DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGY, MADRAS
CHENNAI-600 036.
Name of the Report : Report on Dynamic Load Testing on 12 Strand 15 Systems.
Name of the Project : Mumbai Ahmedabad High Speed Rail (Package No. MAHSR- C4)
Client : National High Speed Rail Corporation Limited (NHSRCL)
Contractor : Larsen & Toubro Ltd, HCI IC
Sub-Contractor : M/s. DSI - Bridgecon India Private Limited
265, Okhla Industrial Estate, Phase III,
New Delhi -110020.
Ref No. : Your Mail dated 24.09.2021
Consultant : Dr. G. APPA RAO
Professer
Department of Civil Engineering
Indian Institute of Technology Madras
Chennai - 600 036.
The report deals with “Report on Dynamic Load Testing on 12 Strand 15 Systems”. Submitted
by M/s. DSI - Bridgecon India Private Limited, New Delhi. This report contains Eight
pages.
Date : 10.11.2021 Dr. G. APPA RAO
LABORATORY TEST REPORT
STRUCTURAL ENGINEERING LABORATORY
DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGYMADRAS, CHENNAI- 600 036
Title : Report On Dynamic Load Test On 12 Strand 15 System
Client : M/s DSI - Bridgecon India Private Limited. Date of Testing: 29th Oct to 5th Nov 2021
INTRODUCTION:
M/s. DSI - Bridgecon India Private Limited, New Delhi approached the Indian Institute of
Technology Madras to carry out Dynamic Load Test on 12 strand 15 Anchorage System. The Indian
Institute of Technology Madras represented by Dr. G. Appa Rao, Professor (Structural Engineering
Laboratory) agreed to take up the above work and test was carried out in accordance with FIP – 1993 for
the acceptance of post tensioning systems. This report deals with details of test, observations made, and
results obtained from the tests.
DESCRIPTION OF SPECIMENS
The test specimen consisted of DSI 12 strand 15 Anchorage System. The test set-up consists of
strand, wedge, anchorage System was fitted in steel frame and material was supplied by M/s. DSI -
Bridgecon India Private Limited. 12 strands of 15.2 mm diameter class II low relaxation strands, with
specified breaking load of 260.7 kN (IS 14268-2017) and nominal cross-sectional area of 140 mm2, were
used for testing. Using LVDT (Linear Variable Displacement Transducer) slip was measured. The least
count of LVDT is 0.01 mm. System was loaded, so as to limit total load within capacity of the fatigue
testing machine, as permitted by FIP recommendations.
TEST MATERIALS
A. HT Strand
Supplier : Usha Martin
Coil Number : B532480358
Heat Number : 4118390
Specified values of the characteristics of the strands are given below:
Characteristic diameter of strand Øpk : 15.2 mm
Characteristic steel area Apk : 140 mm2
Characteristic breaking load Fpks : 260.7 kN
CHARACTERISTICS OF THE TENDONS – (12T15)
Number of strands in tendon : 6 Nos
Anchorage to Anchorage distance : 7000 mm
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LABORATORY TEST REPORT
STRUCTURAL ENGINEERING LABORATORY
DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGYMADRAS, CHENNAI- 600 036
Title : Report On Dynamic Load Test On 12 Strand 15 System
Client : M/s DSI - Bridgecon India Private Limited. Date of Testing: 29th Oct to 5th Nov 2021
Characteristics breaking load of tendon : Fpk = 6 x 260.7 = 1564.2 KN
B.ANCHOR HEAD
Supplier - DSI Bridgecon India Pvt. Ltd
Heat Number - C-2682
Batch Number - C-2682
C.WEDGES
Type - 68 00 0036 H/D
Supplier - PT ULTIMAX MITRA AGUNG
Batch Number - 251
TEST PROCEDURE
1. It is desirable to conduct an initial static load test on the system to check the system performance
by gradually loading up to a 110 kN at increments of 10 kN. The slip measurements of strand
and wedge are to be recorded.
2. The aim of the dynamic load test is to determine capacity of tendon anchorage assembly under
load fluctuations as an indication of reliability and durability of the assembly. Cyclic loading
was to be done at a constant force frequency of 210 load cycle / minute. Amplitude of the
applied loading (Fmin, Fmax) is specified by FIP recommendations, such that Fmax corresponds to
65% of the characteristic strength of prestressing steel. The value of F min is to be fixed such that
the stress range is 80 MPa.
Accordingly, considering strands of 15.2 mm dia, with specified breaking load of 260.7 kN,
Fmax= 0.65 x (260.7 x 6) = 1016.73 kN.
Fmin = 0.60 x (260.7 x 6) = 949.53 kN.
Δ F = Fmax–Fmin = 67.2 kN
The anchorage system was stressed up to minimum load of 949.53 kN and nuts were tightened
to achieve system’s minimum force of 949.53 kN always. Then the loading was made to fluctuate
between Fmax = 1016.73 kN and Fmin = 949.53 kN for 2 million cycles at a rate of 210 cycles/minute. The
relative displacements between prestressing steel and individual anchorage components, as well as
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LABORATORY TEST REPORT
STRUCTURAL ENGINEERING LABORATORY
DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGYMADRAS, CHENNAI- 600 036
Title : Report On Dynamic Load Test On 12 Strand 15 System
Client : M/s DSI - Bridgecon India Private Limited. Date of Testing: 29th Oct to 5th Nov 2021
between anchorage components themselves, were measured at regular intervals. Observations were taken
at regular intervals and noted whether occurrence of any damage to the anchorage system or the tendons
has taken place. Fracture of some wires in the strands away from the anchorage blocks is permissible,
provided this does not result in reduction in the initial cross-sectional area by 5%.
