Larsen & Toubro Limited Construction @ LARSEN & TOUBRO Heavy Cul Infrastructure MAHSR ~ C4, Swastik Universal, Unit No. 202, 2 Floor Building No. B, Rundh Village, Piplod ~ Dumas Road, Surat, Gujrat = 395007, India Ref. No: LTC/MAHSR/Pkg-C4/QMS/2022/4346 11” August 2022 To, The Engineer, TCEL-CEGL-AARVEE ASSOCIATES-PADECO JV, 8-1007 to 1012, 10" Floor, Tower B, Swastik Universal, Opp. Central Mall, Dumas Road, New Magdalla, Piplod, Surat, Gujrat ~ 395007, India Email id: [email protected] Kind Attn.: Mr, S Sreedharan, Engineer's Representative SUB: C4 Package - Design and Construction of 237 km long Viaduct (Ch. 156.6 - 393.7) including 4 stations (Vapi, Bilimora, Surat, Bharuch) & Surat Depot for MAHSR Project Reg.: Addendum to the Method statement for Prestressing Works for Segmental Span, |-Girder and T-Girder (by BBR India Pvt Ltd.) Ref: i) LOANo, NHSRCL-CO/MA/CA/O1/PACKAGE-Ca/6/.2/0HQ975; Dated: 28.10.2020 ii) Clause 5.0; Division 02000; Section VI-3. Employer's Requirements (Technical Specifications) of the Contract Agreement. ill) LTC/MAHSR/Pkg-C4/OMS/2021/2285 dated 18.12.2021 iv) Engineers Reply on our Letter no. 2285 dated 27.01.2022 Vv) LTC/MAHSR/Pkg-C4/QMS/2022/3369 dated 20.04.2022 i) Engineers Reply on our Letter no, 3369 dated 16.05.2022 vii) LTC/MAHSR/Pkg-C4/QMs/2022/3772 dated 08.06.2022 Viii) Engineers Reply on our Letter no. 3772 dated 21.06.2022 (NONO) Dear Sir, This is in reference to the above cited subject and Contract Clause mentioned in Ref. (i) In continuation to the Contractor's submission vide Letter under Ref (ii, v & vii), and Engineer's comments vide letter under Ref. (iv, vi & viii), the Contractor under the cover of this Letter submits the Addendum to the Method statement for Prestressing Works for Segmental Span, I-Girder and T-Girder (by BBR India Pvt Ltd.). ‘The Contractor requests kind review and approval, please Thanking you and assuring our best services at all the times, Page 1 of 2 Te: 491443319 2000 3319 3000 Fax: ¥91 443319 2950 / 4811 wnintecccom hegistered Office: L&T House, NM. Mora, ollord ste, Mumbo 400 001 ~ HA {a Consteution — Heavy Cuil infrastructure isa brondofarsen& Tout Limited (GW 8999entsaspicona7EsLarsen & Toubro Limited Construction Heavy Civil Infrastructure Ep) tarsen a rousro Set Unit No. 201, 2” Floor Building No. B, Rundh Village, Piplod — Dunas Road, Swe cur S8007 nd Yours faithfully, For Larsen & Toubro Limited fay mavisr \E"\ (Slcisse)s ) Enclosed: Addendum to the Method statement for Prestressing Works for Segmental Span, I-Girder and T- Girder (by BBR India Pvt Ltd.) - MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0 Copy: The Employer (Mr. Amiyansu Das, Chief Project Manager / Surat, NHSRCL) Page 2 of 2 Tel: 491 4 3319 2000, 3319 3000 Fox #9144 3319 2950/8811 wo. Intec cam Registered Office: LT House, H.M. Marg, llr Estate, Mumbo ~ 400 001 ~ INDIA LET Construction ~ Heavy Cuil infrastructure is a brand of Larsen & Toubro Limited (GW LoassaMHzo4ePLCOON768BBR (INDIA) PVT LTD No318, 01* & 02% Floors 15# Cross, 06! Main Sadashivanagar, Bangalore ~ 560080 Karnataka ~ INDIA, Ph No: +91-80-40250000 Em: [email protected], Web Site: www.bbrindia.co.in Main Contractor Mis. L&T Construction Ltd i Project MAHSR Project, C4 Package a Client Mis. L&T Construction Ltd W.O. RefNo L&T/MAHSRC4/PROC/LOVAKV/CHM/AH/290921/01, date : 29/09/21 Document Ref No MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0 Addendum to Method statement for Prestressing Works for Segmental Span, I-Girder and T- Girder (by BBR India Pvt Ltd.) SINO DATE. [ REV NO DESCRIPTION fi | 18/12/2021 jo For Approval 2 2010472022 a1 Incorporated with comments 3 080672022 @ Incorporated with comments 4 110s?2022 00 AddendumBBR (INDIA) ADDENDUM TO Document No. | MS-NECL-01 PVTLTD METHOD STATEMENT | #318, 01" & 02" Floors Prestressing works for Segmental Rev No. a Eerireesssereten Span, I-Girder &T-Girderat x,y Bangalore 560080 MAHSR Package-C4 \ Date | 11/08/2022 CONTENTS 10 OBJECTIVE 2.0 SCOPE OF WORK ' 3.0 REFERENCES 40 RESOURSES 5.0 CONSTRUCTION METHODOLOGY 60 SAFETY MEASURES 70 INSPECTION, TESTING AND CONTROL 3.0 ILLUSTRATIVE PHOTOS OF POST TENSIONING JACKS 9.0 ANNEXURES MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR (INDIA) ADDENDUM TO | Document No. | MS-NECL-O1 2vELED| METHOD STATEMENT #318, 01" & 02 \ : ple Prestressing works for Segmental | Rev No. {oz aietioaage” Span, 1-Girder & T-Girder at is | Bangalore-360080 MAHSR Package-C4 age No | i | Date | 11/08/2022 1.0 Objective i ‘The objective of this method statement is to describe in detail all the operation connected with the prestressing works at Segmantal Span, I Girder & T Girder at MAHSR, Package- (C4 with the help of 406/506/306 jacks as applicable. There are no changes in the following 2.0 Scope of Work: Addemdum Includes ‘Wedge locking pressure calculation ' Calculation part of grip length elongation Slip at dead end not considered in format | Calculation of gross clongation — added in stressing format 406 & 506 multi jack diagram and technical speci 3.0 References No Change 4.0 RESOURCES 4.1 Materials ‘No Change i 4.1 Plant and Equipment if 42.1 Equipments Required for Stressing i a) Hydraulic Jack with wedge seating device (306/ 406/506) -3 nos I 5.0 CONSTRUCTION METHODOLOGY A No Change | 5.2.3. STRESSING OPERATION OF TENDONS 4 ‘The jack grip length elongation is predetermind value and it may vary jack to jack and depends on the jack’s length. The grip length elongation shall be added only to figure out the gross elongation and it should be subtracted from the actual cumulative elongation to calculate Net elongation. And it's not necessary to added MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev'O_ |BBR (INDIA) | ADDENDUM TO Document No, | MS-NECL-01 PVILTD METHOD STATEMENT #318, 01% & 029 Is Crecoct ain, PTesttessing works for Segmental Rev No. | 02 085,06 Main, | , : | Span, I-Girder & T-Girder at | Sadashivanagar, — | Page N 9 Bangalore-560080 ‘MAHSR Package-C4 ‘age No | | Date 11/08/2022 6.0 1.0 8.0 ‘on modified elongation (or) + 5 percentage calculation carried out with modified | elongation value. The slip at dead end is called wedge engagement into anchorage system and the movement of wedge seating shall not be considered as wedge draw-in/slip and the | movement of wedge is compensated