to the required no. of jacks ref Fig-8 and Fig-9.

Fig -8 Jacks being assembled with steel bearing Fig-9 Assembled arrangement rea
to plates be installed in pile
Fig-10 Jack assembly attached to pile Fig-11 Jack assembly attached to pile
Jack assembly casing for driven pile shall include anchorage that will safely withstand
handling and driving stresses. Refer Fig-12.

Fig-12 Lowering of assembly with cage reinforcement

7.1 the measuring and reference systems. Refer Fig-13.

Fig-13 On site test set up location

Segm
IS: 15388-2003
 Microsilica production IS: 15388-2003
Smelting plant with furnaces,
coolers and baghouse
Quartz, coke and
wood as raw
materials

Microsilica

Silicon or ferro-silicon
2000 oC
electric arc furnace
 Specifications for Silica Fume
IS: 15388-2003
Chemical requirements
Test values
SiO2 min. (%) 85.0
Moisture Content Maximum (%) 3.0
Loss on ignition, maximum (%) 6.0

Physical requirements
Accelerated pozzolanic strength
activity index with Portland cement at 105
7 days,, minimum (%) of control.
Fineness, max (%) retained on 45 m
sieve 10
Percentage retained on 45m, max
variation from average (%) 5
Reactivity with cement alkalies min.
reduction (%) 80
 Research Scheme On “HPC” No B- 32 Sponsored by MOST Test Results
of concrete showing the effects of silica fume /superplasticizers
1:1.41:2.18, density = 2.44gm/cu cm.,
W/C = 0.386, W/B = 0.351, cement 43 Grade
Sl No. Silica Super Compressive Flexural
Fume (%) Strength (kg/cm2) Strength (kg/cm2)
Plasticizer(%)
7days 28days 7days 28days
_______________________________________________________________

1. 0 0 270 360 37 48

2. 0 1 319 446 42 45

3. 10 0 360 530 56 67

4. 10 1 445 570 58 69
Hydroelectric Power Projects
•NATHPA JHAKRI •KHIMTI
•BASPA •KHALI GANDAKI NEPAL
•CHAMERA -II •MIDDLE MARSYANGDI
•SALAL (Repair Works)
•CHAMERA I (Repair Works) •KURICHU &
BHUTAN
•BAGLIHAR •TALA
•DUL HASTI
•SRI SAILAM (Repair Works) INDIA
•DHAULI GANGA
•VISHNU PRAYAG
•TEHRI
• URI
TEESTA - V
•PARBATI - II
•SEWA - II
•SUBANSHRI - lower
INSTRUMENTATION OF HIGH EMBANKMENTS-
IRC 75, IRC 78 Filter Media

• MSG, magnetic strain guage for settlement gauge

• Inclinometer for lateral displacement
• Pizo-meter for pore pressure

• N < 4 Clay ( 4 tonne/ sq m ) = (4000 kg/100*100 cm2) = CBR = 4%

• (0.4 kg/cm2 ) = 0.04 MPa = 40 kPa

• N> 15 Stiff Soil = 0.8 Mpa, N 60 = Granular Material

• Permeability
• = 10m/day = 10000 mm /24*60*60 sec = 0.1 mm /sec = 0.01 cm/sec

• Speed 1 km/hr = 1000 00 cm/60*60 28 cm /sec

• 1000 km/hr = 2.8 m /sec 1km = 0.06 min = 3.6 sec /km
VID_20160930_155331.mp4
 Avoid Diagonal Crack
Good compaction Filter Media
• D15 (Filter)/D 85 (base) <5
• To resist earth pressure
• Only after filling abutment cap
Poor Good
 Pier cap/abutment cap clause 1206.4
page 316
• Shall be finished smooth

• Slop for draining off water

• Wood float finish for seating bearing 1.5 mm

• Bearing 25 mm below bottom level of bearing

Mastic as Composite Pavement IRC 107-2013 on Many Deck of Bridges
 Stone pitching
• 25 kg design velocity 2 m/sec
• 40 kg design velocity 3.5 m/sec
• Thickness 225 mm
• Spall 25 mm
• Alternatively stone/block in wire crates
• M 15 concrete