Cross Drainage

A cross drainage is defined as a culvert rather than a bridge
if the ratio of its streamwise length to the height of its opening is greater than about 5,
or the opening width (or span) is less than about 2 m.
A short structure that is at the arbitrary size limit of 2 m span may be modelled by either application.

Hydraulic Structure

Hydraulic: Movement of liquid with / under pressure.
Hydraulic Structure: A structure is made to control water. Made submergedly with water.

 

METHODOLOGY FOR INSTALLATION OF EXPANSION JOINT

Traffic Control

At first start the work in half width of carriageway and remain opened the rest of width for traffic.

FOR NEW BRIDGES

Leave a cavity during placing the concrete and fill the cavity with sand.

FOR EXISTING BRIDGE

Create such cavity for installing the expansion joint by using chisel or pneumatic equipment. The existing reinforcement of deck slab must not be damaged but to be cleaned, straightened and preserved. Never use jack hammer for this job. Clean the created cavity with brush.

Use bonding agent sikadur-32 lp or (equivalent) to the exposed edges of the concrete, for bondage between concrete.

Use water reducing agent sikament-163 (600 ml / cement bag) along with hardener accelerator as sikarapid-1 (750 ml / bag) or equivalent, for high early strength of concrete. Don’t use low cost admixtures containing chlorides and sulphates.

Use concrete of minimum compressive strength (350 kg / cm2).

Use steel of Grade – 60 requirements.

Don’t place the concrete on plates or formwork heated under sun beyond 32° c.

Complete wet curing for 7 days is must, otherwise prefer using concrete curing compound anticsol-e15 (0.20 kg / m) or equivalent within 6 Hours of concreting and cover the concrete area with opaque / colored plastic sheets.

When the bridge is located over a river / canal / nullah, sealing of joint using backup rod and sikaflex-pro 3ws filler is not required and let

The water flow down to the nullah underneath. But in case of overhead bridges, following additional treatment is required for sealing of joint.

 after the installation and curing of the joint, clean the joint gap with wire brush and remove the dust with a blower.

 fix the backup rod of specified dimension at a depth of 25 mm from the top.

 apply sikaprimer-3 (or equivalent) with paint brush.

 apply oil resistant resins sikaflex-pro 3ws (or equivalent) in the upper 25mm cavity in a concave shape, over filling of compound should be avoided.

Indigenous expansion joint is not a propriety item. It can be copied and the joint can be manufactured and placed by any designated.

Temporary steel strips 25x60 thicness 3mm at 500 c/c, welded to top and bottom of vertical plates, have been added to maintain spacing of vertical plates during the construction of the joint, don't forget to remove temporary steel strips within three days of concreting of joints.

Preferably the expansion joint should be manufactured in 2m length or less than 2m and assembled at the site.

In Situ

In situ
is a latin word, which meanings are to "in position".
Construction of the precast or prefabricated items, that made in factory or plant and than placed at site as required. such as concrete girders are precasted at plant and than placed at site.

Steel

Difference of Grades

There are three grades of steel
Bar end of  Grade 60  will be marked with yellow paint

Grade	Grade	Minimum Yield Strength
		in pounds	in
inch-pound	metric	per square inch	megapascals
Grade 40	Grade 280	40,000	280
Grade 60	Grade 420	60,000	420
Grade 75	Grade 520	75,000	520



For the grades 60 & 75 the bar will be marked

Grade	Metric grade	Continuous line system	Number system
			number stamped onto bar
60	420	1 line running the length of the bar	60	4
		offset at least five spaces from the center of the bar
75	520	2 lines running the length of the bar	75	5
		offset at least five spaces from the center of the bar

Semi Finished

Slabs: Steel slabs are hot-rolled from an ingot or strand cast. They are wide and rectangular in shape.

They are used for the manufacture of all 'flat' steel products such as coils, sheets, strip, plates and other flat-rolled steel products.

Billets

Steel billets result from the second stage of the steel production process. They are hot-rolled or forged from an ingot or strand cast. Smaller and longer than a bloom, billets are usually a square cross section less than 36 square inches.
They are used for the manufacture of all 'long' steel products such as bars, rods, pipes, tubes, wire and wire products.

Blooms

Blooms are hot-rolled or forged from an ingot or strand cast. They usually have a square cross section exceeding 36 square inches.
They are mainly used in the manufacture of ‘long’ products such as structural shapes, structural profiles, building beams, rails and columns.

 Flat

 Hot Rolled Coil (HRC)

Hot rolled coil is rolled on a hot strip mill from slabs. It can be found on the market in coil or sheet form and is further processed into finished products by the manufacturer. Hot rolled coil is typically 2-25mm thick and up to 2,250mm wide.
Hot rolled coil is produced as a feedstock for cold rolled coil and coated coil, but also for direct use in a variety of industrial applications including steel tubes used in transport, construction, shipbuilding, gas containers, pressure vessels and energy pipelines. Hot rolled sheet with an anti-slip surface and a diamond or teardrop pattern is typically used for stairs, industrial floors and tailboards for goods vehicles.

