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Inspection of
Concrete Bridges
Bridge Inspection
Systematic observation of
condition and behaviour
of various components/
parts of a bridge
Inspection Includes
 Going to the bridge
 Seeing the bridge with an eye of the
Doctor (Engineer) with unaided as well
as an aided eye.
 Systematic observation over a period
of time
 “Thok baja ke dekhna”
Objectives of Inspection
• To know whether the bridge is structurally
safe
• Will it continue to be safe
• Identify actual and potential sources of trouble at
earliest possible stage
• To record systematically and periodically the
state of the structure
• To decide about the repair measures to be
taken
• To provide feedback to the designer and the
construction engineers on those features
which give maintenance problems
Current Scenario on IR
 Concrete bridges increasing with time
 Advantage of ballasted deck
 Concrete – a heterogeneous material
 Durability depends on many factors
 Affected by environmental factors
A Statement - may be
controversial
 Concrete structures are inherently
durable as compared to steel as long as
they are rationally designed and
constructed
 Deterioration of concrete is but a result
of wrong concrete mix or poor
construction work quality control.
But…
 Possibility of mistakes to happen during
construction is far greater than the steel
because
 Most of the material of a concrete structure
are supplied and assembled on site.
Therefore…
 the examples and anomalies and defects
on concrete structure, resulting from
poor quality of construction or material
are numerous in number and kind.
 The possibility for mistakes of the type is
even higher in PSC girders, where
additional processes such as pre-
stressing, grouting and erection of
girders are necessary.
and…
 There are certain phenomenon in
concrete that occur in the inside and
some which occur on the outside and
thus some can be seen and some get
manifested in the form of surface defects
over the years.
 The behaviour of those defects is not
easily predictable and analysable.
 Mostly it would be in the form of cracks
So in concrete it becomes
important to
 To find for cracks, which in the initial
stage
 study them with a view to ascertain
their cause
 Track their growth and movement
How to inspect?
 Decide number of spans to be inspected each day
 Scrutinize the previous years inspection notes
 Try to have plan, drawings and other details of
the important bridges
 Go through the drawings (important bridges to
identify critical locations)
 Plan any special inspection equipment, temporary
staging etc. (like tunnel inspection)
 Don’t rush to complete – done once a year
Precautions
 Clothing
 Glasses
 Shoes
 Scaffolding and ladders
 No short cuts please
 Watch your steps and your ego too
Inspections – Open Line
 Para 1101 SE (Works) will inspect before
monsoon every year.
 Para 1103 AEN open line will inspect after
monsoon every year.
 Para 1104 (1)(a) Important bridges and
bridges that call attention by DEN/SrDEN
Inspection- Bridge Organization
 Para 1102 SE (Br) will inspect all RCC, PSC
and Composite girders within one year of
installation
 Para 1102 SE (Br) will inspect all these
girders once in five years on planned basis
 SE (Br) will measure camber of PSC girders
once a year with any reliable method
 Para 1105 AEN (Br) shall test check 10% of
the bridges inspected by the bridge
inspector
Special Inspection (Need
based)
 When signs of weaknesses discovered
during routine or detailed inspection or
by any other observation.
 When the bridge loading is to be
increased due to revised or increased
loading standard.
 Distressed bridges.
 Exceptional events like fire, earthquake,
heavy floods etc
What to take along? (Anne. 11/15 of IRBM)
1. Pocket tape (3 or 5 m long)
2. Chipping hammer
3. Plumb bob
4. Straight edge (at least 2 m
long)
5. 30 metre steel tape
6. A set of feeler gauges (0.1 to 5
mm)
7. Log line with 20 kg lead ball
8. Thermometer
9. Probing rod
10. Wire brush
11. Mirror ( 10x15 cm)
12. Magnifying glass (100 mm
dia.)
13. Chalk/water poof pencil/pen
or paint
14. Centre punch
15. Callipers (inside and
outside)
16. Torch light (5 cell)
17. Paint and paint brush for
repainting areas damaged
during inspection
18. Gauge-cum-level
19. Piano wire
20. 15 cm steel scale
21. Inspection hammer (350-
450 gm)
22. Microscope
23. Binoculars
24. Camera
25. Crack meter
27. And common sense
What to Inspect … but
before that
 Work through a checklist prepared for the
particular type of structure.
 Should be familiar with the details of the structure
and as to how it is intended to function.
 Should study previous reports before conducting
inspection, so that the condition of the defects
noticed earlier could be checked.
 Should be aware of rectification work done earlier,
the same should be inspected and its performance
should be recorded.
…and the most important
 thing is to know and realize that every
deterioration has a cause and the aim of
inspecting official is to determine that
cause
Routine Inspection by AEN
Purpose
 Whether there is any defect in structure?
 If yes, what is the degree of the defect?
 Is it progressing?
 Is it affecting the function of the structure?
 Is there any change in the environment?
 Heavy rains.
 Other factors like trespassing and other usage
 Is it going to affect the train operation?
 Is there a necessity of doing preventive work?
 Does it require detailed inspection?
What to see?
 Cracks
 Texture of Concrete
 Wear and erosion of concrete
 Leaching of chemicals
 Stains such as corrosion in steel, dampness,
growth of algae, marine microbes
 Painting coat condition
 Bearings
 Camber
 Other observations
What to see?
 Cracks
 Texture of Concrete
 Wear and erosion of concrete
 Leaching of chemicals
 Stains such as corrosion in steel, dampness,
growth of algae, marine microbes
 Painting coat condition
 Bearings
 Camber
 Other observations
Cracks?
 Cracks identification
 Length
 Size
 Orientation
 Location
 Breathing of not
 Accompanying stains
Measuring Magnifier - Proceq
Least count 0.02 mm
Crack meter
Cracks?
