This library of books, audio, video, and other materials from and about India is curated and maintained by Public Resource. The purpose of this library is to assist the students and the lifelong learners of India in their pursuit of an education so that they may better their status and their opportunities and to secure for themselves and for others justice, social, economic and political.
This item has been posted for non-commercial purposes and facilitates fair dealing usage of academic and research materials for private use including research, for criticism and review of the work or of other works and reproduction by teachers and students in the course of instruction. Many of these materials are either unavailable or inaccessible in libraries in India, especially in some of the poorer states and this collection seeks to fill a major gap that exists in access to knowledge.
For other collections we curate and more information, please visit the Bharat Ek Khoj page. Jai Gyan!
IRC:83 (Part I)- 1999
SECTION : IX BEARINGS
PART I: METALLIC BEARINGS (First Revision)
Published by
THE INDIAN ROADS CONGRESS
Jamnagar House, Shahjahan Road,
New Delhi-110 011 1999
Price Rs.200/-
(Plus Packing & Postage)
MEMBERS OF THE BRIDGE SPECIFICATIONS AND STANDARDS COMMITTEE (As on 27.9.97)
1. | A.D. Narain* (Convenor) |
DG(RD) & Addl. Secretary to the Govt. of India, Ministry of Surface Transport (Roads Wing), Transport Bhawan, New Delhi-110001 |
2. | The Chief Engineer (B) S&R (Member-Secretary) |
Ministry of Surface Transport (Roads Wing), Transport Bhawan, New Delhi-110001 |
3. | S.S. Chakraborty | Managing Director, Consulting Engg. Services (I) Pvt. Ltd., 57, Nehru Place, New Delhi-110019 |
4. | Prof. D.N. Trikha | Director, Structural Engg. Res. Centre, Sector-19, Central Govt. Enclave, Kamla Nehru Nagar, PB No. 10, Ghaziabad-201002 |
5. | Ninan Koshi | DG(RD) & Addl. Secretary (Retd.), 56, Nalanda Apartments, Vikaspuri, New Delhi |
6. | A.G. Borkar | Technical Adviser to Metropolitan Commr. , A-l, Susnehi Plot No. 22, Arun Kumar Vaidya Nagar, Bandra Reclamation, Mumbai-400050 |
7. | N.K. Sinha | Chief Engineer (PIC), Ministry of Surface Transport (Roads Wing), Transport Bhawan, New Delhi-110001 |
8. | A. Chakrabarti CE, CPWD, representing |
Director General (Works) Central Public Works Department, Nirman Bhavan, New Delhi |
9. | M.V.B. Rao | Head, Bridges Division, Central Road Res. Institute, P.O. CRRI, Delhi-Mathura Road, New Delhi-110020 |
10. | C.R. Alimchandani | Chairman & Managing Director, STUP Consultants Ltd., 1004-5, Raheja Chambers, 213, Nariman Point, Mumbai-400021 |
11. | Dr. S.K. Thakkar | Professor, Department of Earthquake Engg., University of Roorkee, Roorkee-247667 |
12. | M.K. Bhagwagar | * Consulting Engineer, Engg. Consultants (P) Ltd., F-14/15, Connaught Place, Inner Circle, 2nd Floor, New Delhi-110001 |
13. | P.D. Wani | Secretary to the Govt. of Maharashtra, P. W.D., Mantralaya, Mumbai-400032i |
14. | S.A. Reddi | Dy. Managing Director, Gammon India Ltd., Gammon House, Veer Savarkar Marg, Prabhadevi, Mumbai-400025 |
15. | Vijay Kumar | General Manager, UP State Bridge Corpn. Ltd. 486, Hawa Singh Block, Asiad Village, New Delhi-110049 |
16. | C.V. Kand | Consultant, E-2/136, Mahavir Nagar, Bhopal-462016 |
17. | M.K. Mukherjee | 40/182, C.R. Park, New Delhi-110019 |
18. | Mahesh Tandon | Managing Director, Tandon Consultants (P) Ltd., 17, Link Road, Jangpura Extn., New Delhi |
19. | Dr. T.N. Subba Rao | Chairman, Construma Consultancy (P) Ltd., 2nd Floor, Pinky Plaza, 5th Road, Khar (West) Mumbai-400052 |
20. | A.K. Harit | Executive Director (B&S), Research Designs & Standards Organisation, Lucknow-226011 |
21. | Prafulla Kumar | Member (Technical), National Highways Authority of India, 1, Eastern Avenue, Maharani Bagh, New Delhi-110065 |
22. | S.V.R. Parangusam | Chief Engineer (B) South, Ministry of Surface Transport (Roads Wing), Transport Bhawan, New Delhi |
23. | B.C. Rao | Offg. DDG (Br.), Dy. Director General (B), DGBR, West Block-IV, Wing 1, R.K. Puram, ' New Delhi-110066 |
24. | P.C. Bhasin | 324", Mandakini Enclave, Alkananda, New Delhi-110019 |
25. | P.K. Sarmah | Chief Engineer, PWD (Roads) Assam, P.O. Chandmari, Guwahati-781003 |
26. | The Secretary to the Govt. of Gujarat | (H.P. Jamdar) R&B Department, Block No. 14, New Sachivalaya, 2nd Floor, Gandhinagar-382010 |
27. | The Chief Engineer (R&B) | (D. Sree Rama Murthy), National Highways, Irrum Manzil, Hyderabad-500482 |
28. | The Chief Engineer (NH) | (D. Guha), Public Works Department, Writers’ Building, Block C, Calcutta-700001 |
29. | The Engineer-in-Chief | (K.B. Lal Singal), Haryana P.W.D., B&R, Sector-19 B, Chandigarh-160019ii |
30. | The Chief Engineer (R) S&R | (Indu Prakash), Ministry of Surface Transport (Roads Wing), Transport Bhawan, New Delhi-110001 . |
31. | The Director | (N. Ramachandran) Highways Research Station, 76, Sarthat Patel Road, Chennai-600025 |
32. | The Director & Head | (Vinod Kumar), Bureau of Indian Standards Manak Bhavan, 9, Bahadurshah Zarfar Marg, New Delhi-110002 |
33. | The Chief Engineer (NH) | M.P. Public Works Department, Bhopal-462004 |
34. | The Chief Engineer (NH) | (P.D. Agarwal), U.P. PWD, PWD Quarters Kabir Marg Clay Square, Lucknow-226001 |
35. | The Chief Engineer (NH) | Punjab PWD, B&R Branch, Patiala |
Ex-Officio Members | ||
36. |
President, Indian Roads Congress |
H.P. Jamdar, Secretary to the Govt. of Gujarat, R&B Department, Sachivalaya, 2nd Floor, Gandhinagar-382010 |
37. | Director General (Road Development) |
A.D. Narain, DG(RD) & Addl. , Secretary to the Govt. of India, Ministry of Surface Transport (Roads Wing), Transport Bhawan, New Delhi |
38. |
Secretary, Indian Roads Congress | S.C. Sharma, Chief Engineer, Ministry of Surface Transport (Roads Wing), Transport Bhawan, New Delhi |
Corresponding Members | ||
1. | N.V. Merani | Principal Secretary (Retd.), A-47/1344, Adarsh Nagar, Worli, Mumbai-400025 |
2. | Dr. G.P. Saha | Chief Engineer, Hindustan Construction Co. Ltd., Hincon House, Lal Bahadur Shastri Marg, Vikhroli (W), Mumbai-400083 |
3. | Shitala Sharan | Advisor Consultant, Consulting Engg. Services (I) Pvt. Ltd., 57, Nehru Place,New Delhi-110019 |
4. | Dr. M.G. Tamhankar | Emeritus Scientist, Structural Engg. Res. Centre 399, Pocket E, Mayur Vihar, Phase 11, Delhi.-110091iii |
* ADG(B) being not in position. The meeting was presided by Shri A.D. Narain, DG(RD) & Addl. Secretary to the Govt. of India, Ministry of Surface Transport
BEARINGS
Part I : METALLIC BEARINGS
The Standard Specifications and Code of Practice for Road Bridges Section: IX-Bearings-Part I:. Metallic Bearings was initially prepared by the Sub-Committee for Bridge Bearings and Expansion Joints and approved by the Bridge Specifications & Standards Committee, Executive Committee and the Council. This was subsequently published as IRC:83-1982 - Part I in December, 1982. The requirement of revising the IRC:83-1982 - Part I to cope up with the technological developments which have taken place in this field of engineering has been felt for quite some time. The first draft revision was prepared by the Technical Committee on Bearings, Joints & Appurtenance during 1991-93 with Shri B.J. Dave as the Convenor. This Committee was reconstituted in January, 1994 consisting of the following personnel :
N.K.Sinha | .. | Convenor |
K.B. Thandavan | .. | Member-Secretary |
MEMBERS | ||
D.K. Rastogi | S.P. Chakrabarti | |
A. Chakrabarti | S.S. Saraswat . | |
A.K. Saxena | P.Y. Manjure | |
P.L. Manickam | Ajay Kumar Gupta | |
D.K. Kanhere | Achyut Ghosh | |