at live end anchorage and mm wedge | draw-in is already considered in design | ‘The wedges are locked by wedge seating device (WSD) and the load is slowly | transferred to the anchorage system by operating slowly the shutoff valve and D.C | valve in the purnp. Locking pressure of the WSD is 300K /sq.em for longidutinal | cables. However, BBR system found 1.5MT is suitable load per wedges/strand | required for proper locking of wedges in transverse cables. The wedge locking pressure calculated with the consideration of following (1) No. of strands in tendon. (2.) effective wedge locking cylinder area, I “Pressure = Load / Effective Area” | © Load to be applied for 4 strands = 4x1.5MT = 6,0MT (or) 6000 kgs. © Load to be applied for 3 strands = 3x1.SMI = 4,5MT (or) 4500 kgs. © Effective area of the wedge locking device = 46.15 sq.cm (or) 17.561 quem (of) 37.69 sq.om Pre-Grouting Operations No Change SAFETY ya No Change i INSPECTION, TESTING AND CONTROL | ‘No change | ILLUSTRATIVE PHOTOS OF POST TENSIONING COMPONENTS AND | SPECIAL EQUIPMENTS - Additions as appended i MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rey 0BBR (INDIA) ADDENDUM TO Document No. MS-NECL-01 PvT LTD METHOD STATEMENT #318, 01% & 02! aout Prestressing works for Segmental Rev No. 02 Diciekeesee Span, I-Girder & T-Girder at i sadshivanagar, . Bangalore-560080 MAHSR Package-C4 age Date 11/08/2022, | i \ ! ; A Oo as I - ae 1 - 50 406 FLAT BEARING PLATE dee ANCHOR RLOCE 406 ANCHORAGE SYSTEM 406 Wedge MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR(NDIA4y) ADDENDUM TO Document No. MS-NECL-O1 5 rere METHOD STATEMENT #318, O1% & 02" Lh Cees ain, Peestressing works for Segmental Rev No. 02 ross,00% Main, Span, I-Girder & T-Girder at Se MAHSR Package-C4 | Page No " | | ate + wosi2022 ate | at AC Emr was eo ses ‘rasan {TORE Db SFR FR 1 i . 06 wu yok ‘| MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR (INDIA) PVT LTD #318, 01% & 02" Floors 15% Cross,06" Main, Sadashivanagar, Bangatore-560080 ADDENDUM TO METHOD STATEMENT Prestressing works for Segmental Span, I-Girder & T-Girder at MAHSR Package-C4 Document No. Rev No. Page No Date MS-NECL-01 02 12 11/08/2022 MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR (INDIA) ADDENDUM TO Document No. MS-NECL-01 ee METHOD STATEMENT #318, O1% & 02" ioe eee Prestressing works for Segmental Rev No. 02 it eaieat eee Span, I-Girder & T-Girder at Bangalore-560080 MAHSR Package-C4 Page No 13 Date 11/08/2022 Wedge Locking Pressure Calculation for 406 Jack Wedge Locking Device - The Wedge Locking device is a hydraulic Cylinder operated with a hydraulic power pack used for proper lacking / seating of wedges into the Anchor head by hydraulic force alter stressing Force Required for Locking : [As por BBR system 1.5 MT load per wedge/strand required for proper locking of wedges. Depending on no of strands the wedge locking load to be calculated & applied accordingly, As this jack is designed for 4 strands, 6 MT load to be applied for lacking of 4nos.of strands. Depending on the effective area of the wedge lack cylinder, the pressure tobe applied as allows Load to be applied = 6 MT = 6000 kg {ectve area ofthe wedge locking device = 46.15 s4.cm, Pressure = Load Effective area = (6x1000)/46.15 = 130 kg/sq.em Ctajapalts Koc Authorised Signatory MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR (INDIA) | ADDENDUM TO | Document No. MS-NECL-OL PVTLTD = | METHOD STATEMENT #318, 01% & 02" | | it Semone | Prestressing works for Segmental Rev No. 102 cement | Span, -Girder & T-Girder at 4 Bangalore-560080 | AHIR Package-C4 Page No it i Date i 11/08/2022 3a vex coat oA y i | 506 JACK MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR (INDIA) ADDENDUM TO Document No. MS-NECL-01 PVT LTD METHOD STATEMENT #318, 01% & 02" eee Prestressing works for Segmental _ Rev No. 02 Seen Span, I-Girder & T-Girder at, Bangalore-S60080 MAHISR Package-C4 eee a | Date 11/08/2022 Technical Data & Specifications of 506 Multi pull Jack i Sino Specification Units | Type of Jack (140MT Multi Jack) i Maximum Force MT 140 | 2 Maximum Pressure Kg/Sq.cm 620 | 3 ~~ Active piston area ‘Sqem 226.194 4 Maximum stroke mam 100 3 Length of ack mm 540 6 | ___ Width of jack mm 258x591 Technical data & Specification for wedge locking cylinder 1 Effective Area Sqem 17.56 2 Load at 340 Bar Mr 6 3 ‘Working pressure Kg/Sq.cm 340 MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR (INDIA) ADDENDUM TO Document No. MS-NECL-01 ee METHOD STATEMENT Floors Prestressing works for Segmental Rev No. 02 15 Grose (Mai, Span, I-Girder & T-Girder at Sadashivanagar, Page No 16 Bangalore-560080 Date 11/08/2022, Wedge Locking Pressure Calculation for 506 Jack Wedge Locking Device - The Wedge Locking device is a hydraulic Cylinder operated with a hydraulic power pack used for proper locking / seating of wedges into the Anchor head by hydraulic force after stressing, Force Required for Locking :- As per BBR system 1.5 MT load (Force) per wedge/strand required for proper locking of wedges. Depending on no. of strands the wedge locking load to be calculated & applied accordingly. As this jack is designed for 4 strands, 6 MT load to be applied for locking of nos of strands. Depending on the effective area of the wedge lock cylinder, the pressure to be applied as follows Load to be applied = 6 MT = 6000 kg Effective area of the wedge locking device = 17.561 sq.cm. Pressure to be applied = Force/ Effective area = (6x1000}/17.561 = 340 kg/sqjcm Con fapatte Keo Authorised Signatory MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR (INDIA) PVT.LTD #318, 01% & 02 Floors 15 Cross,06" Main, Sadashivanagar, Bangalore-560080 ADDENDUM TO METHOD STATEMENT Prestressing works for Segmental Span, I-Girder & T-Girder at MAHSR Package-C4 Document No. Rev No. Page No Date MS-NECL-01 02 17 11/08/2022 MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR (INDIA) PVT LID #318, 01" & 02" Floors 15% Cross,06" Main, Sadashivanagar, Bangalore-560080 140 TON HYDRAULIC JACK WITH WSD_ ADDENDUM TO | Document No. | Ms.NECL-O1 METHOD STATEMENT | LRevNo. | 02 Prestressing works for Segmental Span, I-Girder & T-Girder at | MAHSR Package-C4 Page No 18 Date 11/08/2022 406 JACK -01 MAHSR-L&T-PKG-C4-QAQC-MS-01261, Rev 0BBR (INDIA) ADDENDUM TO Document No. MS-NECL-O1 PVTLTD METHOD