 Cracks need to be analysed and then
only conclusions may be drawn
 All cracks lead to durability problems
 Some cracks are not serious
 Require only covering
 Other cracks are serious
 Affect load carrying capacity
 Require retro-fitment as well as covering to
prevent corrosion
 Tell tales help in decision making
Tell tales
Types of Cracks and spalling
 Fresh concrete
 Hardened Concrete
 Structural Cracks
 Due to loads
 Compatibility cracks
 Due to Detailing
 Corrosion
 Steel
 Concrete
 Others
 Alkali-aggregate reaction
 Sulphate attack
Cracks in fresh Concrete
 Crazing
 Plastic Shrinkage
 Drying Shrinkage
 Plastic settlement
 Long term Drying Shrinkage
 Thermal expansion/contraction
 Settlement of formwork
Crazing
 Probable Area
 Against formwork or surface
 Probable Locations
 Fair faced slabs
 Cause
 Impermeable formwork, over trawling
 Rich mixes, poor curing
 Remedy
 Improve curing and finishing
 Time of Appearance
 1-7 days, sometimes later
Plastic Shrinkage
Plastic Shrinkage
 Probable Area
 Random over reinforcement mesh, Diagonal,
Normal to wind direction
 Probable Locations
 RCC slabs
 Cause
 Rapid early drying
 Low bleeding and fast surface evaporation
 Remedy
 Improve early curing and trowel
 Time of Appearance
 Thirty min. to six hours
Plastic Settlement
Plastic Settlement
 Probable Area
 Over reinforcement, Arching, Change of depth
 Probable Locations
 Deep sections, Top of Columns/ troughs
 Cause
 Excess Bleeding
 Rapid early drying
 Remedy
 Reduce Bleeding
 Reverberate mildly
 Time of Appearance
 Ten min. to three hours
Early Thermal Expansion
and Contraction
 Probable Area
 External/ Internal restraint
 Probable Locations
 Thick walls, Thick slabs
 Cause
 Excess heat generation, Excess temp. gradient
 Rapid cooling, Curing by cold water
 Remedy
 Reduce heat and/or insulate, cool concrete, reduce
spacing of steel
 Time of Appearance
 One day to 2-3 weeks
Long term drying shrinkage
 Probable Area
 -
 Probable Locations
 Thin walls, Thin slabs
 Cause
 Absence of movement, inefficient joints
 Excess shrinkage, Inefficient curing
 Remedy
 Reduce w/c ratio, Improve curing
 Time of Appearance
 Several weeks or months
Action in case of cracks in
Fresh Concrete
 For purely surface cracks, normally no
action taken if appearance is not an issue
 In case cracks are wider and deeper, the
repair method as suitable may be
decided based on the crack size.
 In case of time dependent crack like
shrinkage and settlement – the action
should be delayed if not affecting the
structure.
Cracks in Hardened Concrete
during service
Compatibility cracks
REINFORCED CONCRETE BEAM UNDER LOAD
Crack in the deck slab
Location Reason
Bottom surface
of the deck slab
in the middle
Compatibility cracks
Excessive load on
the deck
Compatible Cracks
 Cracks which occur in course of normal loading in
RCC components for reinforcement to take the
tensile stresses. Specified in Para10.2.1 (a) of
CBC.
Environment Design Crack Width (mm)
Moderate 0.25
Severe 0.20
Extreme 0.10*
STRUCTURAL CRACKS
Slabs
RCC Slab
Location Reason
Diagonal cracks near
support and 1m to
2m from support
Excessive shear
force
Cross cracks in center
Location Reason
Center of span Excessive Load
Less reinforcement or location
of reinforcement
Shrinkage cracks (rare)
Less Cover
Longitudinal cracks at bottom
Location Reason
Longitudinal
cracks on
lower surface
of girder
Shortage of distribution
reinforcement
Less cover to main bars
Corrosion of main bar
Cross cracks at ends
Location Reason
Transverse
cracks on
upper
surface of
girder
Shortage of bent up or top
bars in upper area
Drying Shrinkage
Location Reason
Longitudinal
cracks on upper
surface of
cantilever
Excessive load on cantilever
Less reinforcement in
cantilever
Main reinforcement in
cantilever placed lower
Crack near the support of cantilever
STRUCTURAL CRACKS
Girders
What to inspect in concrete bridges –
Major Bridges – PSC girders
 All the items what are there in the
small spans
 In addition
 Items related to pre-stressing (post
tensioning) and Anchorage Zone
 Slab, diaphragms, Junctions of cast in
situ and precast units or RCC/PSC
 Inside of the Box girder
 Bearings and Expansion arrangements
PSC Box
Location Reason
Perpendicular to
girder on the lower
surface of the girder
Shortage of Pre-stressing
force
Excessive Load
Breakage of PSC strand
PSC Box
Location Reason
Perpendicular to
girder on the
upper surface of
the girder
Overstressing of girder
Shortage of loading
Closes during passage
of train
PSC Box
Location Reason
Diagonal Cracks
near the support
Shear stress due to
loading
Drying Shrinkage
Structural Cracks
Structural Crack
What to inspect in concrete bridges –
Major Bridges – PSC girders
 All the items what are there in
the small spans
 In addition
 Items related to pre-stressing (post
tensioning) and Anchorage Zone
 Slab, diaphragms, Junctions of cast
in situ and precast units or RCC/PSC
 Inside of the Box girder
 Bearings and Expansion
arrangements
Anchorage Zone
•Maximum stresses
during stressing
operation
•Concrete strength
increases with age
•Losses in Pre-stress
increases with time
•So, in no case there
can be distress after
the initial period
•If there is some
cracking it has to be
from the time of
construction
Bursting Cracks in anchorage
area
What to inspect in concrete bridges –
Major Bridges – PSC girders
 All the items what are there in
the small spans
 In addition
 Items related to pre-stressing (post
tensioning) and Anchorage Zone
 Slab, diaphragms, Junctions of cast
in situ and precast units or RCC/PSC
 Inside of the Box girder including
drainage inside the Box Girder
 Bearings and Expansion
arrangements
Location Reason
At the interface of
the precast I – Girder
and the diaphragm as
well as deck slab
Differential shrinkage
between the elements
cast at different time
Mishandling during lifting
Diaphragm
and cast-in-
situ deck or
RCC/PSC
Structural crack in diaphragm
Crack at the junction of web and the slab
Location Reason
At the
junction of the
web and the
slab
Construction joint, no crack
Relative movement due to
shear between the box and
slab
What to inspect in concrete bridges –
Major Bridges – PSC girders
 All the items what are there in
the small spans
 In addition
 Items related to pre-stressing (post
tensioning) and Anchorage Zone
 Slab, diaphragms, Junctions of cast
in situ and precast units or RCC/PSC
 Inside of the Box girder
 Bearings and Expansion
arrangements
Cracks around blisters
Crack at the front
of the blister – due
to prestressing
force
What to inspect in concrete bridges –
Major Bridges – PSC girders
 All the items what are there in
the small spans
 In addition
 Items related to pre-stressing (post
tensioning) and Anchorage Zone
 Slab, diaphragms, Junctions of cast
in situ and precast units or RCC/PSC
 Inside of the Box girder
 Bearings and Expansion
arrangements
Structural Crack over bearing
Poor expansion arrangements
 If the girder not free to expand, stresses
will build up.
 Can cause cracks near the expansion
arrangement
 Choking by ballast in the expansion joint
will also cause problems
Cracks due to detailing
defects
Horizontal crack in the web
Cracks Due to Corrosion
 Corrosion of the steel
 Corrosion Phenomenon
 Carbonation of concrete
 Volume increase on corrosion
 Alkali aggregate reaction
Electrochemical corrosion
 Iron reacts as
Fe >> Fe++ + 2e- (Anode process)
 Water takes oxygen from Atmosphere
2H2O + O2 + 4e- >>> 4 OH- (Cathode
Process)
 Fe++ and OH- creates Fe(OH)2
 Fe(OH)2 is not stable, oxidizes to
form Fe(OH)3
 Takes water to form Fe(OH).3nH2O
(Rust)
Electro-
chemical
corrosion
Corrosion of Steel
Fe
Fe(OH)2
Fe3O4
Fe(OH)3
Fe(OH)3nH2O
1 2 3 4 5 6
Volume
Corrosion of Steel
 Probable Area
 Natural and slow, fast if CaCl is present
 Probable Locations
 Alternate drying and wetting, humidity
 Cause
 Lack of cover and dampness, Carbonation, Chlorides
 Poor quality concrete
 Remedy
 Use dense concrete (Portland Blast Furnace Slag cement),
Dehumidify, Cathode protection
 Time of Appearance
 More than two years
Corrosion of Concrete-
Carbonation
Ca(OH)2 + 2CO3 > CaCO3 + 2H2O
3CaO•2SiO2•3H2O + 3CO2 > 3CaCO3•2SiO2•3H2O
 The pH-value decreases to less than 9, which normally
is insufficient to protect the reinforcement against
corrosion.