Cold Rolled Coil (CRC)

Cold rolled steel is a 'flat' steel product. The material is manufactured from hot rolled steel, the thickness of which is further reduced on a strip mill without the use of heat. The resulting thinner and flatter material is known as cold rolled steel. Typical thickness is from 0.15 to 3 mm. Typical width is from 600 to 2,100 mm.
Finished cold rolled steel coil has excellent forming properties, electromagnetic properties, paintability and weldability It is suitable for fabrication by forming, pressing and bending. Applications include domestic applications, automotive manufacturing, lighting fixtures, electrical components (stators, rotors), various kinds of sections, roofing applications, profiled sheets, and wall elements.

Hot Dipped Galvanised Coil / Sheet

Obtained by passing cold rolled coil through a molten zinc bath, in order to coat the steel with a thin layer of zinc to provide corrosion resistance. Hot dipped galvanized coil can be found on the market in coil or in sheets and is further processed into finished products by the manufacturer. Typical thickness is from 0.3 to 3 mm. Typical width is from 600 to 2,100 mm.
Hot dipped galvanized coil has excellent forming properties and is suitable for fabrication by forming, pressing and bending. Applications include domestic appliances, building applications (e.g. wall elements, roofing, automotive parts (e.g. underbody), lighting fixtures, drums and various kinds of sections and profiled sheets.

Hot Rolled Plate

Hot rolled plate is produced by hot rolling a steel slab to form a plate. Typical thickness is between 2 to 20mm and maximum width is 1860 mm.
The material is used in the shipbuilding, pressure equipment and construction industries.

Cold Rolled Sheet

Flat rolled products for which the required final thickness has been obtained by rolling at room temperature. To meet the various end use requirements, cold-rolled sheet products are metallurgically designed to provide specific attributes such as high formability, deep drawability, high strength, high dent resistance, good magnetic properties, enamelability and paintability.
Cold rolled steel sheet is used in a wide variety of end applications such as appliances refrigerators, washers, dryers and other small appliances, automobiles - exposed as well as unexposed parts - electric motors, and bathtubs.

Tin Plate

Tinplate is cold reduced steel sheet coated with a thin layer of tin. Tin mill products are produced in a variety of types including electrolytic tinplate, electrolytic chromium coated steel and black plate, an uncoated product. It has good corrosion resistance and food compatibility – although many products require a thin coating of lacquer to maximise the shelf life of the contents.
Around 90% of tinplate is used in packaging, with food and drinks cans the biggest market, but it is also widely used for other consumer and general packaging, such as aerosols, paints and oils.

Coated Sheet

Coating steel sheet improves durability and lengthens product life. It is manufactured to meet specific customer requirements for corrosion resistance, strength and formability. Thickness, width, surface quality and surface finish vary greatly.
The most typical applications are for metal roofing and automotive manufacturing.

Coated Steel Coil
Colour coated, or pre-painted, steel, is steel coil to which a paint, powder or film coating has been applied in a continuous process prior to it being cut and shaped. It provides a durable uniform surface finish, and can be an alternative to conventional post-manufacture painting of steel parts. The coil is coated on one or both sides. Rolls apply first a primer and then a topcoat to the moving steel strip. The substrate is usually cold reduced galvanised coil, but galvanised HRC and even uncoated coil is used.
Building applications account for around two thirds of consumption, with cladding on steel frame buildings a well known use. It is also widely used for domestic appliance casings and for some furniture.

Long

Reinforcing Bar

Reinforcing bar (or Rebar) is formed from a steel billet, normally having surface deformations for use in reinforcing concrete. The bar can be produced in straight lengths as well as coiled.

Rebar is used in the construction industry to reinforce concrete.

Merchant Bar

Merchant bar is a range of commodity carbon steel long products including round, square and hexagonal bars, angles, channels and flats. Maximum diameter or width is usually 80-100mm, although flats up to 150mm wide are included. These are a staple item for many steel stockholders, large or small.
Merchant bar is widely used in the manufacture and fabrication of a broad range of engineered products.

Structural Sections

Heavy or structural sections are steel products such as beams or columns which are usually formed with a specific cross section shape e.g. H, I or U.
Used to build large structures such as multi-storey buildings and bridges.

Wire Rod

Hot rolled from steel billet, wire rod is delivered as coil, most commonly at 5.5mm dia, but in sizes up to 60mm dia. Close control of final cooling is a critical part of production. The most important characteristic for determining a rod's end use is its drawability; the extent to which the rod's diameter can be reduced during the drawing process.

Engineering Steels

Engineering steels, or special bar quality (SBQ), is used to describe steel long products for more demanding processing or end-use applications than can be met by commodity grades. Products include bright bars, rolled carbon and alloy bars, forged, tool and stainless steels. These are generally machined, forged or cold drawn during subsequent processing.
The main application area is the automotive industry for engine, transmission, steering and suspension components, but engineering steels are also used for a wide range of industrial applications including hand tools, oil & gas exploration and wind turbine components.

