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INTRODUCTION
In broader terms rehabilitation of bridge means making the
distressed bridge fit for normal traffic. This may be achieved either by
major repair or by repairing some of the parts of the bridges e.g.
regirdering or by jacketing.
CAUSE OF REHABILITATION
A bridge may require rehabilitation on account of the various
reasons; some of the reasons may be as under:
i) Physical distress
ii) Vulnerability of hydrological consideration
iii) Use of obsolete / non-standard materials such as
a) Early steel girders
b) Laterite stones
c) Cast iron screw piles
d) Corrugated steel pipes
e) Earthen ware pipes
In case due to introduction of new rolling stock existing bridge is not
safe, either strengthening or rebuilding is to be done.
A bridge may be declared as distressed by DEN or Sr.DEN. There are
two type of distressed bridge as given below:
CATEGORY OF DISTRESSED BRIDGE
Category - I
Those bridges requiring immediate rehabilitation
Category - II
Those bridges requiring rehabilitation on programmed basis.
From safety point of view, suitable speed restriction is to be
imposed to those bridges requiring rehabilitation.
A list of distressed bridges is to be maintained in each divisional
office, as per proforma given in Indian Railway Bridge Manual (IRBM).
c) Equipment used:
The equipment required for cement pressure grouting are:
i) Air compressor with a capacity of 3 of 4 cum per minute and
with a pressure of
2 to 4 kg per sq cm.
ii) Grout injecting machine or grouting pump with inlet and
outlet valves and pressure gauges. This can be power or
hand driven.
iii) An air tight, pressure mixer chamber, with stirrer for proper
mixing of the grout and keeping it in proper colloidal
suspension during grouting.
iv) Flexible pressure hose pipes for transmitting grout from
pressure chamber to pipes embedded in the masonry.
v) Drilling equipment, pneumatic or electric, for drilling of holes
upto 25mm dia.
vi) 12-20mm dia. G.I. pipes with couplers.
EPOXY GROUTING
a) Composition:
The epoxy grout consists of an epoxy resin and a hardener
which react chemically when mixed. Epoxy resins are thermosetting
and by suitably proportioning of the mix of resin, hardener and
thinner (if necessary), the viscosity of the mix can be varied to suit
all types of conditions.
b) Specification:
Considering the width, depth and extent of cracks and other
relevant details, the viscosity of the resin hardener mix, their
proportions, pot life, application procedure etc. should be chosen in
consultation with the manufacturers. The shear strength on a
specimen of two mild steel plates should not be less than 100
kg/cm2. The epoxy mortar should not be susceptible to fire and
explosion during injection process and must be stable under varying
climatic conditions.
c) Test certificates:
The supplier should produce test certificates for Pot life test,
strength test and shear test from approved test houses.
d) Equipments required:
i) Pneumatic or electric hole drilling equipment.
ii) Pressure injection equipment of standard make with necessary
control valves and
gauges, etc.
iii) Air compressor of capacity 3 to 4 cum/min. and pressure of 10
kg/cm2.
iv) Polythene or metal pipe pieces 6-9mm dia.
v) Polythene/plastic containers for mixing the epoxy formulation.
vi) A portable generator.
SHOTCRETING / GUNITING
a) Shotcrete is mortar or concrete conveyed through a hose and
pneumatically impinged at high velocity on to the surface to be
treated. The force of the jet impinging on the surface compacts the
material. Generally a relatively dry mixture is used so that it
supports itself without sagging even for vertical and overhead
applications. This process is also known as Guniting.
b) Shotcrete or gunite is suitable for repairing spalled concrete surface
as well as for strengthening weathered stone or brick masonry. For
most applications mortar applied by the dry process (guniting) is
adequate. With concrete (shotcrete) the wet process is adopted. In
both the cases reinforcement in the form of wire 3mm dia, wire
fabric or steel bars upto 16mm dia may be used, as necessary.
c) Equipment required
i) Guniting machine complying requirements given in IS: 6433.
ii) Air Compressor with a capacity of 10 cum per minute and
which can develop a
pressure of upto 7 kg/cm2.
iii) Placing nozzle with hose.
e) Preparation of surface:
All weathered or deteriorated material should be removed
until the surface exposed is sound and properly shaped to receive
the gunite (Shotcrete). The surface should be cleaned of all loose
and foreign materials with an air/water jet. If the joint mortar is
weak, the joint should be raked to about 10mm depth and all loose,
dry mortar scraped out. Exposed reinforcement should be cleaned
free of rust, scale etc. and given a coat of neat cement or any other
anti-corrosive material.
f) Form work:
The forms where required shall be plywood or other suitable
material set true to line and dimension. They should be adequately
braced and constructed so as to permit the escape of air and
rebound during the guniting operation (particularly in the case of
thick members).
g) Reinforcement:
Depending on the thickness and nature of the work,
reinforcement may consist of either round bars or welded wire fabric
3mm diameter. Sufficient clearance should be provided around the
reinforcement. The minimum clearance between the reinforcement
and form or other back up material may vary between 12mm for
the mortar mix and wire fabric reinforcement to 50mm for the
concrete mix and 16mm dia reinforcing bars. However, the
minimum cover for reinforcement shall be as per IS:456. The
minimum wire mesh spacing should be 50 mm by 50 mm. Clear
spacing between bars should be at least 65 mm.
For repair work, the reinforcement should be fixed to existing
masonry by wiring to nails driven into the masonry and rigidly
secured.
j) Placing:
The total thickness of gunite required should be built up in a
number of layers with an interval of about 4 hours. Each layer is
built up by making several passes or loops of the nozzle over the
working area. The distance of the nozzle from the work, usually
between 0.5 and 1.5m, should be such as to give the best results.
Particular care should be taken when gunning through and encasing
reinforcing bars. (For walls, columns and beams, the application
should begin at the bottom). In guniting slabs, the nozzle should be
held at a right angle so that the rebound is not blown on to the
completed portion.
k) Rebound:
The rebound is mortar or concrete which bounces off the
surface during the application. Rebound should not be worked back
into the construction and should be rejected.
m) Curing :
The surfaces should be kept continuously wet for at least 7
days.
JACKETING
General
Procedure