Corrosion of Concrete-
Carbonation
X= K T ½
 Where X is measured in mm
and T in years
 K is function of concrete
strength
 Above relation is for RH 50%
Corrosion of Concrete-
Carbonation
Depth of Carbonation –
Strength of Concrete
Alkali Aggregate Reaction
 Probable Area
 -
 Probable Locations
 Damp area, shows gel type or
dried resin type deposit in cracks
 Cause
 Reactive silicates and carbonates
in aggregates reacting with Alkali
in cement
 Remedy
 Use proper aggregates, Use
Portland Blast Furnace Slag
cement, Keep water away
 Time of Appearance
 More than five years
Alkali Aggregate
Reaction
Sulphate Attack
 Sulphate salts from surrounding soil react
with C3A . No deposits like those in Alkali-
Aggregate reaction
 Use low C3A cement, Portland Blast
Furnace Slag cement
 After two years or so
Sulphate Attack
 High concentrations of sulphate ions
(SO4
- -) + Ca(OH)2 + 2H2O ->
CaSO4.2H2O + 2OH- + expansion
 Low Sulphate ion concentration
Calcium Aluminate Hydrate + CaSO4.2H2O ->
3CaO.Al2O3.CaSO4.32H2O (ettringite) +expansion
 Magnesium and Ammonium Sulphate(Serious)
MgSO4 reacts with Calcium Aluminate Hydrate
MgSO4 + Ca(OH)2 ->
CaSO4 + Mg(OH)2 + volume expansion
What to see?
 Cracks
 Texture of Concrete
 Wear and erosion of concrete
 Leaching of chemicals
 Stains such as corrosion in steel, dampness,
growth of algae, marine microbes
 Painting coat condition
 Bearings
 Camber
 Other observations
Texture of Concrete
 Possibility of a leakage, chemical attack by
softening, leaching
 Sulphate attack - whitening of the concrete.
 Rust stains may indicate the corrosion of
reinforcement/pre-stressing steel.
 In fire damaged structure, the colour of the
concrete gives an indication of the maximum
temperature reached.
 Wear and tear of concrete surface
 Defects like honeycombing, marine growth etc.
Leaching of chemicals
Corrosion stains on concrete
surface
Corrosion stains on concrete
surface
Corrosion in reinforcement
bar
Spalling of concrete
Spalling on concrete surface
Honeycombed concrete
MARINE
GROWTH
Worn out concrete surface
Damage to the surface of
deck slab
 Girder flooring can get worn out with
constant use
 Also if the concrete quality is not good
 Once wearing coat gets eroded and then
the girder will start wearing out
 Check under the ballast once in five
years
 Tell tale sign: water leaking from the
deck slab
STRUCTURAL CONCRETE SECTION
WEARING COAT
Formation of depressions due to
absence of wearing coat
1. The condition of deck top should be
checked after removing ballast at sample
locations
2. The drainage of the deck should be clear
3. If damage is there, will affect the life of the
structure
Water leakage
Water leakage
Dampness
Drainage in Box culverts
109
Drainage in the bottom slab
• In case there is some leakage from the deck
slab, the water should be able to drain out
otherwise it will affect the durability of the
bottom slab of the Box
• These drainage spouts should be checked
What to see?
 Cracks
 Texture of Concrete
 Wear and erosion of concrete
 Leaching of chemicals
 Stains such as corrosion in steel, dampness,
growth of algae, marine microbes
 Painting coat condition
 Bearings
 Camber
 Other observations
Bearings
 Cleanliness around bearings
 Seating of girder on bearing
 Seating of bearing on pedestal
 Movement of the girder: actually
measured vis-à-vis theoretical
calculations
 Tell-tale signs of overstressing or locked
up movement around the bearings
Pot – PTFE bearings
 What to inspect?
 Movement during peak winter (early
morning) and peak summer (afternoon)
 Compare the movement along with temperature
with design values
 Measure dimensions to ascertain excessive
stress or strain
 Evidence of any locked up or jammed
condition
 Corrosion
 Adjoining areas of bearing for trouble
Neoprene bearings
 What to inspect?
 Titling
 Bulging
 Tearing
 Excess vibrations (soft bearings)
 Adjoining areas of bearing for trouble
Bulged Bearing
Tilted Bearing
Torn Bearing
Crack in Pedestal
Crack at the junction of cast-in-
situ end portion in PSC girders
What to see?
 Cracks
 Texture of Concrete
 Wear and erosion of concrete
 Leaching of chemicals
 Stains such as corrosion in steel, dampness,
growth of algae, marine microbes
 Painting coat condition
 Bearings
 Camber
 Other observations
CAMBER
 Unlike steel bridges the camber loss in
the PSC bridge would not be without
attendant warnings.
 Camber loss in PSC would result in
 Excessive cracking on the bottom surface of
Box girder or I-girder
 Separation cracks between the deck slab and
the I-girder.
 Stipulation for annual measurement of
camber
Camber
 Camber – Parameter showing overall
health of the girder
 Linked to the efficiency of the pre-stressing
force
 Nominated points chosen for recording
 Smaller spans: Mid span, end of span.
 Longer Spans: Quarter spans also
 Nominated point marked by steel or
ceramic plates fixed with epoxy
 Record carefully and accurately
CATENERY WIRE METHOD
Deflection of catenary (piano
wire)
Dia. of Wire (18 SWG) = Ф = 1.219 mm
Length of wire (Clear span) = L = 16 m (Roughly)
Tension on either end = T = 10 Kgf
(counter wt)
Self wt of wire/unit length (w) = (π Φ 2/4) 7.850/1000
= 0.00917 Kg/m
Deflection @ Mid-Span () = wL2/(8 T)
Where T is the Tension in wire,
= 0. 00917 x 16 2 /8 x 10
= 0.029 m i.e., 29 mm
Mid - Span
10 Kg 10 Kg
18 SWG Wire
mm
Laser range meter
Levelling
instrument
Camber at Mid-Span = R1 – {R2 + R3}/2
R2
R1
R3
Laser Meter
LASER - Light Amplification by Stimulated Emission of Radiation
Laser Range Meter
Laser Range Meter
PD 32 Laser range meter
Dimensions 120×65×28 mm
Weight without batteries : 220 g
Measuring Range : 0.05 to 70 m without target plate, up to
200 m with PDA 50 target plate
Accuracy : ± 1.5 mm
Operating temperature range –10°C to +50° C
Measuring functions : Single and continuous
measurement of areas and volumes.