S.M. Sant | S. Sengupta | |
M.V.B.Rao | Rep. of R.D.S.O. Lucknow | |
R.K. Dutta • | Rep. of Bureau of Indian | |
G.R. Haridas | Standards (Vinod Kumar) | |
A.R. Jambekar | ||
EX-OFFICIO MEMBERS | ||
President, IRC | M.S. Guram, Chief Engineer, Punjab PWD B&R, Patiala | |
DG(RD) | A.D. Narain, Director General (Road Development.) & Addl. Secy., MOST, New Delhi | |
Secretary, IRC | S.C. Sharma, Chief Engineer, MOST, New Delhi | |
CORRESPONDING MEMBERS | ||
B.J. Dave | Prof. Prem Krishna | |
Mahesh Tandon | M.K. Mukherjee | |
Suprio Ghosh |
The reconstituted Committee discussed the draft during number of meetings held between January, 1994 and January, 1997. The draft was finalised by this Committee after making necessary modifications.
The draft was considered and approved by the Bridge Specifications & Standards Committee at their meeting held at New Delhi on 27.9.97 and approved by the Executive Committee on 29.11.97 and then by the Council in their meeting held on 5.1.98 at Bhopal.
The provisions of this Code shall supersede the following clauses of IRC:24-1967. "Standard Specification and Code of Practice for Road Bridges, Section V: Steel Road Bridges".
Clause Nos. 502.10, 504.7, 504.8, 504.9, 504.10, 504.11, 505.11.2 to 505.11.5 and 508.10, Appendix 1, S.No. 8th and 9th of Table 2 giving reference to clause No. 504.7 and 504.11.
This Code deals with the design, manufacture, testing positioning and maintenance of Metallic Bearings,on road bridges. The provisions of this Code are meant to serve as a guide to both the design and construction engineers, but mere compliance with the provisions stipulated herein will not relieve them in any way of their responsibility for the stability and soundness of the structure designed and erected. This code covers longitudinal movement (mainly for monoaxial movement) only, special bearings like spherical bearings are excluded.
For the purpose of this Code, the following definitions shall apply:
The part of the bridge structure which bears directly all the forces from the structure above and transmits the same to the supporting structure.
A type of bearing where sliding movement is permitted between two surfaces, Fig. 1.2
Fig. 1. Sliding Bearing (Typical)
A type of bearing where no sliding movement is permitted but which allows rotational movement, Fig. 2.
A type of bearing where, in addition to the sliding movement, either the top Or bottom plate is provided with suitable curvature to permit rotation. ‘Sliding-cum-Rocker’ bearing should conform to General Design Features.
A type of bearing which permits longitudinal movement by rolling and simultaneously allows rotational movement, Fig. 3.
A plate which is attached to the underside of the structure and which transmits all the forces from it to the other members of the bearing.
A plate which is positioned between the top plate and the roller(s).
A part of bearing which rolls between a top plate and a bottom plate, or between a saddle plate and a bottom plate.
A plate which rests on the supporting structure and transmits forces from the bearing to the supporting structure.
A cylindrical pin provided between recesses of the top and bottom parts of a bearing for arresting relative sliding movement of the top and bottom parts without restricting rotational movement.
A recess in the surface of the bottom/saddle plate or top plate housing a knuckle pin preventing relative movement between two plates without restricting rotational movement.4
Fig. 2. Rocker Bearing (Typical)
5
Fig. 3. Roller-cum-Rocker Bearing (Typical)
A lug on the surface of the bottom plate or saddle plate which fits into corresponding clear recess made in the top plate to prevent relative movement of the two plates without restricting rotational movement, Fig. 3.
A Guide is a device provided to maintain the alignment of the roller during movement.
A Device/arrangement provided in the bottom plate, to arrest movement beyond the specified limit.
A rag bolt or ordinary bolt anchoring the top and bottom plates to the structure.
A bar loosely fixed at each end of a roller assembly for connecting the individual rollers in a nest and to facilitate movement of rollers in unison.
A support/bearing which permits the free relative movement of the parts of the structure.
A support/bearing which prevents the translational movement of the relative parts of the structure.
The symmetrical axis of the bearing.
The total relative movement between the structures in contact with the bearing.7
Fig. 4. Single Roller Bearing (Typical)
Only full cylinderical roller is permitted. Adequate width f base plate shall be provided to cater for anticipated movements of the supporting structure.8
The roller and rocker bearing components shall have suitable bearing guides to prevent them from being displaced during earthquakes. The components shall allow for movement as calculated.
For bridges with skew angle less than 20° the bearings to be provided shall be placed at right angles to the longitudinal axis of the bridge. For bridges with skew angle greater than 20°, very wide bridges and curved bridges where multi directional movements are expected, special type of bearings are to be provided.
The mild steel to be used for the components of the bearings shall comply with the following Indian Standards :
The steel for forging to be used for the components of the bearings shall comply with Class 3, 3A or 4 of IS:1875 and steel forgings shall comply with Class 3, 3A or 4 of IS:2004.
All slabs should be normalised after forging. If welding is involved, and if the slabs are more than 20 mm thick, preheating of the slab upto 200°C should be done.
High Tensile steel for bearings shall comply with IS: 961.
The stainless steel shall be austenitic Chromium-nickel steel, possessing, rust, acid and heat resisting properties generally as per IS:66039
and IS:6911. Mechanical properties/Grade for such stainless steel shall be as specified by the accepting authority but in no case be inferior to mild steel.
Cast steel used in bearings shall conform to Grade 280-520N of IS:1030-1989 "Specification of Steel Castings for General Engineering Purposes Specifications". In case where subsequent welding is unavoidable in the relevant cast steel component, the letter N at the end of the grade designation of the steel casting shall be replaced by letter ‘W'.
Note : Grade W is difficult to produce in comparison to grade N
For the purpose of checking the soundness, castings ’ shall be ultrasonically examined following procedures as per IS:7666 with acceptance standard as per IS:9565. The castings may also be checked by any other accepted method of non-destructive testing as specified in IS:1030.
Welding of steel conforming to IS:2062, shall be as per IS:1024, using electrodes as per IS:814.
The loads and forces to be considered in designing bearings for bridges shall be in accordance with the requirements of IRC: 6. Horizontal forces at bearing level shall be as given in Appendix-1.
The movement of supporting structure shall be assessed and catered for.
The basic permissible stresses in steel shall be as given in Appendix-2.
The basic permissible stresses in stainless steel shall be as specified by the accepting authority, but in no case less than that for mild steel specification Clause 906.1.10
The basic permissible stresses in concrete shall be as specified in IRC: 21.
The allowable working stress shall be based on the following stresses :
Where welds are not subjected to radiographic or any other equally effective methods of testing, but the accepting authority is otherwise satisfied with the quality of work, the allowable working stress specified in Clause 906.4.1 shall be multiplied by a factor of 2/3.
(Length of rollers worked out on the basis of formulas given below shall be exclusive of width of groove.)
The allowable working load for a single or double roller in Newton per mm length of roller shall be as follows :
Roller material | Flat surface material | ||
---|---|---|---|
Cast Steel | Forged Steel | Mild Steel | |
Cast Steel | 11 d | 11 d | 8 d |
Forged Steel | 11d | 11 d | 8 d |
Mild Steel | Mild steel rollers are not permitted | ||
where d is the diameter of the roller in mm11 |
For three or more rollers the values of working load shall be two-thirds of the above mentioned values.
The basic formula for allowable working load in Newton per mm length of roller for single or double roller is
where | σu = | Ultimate tensile strength of the softer material in N/mm2 |
E = | Modulus of elasticity of steel in N/mm2 |
The allowable working load when both the roller and the mating surface are of high tensile steel or any other high grade steel may be found out using the above relationship.
The allowable working load for a single or double roller in Newton per mm length of roller shall be as follows :
Roller material | Curved surface material | ||
---|---|---|---|
Cast Steel | Forged Steel | Mild Steel | |
Cast Steel | ll(dd1)/(d1-d) | ll(dd1)/(d1-d) | 8(dd1)/(d1-d) |
Forged Steel | 11 (dd1 )/(d1-d) | ll(dd1)/(d1-d) | 8(dd1 )/(d1 -d) |
Mild Steel | Mild steel rollers are not permitted | ||
Where, d is the diameter of the roller in mm d1 is the diameter of the concave surface in mm |
For three or more rollers the values of working load shall be two-third of the above mentioned values.
The basic formula for allowable working load in Newton per mm length of roller for single or double roller is
12
The basic permissible pressure shall not exceed 120 N/mm2 The working pressure shall be calculated on the projected area of the mating surface.
The bearings shall be designed to withstand the maximum vertical reactions and longitudinal force under the most critical combination of loads and forces. Provision shall also be made against any uplift to which the bearings may be subjected under the action of the above forces.
The allowable bearing pressure on the loaded area o a base under a bearing shall be given by Clause,307 of IRC: 21.
The loaded area shall be calculated as below :
Where the eccentricity of loads and longitudinal forces are considered alongwith direct compressive forces, the calculated direct bearing stress an 1 the flexural stress, shall satisfy the following equation :
Where, | σco, cal = | the calculated direct bearing stress |
σc0 = | the allowable direct bearing stress as per clause 907.1.2 | |
σc. cal = | the calculated flexural stress | |
σc = | the permissible Fexural stress in concrete or σc0 whichever is higher. |
13
The plates shall be symmetrical to the bearing axis. They shall be of mild steel/cast steel/forged steel/high tensile steel.
The width of plates shall not be less than either of the following :
The thickness of the plate shall not be less than (i) 20 mm or (ii) l/4th the distance between consecutive lines of contact, whichever is higher.
The thickness of the plate shall also be checked, based on the contact stresses arrived at accounting for the actual width of the plate provided, to satisfy the requirements of structural design and permissible stresses as laid down in Clause 906.
Forged steel rollers may be preferred over cast steel rollers, Mild Steel rollers shall not be used. The minimum diameter of roller shall be 75 mm.
The ratio of the length of the roller to its diameter shall normally not be more than 6.
The effective contact length with the plate shall be used for arriving at the length of the rollers to be used in the formula given in Clause 906.5.
The gap between the rollers shall not be less than 5C mm in case of multiple rollers.14
Fig. 5 . Maximum Shifts of Top Plate and Rollers due to Movements of Deck
The minimum width of various plates shall be calculated from the following formulae (Clause 907.2.1.2)
W1 |
⩾ | 100 or 2t1 whichever is greater |
W2 |
⩾ | 100 or [(n-1) C + 2Δ] or [(n-1) C + 2t2] whichever is greatest |
W3 |
⩾ | 100 or [(n-1) C + 2Δ] or [(n-1) C + 2t3] whichever is greatest |
Δ | = | Effective displacement |
n | = | No. of roller |
t1, t2 and t3 as in, Fig. 315 |
The top plates shall project on all sides over the
bottom plate by atleast 10 mm for any extreme position of the bearing.
The thickness of the plate shall satisfy the requirements of structural design and permissible stresses laid down in Clauses 906 and 907.2.1.4, but shall not be less than 20 mm.
The knuckle pins shall be so designed as to be safe in bearing and resist the horizontal shear due to the maximum longitudinal forces acting on the bearing. The permissible bearing stress shall be limited to the value specified in Clause 906.
The pins provided in bearings shall be designed to resist the maximum longitudinal force acting on the bearings. The pins shall be driven force fit in the saddle or bottom plate and shall have corresponding recesses in the top plate with adequate tolerance to allow for rocking.
The rocker pin and the corresponding recess shall satisfy the following :
To ensure movement of multiple rollers in unison, spacer bars may be provided but the arrangement shall be such that the rollers can rotate freely, Fig. 3.16
To prevent transverse displacement of the bearing components suitable guide lugs in plates with corresponding grooves in rollers shall be provided.
To prevent rollers from rolling off the bottom plate, suitable stoppers shall be provided.
The top and bottom plates shall be suitably anchored to the girder and the pier abutment cap or pedestals by means of anchor bolts.
The anchor bolts shall be designed to resist the maximum horizontal force acting on the bearing.
The minimum length of the anchor bolts in concrete may be kept equal to its diameter subject to a minimum of 100 mm.
The anchoring arrangement shall be designed for such a force so as to provide for a stability equivalent to 1.1 times the overturning moment due to permanent load (or 0.9 times if the effect is more severe) and 1.6 times the overturning moments due to temporary loads or live loads.17
An arrangement with slots to prevent the displacement of the roller unit due to siesmic or other dynamic vibrations shall be provided. An example of such an arrangement is shown in, Fig. 4.
All surfaces of the major components like top plates, saddle plate, base plates, rollers of the bearings shall be machined all over for correct alignment, interchangeability, proper fitting, etc.
The plate dimensions shall be in accordance with the approved drawing. Tolerance on the length and width of the plate shall not exceed + 1.0 mm, tolerance on the thickness of the plate shall not exceed + 0.5 mm and no minus tolerance shall be allowed.
All rolling, rocking and sliding surfaces shall have a machine smooth finish to 20 micron maximum mean deviation as per IS:3073.
The tolerance on the diameters of both rollers and convex surfaces shall conform to K 7 of IS:919.
The tolerance on the diameter of concave surfaces shall conform to D8 of IS:919.
Castings
No minus tolerance will be allowed in the thickness of any part of the castings. The edge of all ribs shall be parallel throughout their length.
Unless agreed upon otherwise between the Engineer and the Manufacturer, the Manufacturer shall furnish a complete Quality Assurance Programme (QAP) comprising the process of quality control, raw material testing, various stages of manufacture, testing on bearing components as well as testing on complete bearing etc. in conformity with relevant codal stipulations prior to the commencement of manufacture. The said quality assurance programme shall be approved18
by the Engineer/Accepting Authority. Manufacturing process, quality assurance, testing, documentation, etc. shall be carried out in conformity with the approved quality assurance programme. Proper documentation, records and certificates shall be maintained at all stages of manufacture and inspection by manufacturer to ensure to the conformity with the approved Quality Assurance Programme.
The Engineer may appoint an authorised inspection agency on his behalf for the purpose of inspection as per approved Quality Assurance Programme to certify the acceptance or otherwise of the bearings.
Test certificates of reputed testing laboratories for all raw materials shall be submitted. If such test certificates are not available then bearing manufacturer shall perform the necessary confirmatory tests as per relevant codes of practice and shall furnish the test results. Engineer or his representative may carry out independently tests on raw materials and witness the manufacturing process.
All casting and forgings shall be annealed/normalised and the heat cycle record shall be submitted to the Inspecting Officer/Engineer for scrutiny. Inspecting Officer/Engineer may ensure the proper reduction ratio. Suitable weld data record shall be maintained and submitted.
The Engineer shall reserve the right to witness such inspection at manufacturer’s workshop. For this, bearing manufacturer shall have in-plant minimum testing facilities as follows :
Bearing manufacturer shall maintain a list of consumption of raw materials including test records, for a period of at least preceding two years.
Test certificates of bearings manufactured during preceding two years shall be made available to the Inspecting Officer(s)/Engineer at manufacturer’s works.
Bearing manufacturer shall employ full time sufficient graduate Engineering staff for manufacture and quality control of bearings and shall have full time trained Scientist in chemical and physical testing and also have qualified person for ultrasonic testing.
Bearing manufacturer shall have qualified/certified welders.
The manufacturer has to produce test certificate from original producers of raw materials used in the manufacture of the bearings. Irrespective of the producers test certificates, the manufacturer will carry out the detailed tests on raw materials (both physical and chemical) for different types of raw materials used in the manufacture of the bearings as per relevant codes for such raw materials. For this purpose they will identify stock materials with certain batch number and draw samples from such stock materials and mark the same with same batch numbers. For each batch, 3 sets of samples will be drawn separately for tests of physical and chemical properties on samples. The manufacturer will carry out tests on chemical and physical properties on one set of samples and keep the remaining 2 sets of samples duly identified with the batch number for verification by the Engineer and/or his authorised representatives for conformatory tests with respect to the results obtained by the manufacturer. Such tests can be carried out on a few samples selected at random by the discretion of the Engineer and/or his representatives. The following IS Codes may be referred for carrying out such tests (both physical and chemical) :
IS : 1030 for casting
IS : 2062 for Mild Steel Components
IS : 2004 for forging
Other special materials shall be as per relevant IS/BS/AISI Codes.
All machined cast steel components shall be tested for ultrasonic testing to level IIIrd of IS:9565. Critical surface shall also be checked by Dye Penetration Test (DPT) and/or magnatic particle test for detecting presence of surface defects.20
All forged steel components after machining will be ' subjected to ultrasonic testing. Guidelines given in Appendix-3 could be referred to. To ensure the reduction ratio, macro-etching test will be conducted on the integral test piece (per heat) attached to anyone of the forging.
All bearings shall be tested to 1.25 times design load. Recovery should be 100 per cent. Contact surfaces and welding shall be examined by illumination source/ultrasonic test/DPT for any defects/cracks etc.
All welding shall be checked by Dye Penetration Test. If specifically required by Engineer, the X-ray test may also be done.
Engineer may carry out the destructive testing of any component/components of bearings supplied for conformity of test results submitted.
In case there is any major discrepancy regarding materials, Engineer may declare the whole lot of bearings as unacceptable.
On supporting structures, pockets shall be provided
to receive the anchor bolts. Appropriate method for levelling/grouting of the bearing to both beams and pedestal structure shall be adopted. The pocket shall be filled with mortar of mix 1:1 and the concrete bearing area also shall be finished level by a thin mortar pad of mix 1:1 just before placing of bearing assemblies or bottom plate on the concrete seat.
During installation the bearings shall be pre-set with respect to the bearing axis to account for the movements due to the following :
For bridges in gradient the bearing plates shall be placed in a horizontal plane.
In prestressed construction where launching of girders is employed, in order to avoid slipping or jumping of rollers due to vibrations or jolts, it is suggested that the roller bearings be provided after launching operations or otherwise adequate measures taken to ensure that the roller assembly is not disturbed. It is normal practice to provide rocker bearings on the launching end and place the beam on the rocker end slightly in advance of placing on the roller.
During concreting of girders, the bearings shall be held in position securely by providing temporary connection between the top and bottom plates in case of fixed bearings, and between top plate, saddle plate and base plate in case of a roller-cum-rocker bearing or by any other suitable arrangement which prevents the relative displacement of the components. The bearing plate shall be kept level during concreting.
In pre-stressed pre-cast girders where recesses are left on the underside of girders to receive the anchor bolts, grout holes extending to the beam sides or to the deck level shall be provided. The grout shall have a mix of 1:1.
Suitable easy access to the bearing shall be provided for inspection and maintenance.
Provision shall be made for jacking up of the superstructure so as to allow for adjustment repair/replacement of rollers of the bearings.
Each bridge bearing assembly and the adjacent members in contact shall be inspected at least once a year to ascertain their actual condition and suitable remedial measures taken immediately if defects are noticed including replacement in the event of irrepairable damage. However, the bearings shall also be examined carefully after unusual occurrences like heavy traffic damage, earthquakes, and batterings from debris in high floods. Necessary records of inspection shall be maintained.22
Appendix-1
(Clause 905.1)
HORIZONTAL FORCES AT BEARING LEVEL
The design horizontal forces at the bearings shall be the maximum of the following combination :
(1) For simply supported bridge with a fixed and free bearing (other than elastomeric type on stiff supports)
Fixed Bearing | Free Bearing |
(i) Fh-µ(Rg+Rq) or (ii) Fh/2+µ(Rg+Rq) whichever is greater. |
µ((Rg+Rq) |
Where: | |
Fh = | Braking or seismic force* on the length of decking effective for the bearing |
Rg = | Reaction at the free end due to dead load |
Rq = | Reaction at the free end due to live load |
µ = | Coeff. of friction at the movable bearings, which shall be assumed to have the following values : |
|
In seismic areas, the fixed bearing shall also be checked for full seismic force.
(2) Slab type bridges of span less than 10 m
The force at the bearing shall be Fh/2 or µRg whichever is greater.