Forgings

Forgings are used in a variety of mechanical applications in heavy industries such as mining, construction and oil & gas exploration.

Tubes & Pipes

Seamless Tubes
Boiler tubing, the oil and gas industries and automotive transmission components are typical applications.


Welded Tubes

Welded tubes are made from hot rolled or cold reduced strip, sheet or plate.
Welded tubes are used in a wide range of general engineering applications as well as in power generation plants, oil refineries, automotive manufacturing and furniture production.

Stainless

Stainless Steel

Stainless steel is the generic name for a number of different steels used primarily for their resistance to corrosion. The one key element they all share is a minimum percentage of chromium: 10.5%. Although other elements are added to improve corrosion resistance, chromium is always present. The principal grades are austenitic (typically 16-26%Cr, 6-22Ni); ferritic (10.5-28%Cr with no/low Ni); martensitic (higher carbon content than ferritic and typically 12-19%Cr with low/no Ni); and duplex, a dual-phase austenitic/ferritic steel (Cr>21%, Ni <8%).
Its many varied applications include food production and storage equipment, pumping and storage of oils, gases and acids, specialist components in the automotive industry, cutlery, surgical instruments and fasteners.

Cement Concrete Rule of 6

A good concrete depends on proper quantities of its gradients like cement, crush, sand and water.
Here is a simple rule for proper quantities ratio is the rule of 6's!

1- Minimum cement bags are required for cubic yard concrete = 6 bags
2- Maximum water required per cement bag                             = 6 gallon
3- Minimum curing days required to keep moisture                  = 6 days
4- Air contents required (if concrete will be subject to freezing and thawing) = 6 %

Pilling for Bridge

calculation of helix for pile.
formula of spiral length.

Concrete Works

Workability: concrete can be place and consolidate without bleeding or segregation.
Setting of Concrete: The hardening before its hydration or it gains strength.
Hydration : During evaporation of water from concrete  releases high heat of hydration. The heat may harm ful and may also produce shrinkage, resultant cracks. This can be avoid by water curing to sustain a suitable temperature and moisture in concrete.
Air entrainment : reduces the density of concrete and consequently reduces the strength.
Segregation : separation of materials. There are few types:
Separate settling of aggeregate from rest of concrete.
Separation of the paste from aggregate.
Separation of water from the materials

Concrete Mix Wet Volume

Concrete Mix Proportion Materials
Dry Volume and Wet Volume:
Dry Volume : Bulk Volume with air spaces etc.
Wet Volume : Real Volume to be used.
In dry mix volume empty spaces between particles in bulk material are filled with air. When we add water to concrete the empty spaces are filled with water, So the reduction in volume from dry to wet is not by shrinkage of material.
For example100kg of each material, their dry volume and wet volumes typically are:
Cement: Dry V - 66L, Wet V - 32 L
Sand: Dry V - 62L, Wet V - 38 L
Coarse aggregate: Dry V - 59L, Wet V - 38L
The factor of 1.54 to convert dry volume is just approximate. For each batch of materials we have to measure dry volume and actual density to accurately convert.

Formula of Elongation in Cut Lenth due Bend in Steel

Formula of Elongation in Cut Lenth due Bend in Steel bar during its fabrication and bending:

G.I.Pipe Railing on Bridges

click for excel file
G.I.Pipe Railing on Bridges

Material	S.NO.	1	1	2	3
	Dia of pipe in inches	2	1½	2	2
	Thickness of wall in mm	3
	Rate per 100'	4	10,125	14,250	14,250
	Adustorum 1%	5	101	112	112
	Wastage 2%	6	203	224	224
	Specials 20%	7	5,063	2,850	7,125
	Surface Treatment outer surface with paint	8	450	500	500
	Total 4+5+6+7+8	9	15,941	17,936	22,211
	Contractor,s Profit 10%	10	1,594	1,425	2,043
	Total	11	17,535	19,361	24,254
Labour	No of joints in line	12	5	5	5
	Progress	13	8	5	5
	Daily labour  chargeses	14	1,155	1,155	1,155
	Cost per joint	15	144	231	231
	Jointing material+threading, fixing in P.C.C 1:2:4 (P.joint)	16	200	250	250
	Total(15+16)*12	17	1,144	1,481	2,405
	Carriage	18	153	153	153
	Testing	19	50	50	50
	Total	20	1,348	1,684	2,608
	Add 10% Contractor's profit 17+18+19	21	-	-	261
	Total	22	-	-	261
RATE	Composite for 100 (11+22)	23	8	5	5
	Labour for per foot20/100	24		-	-
	Composite for per foot 21/100	25	190	0	0
	LABOUR
	Plumber	1No	300
	Coolie	2	300
	Mason	1	150
	Painter	1	300
	Total		1,050
	Add10%Sundr		105
	Total		1,155