Calculation function : +, -, x, / and special geometrical
functions
Laser : 635 nm, class 2 (IEC 825-1), class II (FDA 21 CFR)
Operating Time with 2 AA-size Batteries : Up to 15,000
measurements.
Trial results
1) CATENERY WIRE METHOD --
L1 – 0 mm, L2 – 40 mm, L3 – 0 mm
Camber = 40 mm - 29 mm (Deflection of Catenary)
= 11 mm
2) INVERT LEVEL METHOD --
L2 - 2.070 m, L1 - 2.080 m, L3 - 2.080 m
Camber = 5 mm
3) LEVELING AND LASER RANGE METER --
L2 - 1.944 m, L1 - 1.950 m, L3 - 1.939 m
Camber = 8.5 mm
What to see?
 Cracks
 Texture of Concrete
 Wear and erosion of concrete
 Leaching of chemicals
 Stains such as corrosion in steel, dampness,
growth of algae, marine microbes
 Painting coat condition
 Bearings
 Camber
 Other observations
Inspections – Misc. items
 Excess vibrations
 Ventillation arrangement
 Ancillary arrangements such as ladders,
railings
 Hitting of girders by road/ water borne
vehicles
 Other miscellaneous observations
including trespassing
 Bridge board
 HFL/Danger level
 Flood height gauge
Girder hit from below
HOW TO INSPECT?
How to inspect?
Inspection arrangement for
PSC girders
 Permanent arrangement such as Cradles,
ladders, walkways etc.
 Temporary arrangements such as
ladders, challis etc.
 Mobile rail mounted inspection
arrangement
 Few purchased by the railways
Inspection platform for
piers/ abutment
Sliding Platform
Steel cradles
Mobile crane being procured
for inspections
R: DEPTH BELOW
RAIL LEVEL: 12 M
S: HORIZONTAL
RANGE: 9 M
T: MAXIMUM
WORKING HT ABOVE
RAIL LEVEL: 8 M
a: HORIZONTAL
REACH OF
PLATFORM: 7.5 M
ROTATION OF
PLATFORM ABOUT
VERTICAL AXIS 1800
TO 3600
Inspection using crane in
progress
Inspection using crane in
progress
Defects Identified
 Technical solution to the defect
 Flow of stresses to govern the repairs.
Durability aspects important.
 If RDSO standard drawing, RDSO to be
involved in the rehabilitation.
Defects Identified
 Action to be taken as per the paras 503 -
509 of IRBM on any defects
 Analogous locations to the defect on the
same girder, and in other girders on the
same bridge or other bridges on the
system to be inspected in detail
 Efforts for identification of reasons for
the defect. Repair (covering up) not to be
the immediate goal.
Distressed Bridges
 A distressed bridge is the one which
shows physical signs of deterioration,
indicating need for rehabilitation through
special repairs, strengthening or
rebuilding (including replacement of
girders)
 If defects are noticed
 Inspect thoroughly
 Impose suitable SR, including suspend traffic,
if warranted
Distressed Bridges
 Tell tales on defects
 Detailed report to divisional office
 SrDEN/DEN to declare distressed after personal
inspection
 Report to be sent to HQ/ RDSO
 Categories
 I: Needs rehabilitation on immediate basis, say within
a year’s time
 II: Under observation, to be rehabilitated on program
basis
Distressed Bridges
 All distressed bridges may not need SR
 As a general guidance:
 Group I: SR 15 KMPH
 Settlement of foundations, deep scour around piers,
cracks in main members, wide cracks in piers/
abutments etc
 Group II: SR 25 to 50 KMPH
 Cracks in return/ wing walls, spalling of concrete,
slight leaning of spandrel wall, abutment, loose rivets,
excess vibrations etc
Distressed Bridges
 Divisions shall maintain details of distressed bridge
 Railways shall have distressed bridge diagram as per
Annex 5/1
 Inspection of distressed Bridges:
References
 Indian Railways Bridge manual
 IRICEN book on “Bridge Inspection and
Maintenance”
 RDSO report BS-48 – Inspection, Maintenance
and Rehabilitation of Concrete Bridges
 RDSO report BS-63 – Causes, Evaluation and
repairs to cracks in concrete
Few Case Studies
Based on RDSO B & S Reports
3RD GODAWARI BRIDGE NEAR
RAJMUNDRY (BS-81)
The structure
 Span 94 m
 Twin Bow string RCC arch connected by
precast RC struts in lateral direction
 12 pairs of vertical Dina Hangers
comprising 49 wires of 7mm dia
 PSC box tie girder – 16 cables each
comprising of 61 wires of 7 mm dia
 12 cross tie beams in the girder connecting
the columns hanging from Dina hangers
The problem
 Cracks on the tie beam inside the box
girders connecting the columns carrying
the load from the suspenders
 Maximum width of cracks is 0.06 mm
 All other parameters found OK
 Cracks are not found to be active
under train loads
 Crack width is within the limit given
in CBC. No cause for worry
Bridge No.73 – Vasai Creek
28 span of 48.5 m
Problem
 Longitudinal Cracks on the inside of the web of
the Box Girders (9 and 5 on West and East side to
8 and 12 in 2004)
 Width of crack varying from 0.08 mm to 0.40 mm
 Longest crack 19 m long (34.11 m in 2004 by
joining of two cracks)
 Some fine cracks seen on the outside web of the
Box Girders
 Diagonal cracks on the end block passing through
the vent hole
Sketches
Sketches
Current Situation
 Not much progress in the cracks
 SR of 90 Kmph
 RDSO studied thrice
 IIT Mumbai did modeling in 3-D and has
recommended that only local trains be
allowed on the bridge
Be Careful
What to see? Summary
All Over General Condition
Condition of surface coating
Cracks
Corrosion signs, efflorescence, rust
streaks
Scaling/ spalling
Construction joints, drainage, ladders
etc
Anchorage
zone
Cracks
Rusting
Condition of cable end sealing
What to see?
Top and
Bottom deck
slab
Cracks, Delamination, scaling
Drainage, seepage, leaching
Worn out wearing coat, abrasion
damage
Damage due to accidents etc
Support
points of
bearing and
bottom of
girder
immediately
If seating of girder is uniform
Condition of anchor bolts
Spalling/ crushing/ cracking
around bearing support
What to see?
Drainage Spouts Clogging and physical condition
Adequacy of projection of spout
on the underside
Joints in
segmental
construction
Cracks, corrosion signs
Expansion Joints If joint is free to expand/
contract
Sealing Material
Hardening/ cracking in Bitumen
Splitting/ oxidation/ Creep/
flattening/ bulging in elastomer
What to see?
Top and
Bottom flange
of I – girder
Spalling/ cracking/ scaling
Rust streaks along cables/
reinforcement
Bottom slab
in BOX girder
Spalling/ cracking/ scaling
Rust streaks
Drainage
Webs Cracks, corrosion
Diaphragms Cracks at junctions with PSC
Diagonal cracks at corners
Cracks around opening
What to see?
Expansion Joints Condition of sliding plates
Corrosion, condition of weld
Debris in joint
Check for alignment, distortion
Falling debris
Bearing (General) Check if free to rotate/ move
Check for even seating
Check for load sharing between
bearings
Physical condition
cleanliness
What to see?
Metallic Bearing Rusting/ corrosion
Condition of grease
Condition of anchor bolts
Unusual tilt of rollers
Rollers jumping off guides
Elastomeric
Bearings
Flattening, bulging
Splitting/ tearing
Non uniform thickness
Displacement
What to see?
General Trespassing by vehicles, passersby
etc and resultant damage, if any
Ladders, inspection arrangements
etc are OK or not.
Ballast retaining wall
General observations under train
movement i.e. excess vibrations,
excess deflection, odd sounds or ay
other abnormal behaviour.

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A Inspection of concrete bridges-final 280410.ppt

  • 2. Bridge Inspection Systematic observation of condition and behaviour of various components/ parts of a bridge
  • 3. Inspection Includes  Going to the bridge  Seeing the bridge with an eye of the Doctor (Engineer) with unaided as well as an aided eye.  Systematic observation over a period of time  “Thok baja ke dekhna”
  • 4. Objectives of Inspection • To know whether the bridge is structurally safe • Will it continue to be safe • Identify actual and potential sources of trouble at earliest possible stage • To record systematically and periodically the state of the structure • To decide about the repair measures to be taken • To provide feedback to the designer and the construction engineers on those features which give maintenance problems
  • 5. Current Scenario on IR  Concrete bridges increasing with time  Advantage of ballasted deck  Concrete – a heterogeneous material  Durability depends on many factors  Affected by environmental factors
  • 6. A Statement - may be controversial  Concrete structures are inherently durable as compared to steel as long as they are rationally designed and constructed  Deterioration of concrete is but a result of wrong concrete mix or poor construction work quality control.
  • 7. But…  Possibility of mistakes to happen during construction is far greater than the steel because  Most of the material of a concrete structure are supplied and assembled on site.
  • 8. Therefore…  the examples and anomalies and defects on concrete structure, resulting from poor quality of construction or material are numerous in number and kind.  The possibility for mistakes of the type is even higher in PSC girders, where additional processes such as pre- stressing, grouting and erection of girders are necessary.
  • 9. and…  There are certain phenomenon in concrete that occur in the inside and some which occur on the outside and thus some can be seen and some get manifested in the form of surface defects over the years.  The behaviour of those defects is not easily predictable and analysable.  Mostly it would be in the form of cracks
  • 10. So in concrete it becomes important to  To find for cracks, which in the initial stage  study them with a view to ascertain their cause  Track their growth and movement
  • 11. How to inspect?  Decide number of spans to be inspected each day  Scrutinize the previous years inspection notes  Try to have plan, drawings and other details of the important bridges  Go through the drawings (important bridges to identify critical locations)  Plan any special inspection equipment, temporary staging etc. (like tunnel inspection)  Don’t rush to complete – done once a year
  • 12. Precautions  Clothing  Glasses  Shoes  Scaffolding and ladders  No short cuts please  Watch your steps and your ego too
  • 13. Inspections – Open Line  Para 1101 SE (Works) will inspect before monsoon every year.  Para 1103 AEN open line will inspect after monsoon every year.  Para 1104 (1)(a) Important bridges and bridges that call attention by DEN/SrDEN
  • 14. Inspection- Bridge Organization  Para 1102 SE (Br) will inspect all RCC, PSC and Composite girders within one year of installation  Para 1102 SE (Br) will inspect all these girders once in five years on planned basis  SE (Br) will measure camber of PSC girders once a year with any reliable method  Para 1105 AEN (Br) shall test check 10% of the bridges inspected by the bridge inspector
  • 15. Special Inspection (Need based)  When signs of weaknesses discovered during routine or detailed inspection or by any other observation.  When the bridge loading is to be increased due to revised or increased loading standard.  Distressed bridges.  Exceptional events like fire, earthquake, heavy floods etc
  • 16. What to take along? (Anne. 11/15 of IRBM) 1. Pocket tape (3 or 5 m long) 2. Chipping hammer 3. Plumb bob 4. Straight edge (at least 2 m long) 5. 30 metre steel tape 6. A set of feeler gauges (0.1 to 5 mm) 7. Log line with 20 kg lead ball 8. Thermometer 9. Probing rod 10. Wire brush 11. Mirror ( 10x15 cm) 12. Magnifying glass (100 mm dia.) 13. Chalk/water poof pencil/pen or paint 14. Centre punch 15. Callipers (inside and outside) 16. Torch light (5 cell) 17. Paint and paint brush for repainting areas damaged during inspection 18. Gauge-cum-level 19. Piano wire 20. 15 cm steel scale 21. Inspection hammer (350- 450 gm) 22. Microscope 23. Binoculars 24. Camera 25. Crack meter 27. And common sense
  • 17. What to Inspect … but before that  Work through a checklist prepared for the particular type of structure.  Should be familiar with the details of the structure and as to how it is intended to function.  Should study previous reports before conducting inspection, so that the condition of the defects noticed earlier could be checked.  Should be aware of rectification work done earlier, the same should be inspected and its performance should be recorded.
  • 18. …and the most important  thing is to know and realize that every deterioration has a cause and the aim of inspecting official is to determine that cause
  • 19. Routine Inspection by AEN Purpose  Whether there is any defect in structure?  If yes, what is the degree of the defect?  Is it progressing?  Is it affecting the function of the structure?  Is there any change in the environment?  Heavy rains.  Other factors like trespassing and other usage  Is it going to affect the train operation?  Is there a necessity of doing preventive work?  Does it require detailed inspection?
  • 20. What to see?  Cracks  Texture of Concrete  Wear and erosion of concrete  Leaching of chemicals  Stains such as corrosion in steel, dampness, growth of algae, marine microbes  Painting coat condition  Bearings  Camber  Other observations
  • 21. What to see?  Cracks  Texture of Concrete  Wear and erosion of concrete  Leaching of chemicals  Stains such as corrosion in steel, dampness, growth of algae, marine microbes  Painting coat condition  Bearings  Camber  Other observations
  • 22. Cracks?  Cracks identification  Length  Size  Orientation  Location  Breathing of not  Accompanying stains
  • 23. Measuring Magnifier - Proceq Least count 0.02 mm Crack meter
  • 24. Cracks?  Cracks need to be analysed and then only conclusions may be drawn  All cracks lead to durability problems  Some cracks are not serious  Require only covering  Other cracks are serious  Affect load carrying capacity  Require retro-fitment as well as covering to prevent corrosion  Tell tales help in decision making
  • 26. Types of Cracks and spalling  Fresh concrete  Hardened Concrete  Structural Cracks  Due to loads  Compatibility cracks  Due to Detailing  Corrosion  Steel  Concrete  Others  Alkali-aggregate reaction  Sulphate attack
  • 27. Cracks in fresh Concrete  Crazing  Plastic Shrinkage  Drying Shrinkage  Plastic settlement  Long term Drying Shrinkage  Thermal expansion/contraction  Settlement of formwork
  • 28. Crazing  Probable Area  Against formwork or surface  Probable Locations  Fair faced slabs  Cause  Impermeable formwork, over trawling  Rich mixes, poor curing  Remedy  Improve curing and finishing  Time of Appearance  1-7 days, sometimes later
  • 30. Plastic Shrinkage  Probable Area  Random over reinforcement mesh, Diagonal, Normal to wind direction  Probable Locations  RCC slabs  Cause  Rapid early drying  Low bleeding and fast surface evaporation  Remedy  Improve early curing and trowel  Time of Appearance  Thirty min. to six hours
  • 32. Plastic Settlement  Probable Area  Over reinforcement, Arching, Change of depth  Probable Locations  Deep sections, Top of Columns/ troughs  Cause  Excess Bleeding  Rapid early drying  Remedy  Reduce Bleeding  Reverberate mildly  Time of Appearance  Ten min. to three hours
  • 33. Early Thermal Expansion and Contraction  Probable Area  External/ Internal restraint  Probable Locations  Thick walls, Thick slabs  Cause  Excess heat generation, Excess temp. gradient  Rapid cooling, Curing by cold water  Remedy  Reduce heat and/or insulate, cool concrete, reduce spacing of steel  Time of Appearance  One day to 2-3 weeks
  • 34. Long term drying shrinkage  Probable Area  -  Probable Locations  Thin walls, Thin slabs  Cause  Absence of movement, inefficient joints  Excess shrinkage, Inefficient curing  Remedy  Reduce w/c ratio, Improve curing  Time of Appearance  Several weeks or months
  • 35. Action in case of cracks in Fresh Concrete  For purely surface cracks, normally no action taken if appearance is not an issue  In case cracks are wider and deeper, the repair method as suitable may be decided based on the crack size.  In case of time dependent crack like shrinkage and settlement – the action should be delayed if not affecting the structure.
  • 36. Cracks in Hardened Concrete during service
  • 38. Crack in the deck slab Location Reason Bottom surface of the deck slab in the middle Compatibility cracks Excessive load on the deck
  • 39. Compatible Cracks  Cracks which occur in course of normal loading in RCC components for reinforcement to take the tensile stresses. Specified in Para10.2.1 (a) of CBC. Environment Design Crack Width (mm) Moderate 0.25 Severe 0.20 Extreme 0.10*
  • 41. RCC Slab Location Reason Diagonal cracks near support and 1m to 2m from support Excessive shear force
  • 42. Cross cracks in center Location Reason Center of span Excessive Load Less reinforcement or location of reinforcement Shrinkage cracks (rare) Less Cover
  • 43. Longitudinal cracks at bottom Location Reason Longitudinal cracks on lower surface of girder Shortage of distribution reinforcement Less cover to main bars Corrosion of main bar
  • 44. Cross cracks at ends Location Reason Transverse cracks on upper surface of girder Shortage of bent up or top bars in upper area Drying Shrinkage
  • 45. Location Reason Longitudinal cracks on upper surface of cantilever Excessive load on cantilever Less reinforcement in cantilever Main reinforcement in cantilever placed lower Crack near the support of cantilever
  • 47. What to inspect in concrete bridges – Major Bridges – PSC girders  All the items what are there in the small spans  In addition  Items related to pre-stressing (post tensioning) and Anchorage Zone  Slab, diaphragms, Junctions of cast in situ and precast units or RCC/PSC  Inside of the Box girder  Bearings and Expansion arrangements
  • 48. PSC Box Location Reason Perpendicular to girder on the lower surface of the girder Shortage of Pre-stressing force Excessive Load Breakage of PSC strand
  • 49. PSC Box Location Reason Perpendicular to girder on the upper surface of the girder Overstressing of girder Shortage of loading Closes during passage of train
  • 50. PSC Box Location Reason Diagonal Cracks near the support Shear stress due to loading Drying Shrinkage
  • 53. What to inspect in concrete bridges – Major Bridges – PSC girders  All the items what are there in the small spans  In addition  Items related to pre-stressing (post tensioning) and Anchorage Zone  Slab, diaphragms, Junctions of cast in situ and precast units or RCC/PSC  Inside of the Box girder  Bearings and Expansion arrangements
  • 54. Anchorage Zone •Maximum stresses during stressing operation •Concrete strength increases with age •Losses in Pre-stress increases with time •So, in no case there can be distress after the initial period •If there is some cracking it has to be from the time of construction
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  • 58. Bursting Cracks in anchorage area
  • 59. What to inspect in concrete bridges – Major Bridges – PSC girders  All the items what are there in the small spans  In addition  Items related to pre-stressing (post tensioning) and Anchorage Zone  Slab, diaphragms, Junctions of cast in situ and precast units or RCC/PSC  Inside of the Box girder including drainage inside the Box Girder  Bearings and Expansion arrangements
  • 60. Location Reason At the interface of the precast I – Girder and the diaphragm as well as deck slab Differential shrinkage between the elements cast at different time Mishandling during lifting Diaphragm and cast-in- situ deck or RCC/PSC
  • 61. Structural crack in diaphragm
  • 62. Crack at the junction of web and the slab Location Reason At the junction of the web and the slab Construction joint, no crack Relative movement due to shear between the box and slab
  • 63. What to inspect in concrete bridges – Major Bridges – PSC girders  All the items what are there in the small spans  In addition  Items related to pre-stressing (post tensioning) and Anchorage Zone  Slab, diaphragms, Junctions of cast in situ and precast units or RCC/PSC  Inside of the Box girder  Bearings and Expansion arrangements
  • 64. Cracks around blisters Crack at the front of the blister – due to prestressing force
  • 65. What to inspect in concrete bridges – Major Bridges – PSC girders  All the items what are there in the small spans  In addition  Items related to pre-stressing (post tensioning) and Anchorage Zone  Slab, diaphragms, Junctions of cast in situ and precast units or RCC/PSC  Inside of the Box girder  Bearings and Expansion arrangements
  • 67. Poor expansion arrangements  If the girder not free to expand, stresses will build up.  Can cause cracks near the expansion arrangement  Choking by ballast in the expansion joint will also cause problems
  • 68. Cracks due to detailing defects
  • 70. Cracks Due to Corrosion  Corrosion of the steel  Corrosion Phenomenon  Carbonation of concrete  Volume increase on corrosion  Alkali aggregate reaction
  • 71. Electrochemical corrosion  Iron reacts as Fe >> Fe++ + 2e- (Anode process)  Water takes oxygen from Atmosphere 2H2O + O2 + 4e- >>> 4 OH- (Cathode Process)  Fe++ and OH- creates Fe(OH)2  Fe(OH)2 is not stable, oxidizes to form Fe(OH)3  Takes water to form Fe(OH).3nH2O (Rust)
  • 74. Corrosion of Steel  Probable Area  Natural and slow, fast if CaCl is present  Probable Locations  Alternate drying and wetting, humidity  Cause  Lack of cover and dampness, Carbonation, Chlorides  Poor quality concrete  Remedy  Use dense concrete (Portland Blast Furnace Slag cement), Dehumidify, Cathode protection  Time of Appearance  More than two years
  • 75. Corrosion of Concrete- Carbonation Ca(OH)2 + 2CO3 > CaCO3 + 2H2O 3CaO•2SiO2•3H2O + 3CO2 > 3CaCO3•2SiO2•3H2O  The pH-value decreases to less than 9, which normally is insufficient to protect the reinforcement against corrosion.
  • 76. Corrosion of Concrete- Carbonation X= K T ½  Where X is measured in mm and T in years  K is function of concrete strength  Above relation is for RH 50%
  • 78. Depth of Carbonation – Strength of Concrete
  • 79. Alkali Aggregate Reaction  Probable Area  -  Probable Locations  Damp area, shows gel type or dried resin type deposit in cracks  Cause  Reactive silicates and carbonates in aggregates reacting with Alkali in cement  Remedy  Use proper aggregates, Use Portland Blast Furnace Slag cement, Keep water away  Time of Appearance  More than five years
  • 81. Sulphate Attack  Sulphate salts from surrounding soil react with C3A . No deposits like those in Alkali- Aggregate reaction  Use low C3A cement, Portland Blast Furnace Slag cement  After two years or so
  • 82. Sulphate Attack  High concentrations of sulphate ions (SO4 - -) + Ca(OH)2 + 2H2O -> CaSO4.2H2O + 2OH- + expansion  Low Sulphate ion concentration Calcium Aluminate Hydrate + CaSO4.2H2O -> 3CaO.Al2O3.CaSO4.32H2O (ettringite) +expansion  Magnesium and Ammonium Sulphate(Serious) MgSO4 reacts with Calcium Aluminate Hydrate MgSO4 + Ca(OH)2 -> CaSO4 + Mg(OH)2 + volume expansion
  • 83. What to see?  Cracks  Texture of Concrete  Wear and erosion of concrete  Leaching of chemicals  Stains such as corrosion in steel, dampness, growth of algae, marine microbes  Painting coat condition  Bearings  Camber  Other observations
  • 84. Texture of Concrete  Possibility of a leakage, chemical attack by softening, leaching  Sulphate attack - whitening of the concrete.  Rust stains may indicate the corrosion of reinforcement/pre-stressing steel.  In fire damaged structure, the colour of the concrete gives an indication of the maximum temperature reached.  Wear and tear of concrete surface  Defects like honeycombing, marine growth etc.
  • 86. Corrosion stains on concrete surface
  • 87. Corrosion stains on concrete surface
  • 93. Worn out concrete surface
  • 94. Damage to the surface of deck slab  Girder flooring can get worn out with constant use  Also if the concrete quality is not good  Once wearing coat gets eroded and then the girder will start wearing out  Check under the ballast once in five years  Tell tale sign: water leaking from the deck slab
  • 95. STRUCTURAL CONCRETE SECTION WEARING COAT Formation of depressions due to absence of wearing coat 1. The condition of deck top should be checked after removing ballast at sample locations 2. The drainage of the deck should be clear 3. If damage is there, will affect the life of the structure
  • 99. Drainage in Box culverts 109 Drainage in the bottom slab • In case there is some leakage from the deck slab, the water should be able to drain out otherwise it will affect the durability of the bottom slab of the Box • These drainage spouts should be checked
  • 100. What to see?  Cracks  Texture of Concrete  Wear and erosion of concrete  Leaching of chemicals  Stains such as corrosion in steel, dampness, growth of algae, marine microbes  Painting coat condition  Bearings  Camber  Other observations
  • 101. Bearings  Cleanliness around bearings  Seating of girder on bearing  Seating of bearing on pedestal  Movement of the girder: actually measured vis-à-vis theoretical calculations  Tell-tale signs of overstressing or locked up movement around the bearings
  • 102. Pot – PTFE bearings  What to inspect?  Movement during peak winter (early morning) and peak summer (afternoon)  Compare the movement along with temperature with design values  Measure dimensions to ascertain excessive stress or strain  Evidence of any locked up or jammed condition  Corrosion  Adjoining areas of bearing for trouble
  • 103. Neoprene bearings  What to inspect?  Titling  Bulging  Tearing  Excess vibrations (soft bearings)  Adjoining areas of bearing for trouble
  • 108. Crack at the junction of cast-in- situ end portion in PSC girders
  • 109. What to see?  Cracks  Texture of Concrete  Wear and erosion of concrete  Leaching of chemicals  Stains such as corrosion in steel, dampness, growth of algae, marine microbes  Painting coat condition  Bearings  Camber  Other observations
  • 110. CAMBER  Unlike steel bridges the camber loss in the PSC bridge would not be without attendant warnings.  Camber loss in PSC would result in  Excessive cracking on the bottom surface of Box girder or I-girder  Separation cracks between the deck slab and the I-girder.  Stipulation for annual measurement of camber
  • 111. Camber  Camber – Parameter showing overall health of the girder  Linked to the efficiency of the pre-stressing force  Nominated points chosen for recording  Smaller spans: Mid span, end of span.  Longer Spans: Quarter spans also  Nominated point marked by steel or ceramic plates fixed with epoxy  Record carefully and accurately
  • 112.
  • 114. Deflection of catenary (piano wire) Dia. of Wire (18 SWG) = Ф = 1.219 mm Length of wire (Clear span) = L = 16 m (Roughly) Tension on either end = T = 10 Kgf (counter wt) Self wt of wire/unit length (w) = (π Φ 2/4) 7.850/1000 = 0.00917 Kg/m Deflection @ Mid-Span () = wL2/(8 T) Where T is the Tension in wire, = 0. 00917 x 16 2 /8 x 10 = 0.029 m i.e., 29 mm Mid - Span 10 Kg 10 Kg 18 SWG Wire mm
  • 115. Laser range meter Levelling instrument Camber at Mid-Span = R1 – {R2 + R3}/2 R2 R1 R3 Laser Meter LASER - Light Amplification by Stimulated Emission of Radiation
  • 118. PD 32 Laser range meter Dimensions 120×65×28 mm Weight without batteries : 220 g Measuring Range : 0.05 to 70 m without target plate, up to 200 m with PDA 50 target plate Accuracy : ± 1.5 mm Operating temperature range –10°C to +50° C Measuring functions : Single and continuous measurement of areas and volumes. Calculation function : +, -, x, / and special geometrical functions Laser : 635 nm, class 2 (IEC 825-1), class II (FDA 21 CFR) Operating Time with 2 AA-size Batteries : Up to 15,000 measurements.
  • 119. Trial results 1) CATENERY WIRE METHOD -- L1 – 0 mm, L2 – 40 mm, L3 – 0 mm Camber = 40 mm - 29 mm (Deflection of Catenary) = 11 mm 2) INVERT LEVEL METHOD -- L2 - 2.070 m, L1 - 2.080 m, L3 - 2.080 m Camber = 5 mm 3) LEVELING AND LASER RANGE METER -- L2 - 1.944 m, L1 - 1.950 m, L3 - 1.939 m Camber = 8.5 mm
  • 120. What to see?  Cracks  Texture of Concrete  Wear and erosion of concrete  Leaching of chemicals  Stains such as corrosion in steel, dampness, growth of algae, marine microbes  Painting coat condition  Bearings  Camber  Other observations
  • 121. Inspections – Misc. items  Excess vibrations  Ventillation arrangement  Ancillary arrangements such as ladders, railings  Hitting of girders by road/ water borne vehicles  Other miscellaneous observations including trespassing  Bridge board  HFL/Danger level  Flood height gauge
  • 122. Girder hit from below
  • 125. Inspection arrangement for PSC girders  Permanent arrangement such as Cradles, ladders, walkways etc.  Temporary arrangements such as ladders, challis etc.  Mobile rail mounted inspection arrangement  Few purchased by the railways
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  • 132. Mobile crane being procured for inspections
  • 133. R: DEPTH BELOW RAIL LEVEL: 12 M S: HORIZONTAL RANGE: 9 M T: MAXIMUM WORKING HT ABOVE RAIL LEVEL: 8 M a: HORIZONTAL REACH OF PLATFORM: 7.5 M ROTATION OF PLATFORM ABOUT VERTICAL AXIS 1800 TO 3600
  • 134. Inspection using crane in progress
  • 135. Inspection using crane in progress
  • 136. Defects Identified  Technical solution to the defect  Flow of stresses to govern the repairs. Durability aspects important.  If RDSO standard drawing, RDSO to be involved in the rehabilitation.
  • 137. Defects Identified  Action to be taken as per the paras 503 - 509 of IRBM on any defects  Analogous locations to the defect on the same girder, and in other girders on the same bridge or other bridges on the system to be inspected in detail  Efforts for identification of reasons for the defect. Repair (covering up) not to be the immediate goal.
  • 138. Distressed Bridges  A distressed bridge is the one which shows physical signs of deterioration, indicating need for rehabilitation through special repairs, strengthening or rebuilding (including replacement of girders)  If defects are noticed  Inspect thoroughly  Impose suitable SR, including suspend traffic, if warranted
  • 139. Distressed Bridges  Tell tales on defects  Detailed report to divisional office  SrDEN/DEN to declare distressed after personal inspection  Report to be sent to HQ/ RDSO  Categories  I: Needs rehabilitation on immediate basis, say within a year’s time  II: Under observation, to be rehabilitated on program basis
  • 140. Distressed Bridges  All distressed bridges may not need SR  As a general guidance:  Group I: SR 15 KMPH  Settlement of foundations, deep scour around piers, cracks in main members, wide cracks in piers/ abutments etc  Group II: SR 25 to 50 KMPH  Cracks in return/ wing walls, spalling of concrete, slight leaning of spandrel wall, abutment, loose rivets, excess vibrations etc
  • 141. Distressed Bridges  Divisions shall maintain details of distressed bridge  Railways shall have distressed bridge diagram as per Annex 5/1  Inspection of distressed Bridges:
  • 142. References  Indian Railways Bridge manual  IRICEN book on “Bridge Inspection and Maintenance”  RDSO report BS-48 – Inspection, Maintenance and Rehabilitation of Concrete Bridges  RDSO report BS-63 – Causes, Evaluation and repairs to cracks in concrete
  • 143. Few Case Studies Based on RDSO B & S Reports
  • 144. 3RD GODAWARI BRIDGE NEAR RAJMUNDRY (BS-81)
  • 145.
  • 146. The structure  Span 94 m  Twin Bow string RCC arch connected by precast RC struts in lateral direction  12 pairs of vertical Dina Hangers comprising 49 wires of 7mm dia  PSC box tie girder – 16 cables each comprising of 61 wires of 7 mm dia  12 cross tie beams in the girder connecting the columns hanging from Dina hangers
  • 147. The problem  Cracks on the tie beam inside the box girders connecting the columns carrying the load from the suspenders  Maximum width of cracks is 0.06 mm  All other parameters found OK  Cracks are not found to be active under train loads  Crack width is within the limit given in CBC. No cause for worry
  • 148. Bridge No.73 – Vasai Creek 28 span of 48.5 m
  • 149. Problem  Longitudinal Cracks on the inside of the web of the Box Girders (9 and 5 on West and East side to 8 and 12 in 2004)  Width of crack varying from 0.08 mm to 0.40 mm  Longest crack 19 m long (34.11 m in 2004 by joining of two cracks)  Some fine cracks seen on the outside web of the Box Girders  Diagonal cracks on the end block passing through the vent hole
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  • 153. Current Situation  Not much progress in the cracks  SR of 90 Kmph  RDSO studied thrice  IIT Mumbai did modeling in 3-D and has recommended that only local trains be allowed on the bridge
  • 155.
  • 156. What to see? Summary All Over General Condition Condition of surface coating Cracks Corrosion signs, efflorescence, rust streaks Scaling/ spalling Construction joints, drainage, ladders etc Anchorage zone Cracks Rusting Condition of cable end sealing
  • 157. What to see? Top and Bottom deck slab Cracks, Delamination, scaling Drainage, seepage, leaching Worn out wearing coat, abrasion damage Damage due to accidents etc Support points of bearing and bottom of girder immediately If seating of girder is uniform Condition of anchor bolts Spalling/ crushing/ cracking around bearing support
  • 158. What to see? Drainage Spouts Clogging and physical condition Adequacy of projection of spout on the underside Joints in segmental construction Cracks, corrosion signs Expansion Joints If joint is free to expand/ contract Sealing Material Hardening/ cracking in Bitumen Splitting/ oxidation/ Creep/ flattening/ bulging in elastomer
  • 159. What to see? Top and Bottom flange of I – girder Spalling/ cracking/ scaling Rust streaks along cables/ reinforcement Bottom slab in BOX girder Spalling/ cracking/ scaling Rust streaks Drainage Webs Cracks, corrosion Diaphragms Cracks at junctions with PSC Diagonal cracks at corners Cracks around opening
  • 160. What to see? Expansion Joints Condition of sliding plates Corrosion, condition of weld Debris in joint Check for alignment, distortion Falling debris Bearing (General) Check if free to rotate/ move Check for even seating Check for load sharing between bearings Physical condition cleanliness
  • 161. What to see? Metallic Bearing Rusting/ corrosion Condition of grease Condition of anchor bolts Unusual tilt of rollers Rollers jumping off guides Elastomeric Bearings Flattening, bulging Splitting/ tearing Non uniform thickness Displacement
  • 162. What to see? General Trespassing by vehicles, passersby etc and resultant damage, if any Ladders, inspection arrangements etc are OK or not. Ballast retaining wall General observations under train movement i.e. excess vibrations, excess deflection, odd sounds or ay other abnormal behaviour.