Where:
Rg = Reaction due to Dead Load on the bearing
Note : *The component in the direction of traffic of seismic or wind force on the structure caused by the live load, need not be considered along with braking force.23
(3) Continuing Bridge with one fixed bearing and other free bearings (other than elastomeric type on stiff supports)
Fixed Bearing | Free Bearing | |
Case I | ||
(µR-µL) + ve and Fh acting in + ve direction | ||
(a) | If Fh>2 µR Fh-(µR+µL)------- | µ Rx |
(b) | If Fh <2µR![]() |
|
Case II | ||
(µR-µL) + ve and Fh acting in — ve direction | ||
(a) | If Fh>2 µL Fh-(µR+µL)------- |
µ Rx |
(b) | Fh <2µL![]() | |
whichever is greater |
where | ||
µLor nR | = | number of free bearings to the left or right of fixed bearings, respectively. |
µL or µR | = | the total horizontal force developed at the free bearings to the left or right of the fixed bearing respectively. |
µRx | = | the net horizontal force developed at any one of the free bearings considered to the left or right of the fixed bearings.24 |
Appendix-2
(Clause 906.1.)
PERMISSIBLE STRESSES
S.No | Description | High Tensile IS:961-1975 or sp steel | Cast Steel IS:1030-1989 | Forged Steel IS:2004-1978 | Mild Steel IS:226-75/ 2062-84 |
---|---|---|---|---|---|
1. | Max. axial tensile stress on effective sectional area (σy1) | 0.60 σy, | 160 | 160 | 140 |
2. | Max. bending tensile or compressive stress on effective sectional area for extreme fibre (σt/σc) | 0.66 σy, | 180 | 180 | 150 |
3. | Max. shear stress (τ ra) | 0.45 σy, | 120 | 120 | 105 |
4. | Max. bearing stress on nonГsliding surface (σp) | 0.80 σy, | 215 | 215 | 186 |
5. | Max. combined bending shear & bearing, stress (σbc) | 0.92 σy, | 250 | 250 | 21025 |
S.No | Description | High Tensile IS:961-1975 or sp steel | Cast Steel IS:1030-1989 | Forged Steel IS:2004-1978 |
---|---|---|---|---|
1. | Max. axial tensile stress on effective sectional area (σyt) | 0.60 σy, | 160 | 160 |
2. | Max. shear stress .(τra) | 0.37 σy, . | 100 | 100 |
3. | Max. bearing stress on non-sliding surface (σp) | 0.87 σy, | 235 | 235 |
S.No. | Description | Black Bolts conforming to property Cl.4.6 of IS: 1367-1967 | |
---|---|---|---|
1. | Max. axial tensile stress(σt) | 120 | Permissible stresses in a bolt of any other property class will be as per Cl. 8 9.4.3 of IS :800-1984 which is reproduced below for convenience: |
2. | Max. shear stress(τra) | 80 | |
3. | Max. bearing stress (σyt) | 250 | "The permissible stress in a bolt (other than a high strength friction grip bolt) of property class higher than 4.6 shall be those given in Table 8.1 multiplied by the ratio of its yield stress or 0.2 per cent proof stress or 0.7 times its tensile strength, whichever is the lesser to 235 MPa." |
Note : Components of bearings should be designed for the worst combination of loads with no increase in permisible stresses.26
Appendix-3
(Clause 909.2.3)
GUIDELINES REGARDING PROCEDURE FOR ULTRASONIC TESTING OF FORGED STEEL ROLLERS CONFORMING TO IS:2004 CLASS 3 AND ITS ACCEPTANCE STANDARD
Type of Equipment | Krantakrammer/ECIL/EEC or Vibronics make ultrasonic flow detector |
Test Method | Pulse echo direct contact method |
Test | 2-2.5 MHz, 24 mm |
Frequency Probe | Straight beam (normal) probe |
Size Couplant | Oil/Grease |
Text | Scanning by hand probing |
Direction | Throughout the length of the body of forged proof-machine rollers in all possible direction at least covering the surface area upto 180° |
Calibration | Calibration of the machine (UFD) is to be done using IIW block/standard calibration block for a range of 2.00 mm. |
Sensitivity setting | The sensitivity shall be set on a 3.0 mm dia. Flat bottom (FB) hole drilled upto a depth of 25 mm on a 200 mm length x 10 mm dia. Class 3 forged bar having reflection of screen height of 75% from the FB hole. |
Acceptance Standard |
|