TEST SET-UP
The schematic diagram of test set-up is shown in Figure 1. The test set-up consisted of two
Losen Hausen dynamic jacks which were mounted on very rigid test frame to facilitate loading in the
vertical direction. The cable of length 7.0 m was suspended from steel frame (welded anchorage head)
resting over cross arm. The other end of cable was anchored to a similar steel frame, connected to an
upper cross arm on which the jack loads were applied. A cross steel frame was supported on four vertical
springs, one at each corner as shown in figure 1.
In the event of power failure, machine comes to halt, and it was switched on again manually. In
this interim period, ideally, strands should be subjected to minimum tensile force corresponding to F min
(to simulate conditions in practice). This is ensured by an arrangement provided, where by movable
lower cross arm of the test frame is maintained at a reference default position (and the nuts at the test
floor bottom tightened at this position) to give desired minimum tensile force. This is achieved through
pre-tensioning of four bolts connecting the frame to the test floor, each bolt being subjected to 0.25 F min.
The slip between wire & anchorage system and slip between wedges & anchorage system also between
components of the anchorage system was measured by four LVDT (two for wire reading & two for
wedges reading).
ACCEPTANCE CRITERIA
The test is deemed to be successful (as per FIP recommendations) if
1. Fatigue failure of anchorage components does not occur up to 2 million cycles of loading with the
prescribed stress range.
2. Failure of tendons during testing up to 2 million cycles should be limited, such that not more than 5%
reduction of the initial cross-section occurs.
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LABORATORY TEST REPORT
STRUCTURAL ENGINEERING LABORATORY
DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGYMADRAS, CHENNAI- 600 036
Title : Report On Dynamic Load Test On 12 Strand 15 System
Client : M/s DSI - Bridgecon India Private Limited. Date of Testing: 29th Oct to 5th Nov 2021
TESTING EQUIPMENTS AND MEASUREMENTS DEVICES
Axial load was applied through two Losen Hausen dynamic jacks of capacity of 1000 kN which
was controlled by Universal Testing Machine. The applied load was measured using an electrical load
cell of capacity 1000 kN with a least count of 0.01 kN. The deflections at anchorage ends were measured
using LVDT. All the measuring devices were calibrated at the time of testing as per standards.
TEST RESULTS
1. Static Load Test
Results show that the relative displacements of strand and wedge are acceptably low. The values
are shown in Table-1.
Table1. LVDT Readings Before and After Two Million Cycles
Wedge in mm Strand in mm
Load in (kN)
LVDT 1 LVDT 2 LVDT 1 LVDT 2
0 0 0 0 0
1016.73 2.143 2.485 2.292 2.093
After 2 million cycles
1016.73 2.927 2.427 2.186 1.960
2. Dynamic Load Test
When using the Dynamic load cyclic test, no distress was observed in the wedges and the
anchorage system after 2 million cycles indicating the satisfactory fatigue performance of strand, wedges
and anchorage system.
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LABORATORY TEST REPORT
STRUCTURAL ENGINEERING LABORATORY
DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGYMADRAS, CHENNAI- 600 036
Title : Report On Dynamic Load Test On 12 Strand 15 System
Client : M/s DSI - Bridgecon India Private Limited. Date of Testing: 29th Oct to 5th Nov 2021
CONCLUSION:
Fatigue (Dynamic) load test of DSI 12 strand 15 anchorage Assembly was carried out as per FIP
recommendations. DSI 12 strand 15 anchorage assembly supplied by the DSI has passed the test
requirements (withstand 2 million cycles) as per FIP recommendations with regards to the fatigue load
test. However, the fatigue performance of strand, wedges and the anchorage system is satisfactory.
Prof. G.Appa Rao
Project Co-ordinator
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LABORATORY TEST REPORT
STRUCTURAL ENGINEERING LABORATORY
DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGYMADRAS, CHENNAI- 600 036
Title : Report On Dynamic Load Test On 12 Strand 15 System
Client : M/s DSI - Bridgecon India Private Limited. Date of Testing: 29th Oct to 5th Nov 2021
Figure 1: Schematic diagram of Test Setup
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LABORATORY TEST REPORT
STRUCTURAL ENGINEERING LABORATORY
DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGYMADRAS, CHENNAI- 600 036
Title : Report On Dynamic Load Test On 12 Strand 15 System
Client : M/s DSI - Bridgecon India Private Limited. Date of Testing: 29th Oct to 5th Nov 2021
Figure 2: Reinforcement Detailing for Bursting, Primary & Secondary
Figure 3: Test Setup
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LABORATORY TEST REPORT
STRUCTURAL ENGINEERING LABORATORY
DEPARTMENT OF CIVIL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGYMADRAS, CHENNAI- 600 036
Title : Report On Dynamic Load Test On 12 Strand 15 System
Client : M/s DSI - Bridgecon India Private Limited. Date of Testing: 29th Oct to 5th Nov 2021
Figure 4: Installation of LVDT
Figure 5: Top Anchorage head after two million cycle
Figure 6: Bottom Anchorage head after two million cycle
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