STATEMENT #318, 018 & 024 aoa eae a Prestressing works for Segmental Rey No. 02 eee Span, I-Girder & T-Girder at Sadashivanagar, a | Page Ne 19, Bangalore-560080 MAHSR Package-C4 peene | | Date 11/08/2022 ‘Technical Data & Specifications of 406-01 Multi pull Jack Slno Specification Units ‘Type of Jack (140MT ‘Multi Jack) i Maximum Force MT 140 2 Maximum Pressure |“ Kg/Sq.cm 620 3 ~~ Active piston area Sqcm ~ 226.194 i 4 Maximum stroke [mm 100 3 Length of Tack mm 540 6 Width of jack | mm 258x310 Technical data & Specification for wedge locking cylinder 1 Effective Arca Sq.om 37.69 2 Toad at 160 Bar MT 6 3 Working pressure KgiSqem 160 MAHSR-LAT-PKG-C4-QAQC-MS-01261, Rev 0200 | 140 (OD) 110 (OD) = ae a a REDUCER qf: (HDPE ) ssouon free Bt eae | (SURFACE FINISH IRa VALUE - m HOPE REDUCER | r DRAWING No.) BM - 04 - 03 ©50 390 44 . WAR RRIRLE Gp s 35 x 3 ga 3 ao a 8 8 3s .5 a —< LPS SOR RRRPRBELP LILI LILI 4) DET-X . . 19 06 TRUMPET | gl 7 (HDPE ) g N z ol z “ 2 5 ed sue [pou samen a Be Hore mUWFET 905 ee © i 8 BBR (INDIA) Pvt. Ltd. | | 2 SPECIAL THREAD, & ) -04- gs SPECIAL THREAD, RIGHT HAND HELIX SUITABLE TO BEARING PLATE CASTING od ey ee | DRAWING No. BM - 04 - 03 22 Sencalumi~seatt', wamatacemodules of elascity of sand) BBR INDIA PVT. LTD. PRESTRESSING FORMAT MAHSR C4 [Name ofthe work # Span Ne. Dae. [Location Start Time: Span Length (Mis): Finish Time: [Span No [Date of Last Segment Concrting No of Strands [Min. Cube Strength Sepment for Span No of Cables (Totaly [Cube Strength for Stsssing: stressing Cable No: [Prestressing jack informtion THT Strands Details Make & No. [Coa No: [Stessing Ram area in Gr es Value in KNisma™ (eotual [Lock off Ram area in Cx [Locking Presure in Kyu [Aste Value in mex (actual ross sectional of area elastity of strand) [Grip Length with Jack (eum) | Wedge Set Final Slip (mm) Length of Strand (Anchor to Anchor end) [Yack effeieney « Pressure Gauge No. Siessing End): ane De Data(As Drawing) a sig Dat sper Drawing) Wedges: Sheathing Dewtats [GEC Danger No [EVE Valu of Sdn Kwan JMAKE Teoretca! Modulos of Elasticity of 1D (om) Stand) roves [AY Valo Stands nm Maer Tt CTheoreteat Dein Elongation (an) hicks on Lak Free (KN) Design longs Ther, charea AWS 7 Modified Elongation | "Thero, Modulus of lastilty Es? Max. 45% Actual Area A'a'x Actual Bsa mien [Gros ongaton alain: Model dongatlon + grip Inga clongaton nm) + wedge dan lowancet@inm) Ma. 5% Modified Pressure acing Force = Ram Area Jack eft ren x Tack effceney ah STRESSING REPORT TCorrespondeace Cable N Peswre Tlongaton Gam Tongaton Gam) Psion Radin SLN ston (Ky/Sqem) ot * [Ditference|Cumulath P (Ky/Sqem) Piston Reading Difterence| Cumuls 3 30 1 0 [350 50__| “100 2 [3500 100 [150 aan 450 50200 [480500 Tato Concion 3300550 30050 5 250. 300. 7 4) Camutave Eongton om) ip Length Elongation cam) ‘6 lengnion 1C) Slip at Live end (mm) % Pressure [Net Elongation (mm) A - (BHC) After 24 hrs Slip extension achieved i ess than requfe Wh desired jacking force Yes/No tees inereate Jacking force (6 % Maximum) Percentage Rxcest/ Lex Hongation Achieved BBR GNDIA) PYTLTD IFAT Consructon Tinga? Reprosatave Date: Date: ame: Name: senate: stenatre: