Bridge Manual 1998-197-220 PDF

INSPECTION OF BRIDGES CHAPTER - XI INSPECTION OF BRIDGES 1101. By Permanent Way And Works Inspectors  'HWDLOVRILQVSHFWLRQ 'LIIHUHQW 5DLOZD\V IROORZ GLIIHUHQW SUDFWLFHV LQ UHJDUG WR WKH UHVS...

INSPECTION OF BRIDGES CHAPTER - XI INSPECTION OF BRIDGES 1101. By Permanent Way And Works Inspectors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 INSPECTION OF BRIDGES E 7KH 851 RI D EULGJH LV DUULYHG DW EDVHG RQ WKH FRQGLWLRQ RI FRPSRQHQWVDQGD&RQGLWLRQ5DWLQJ1XPEHU &51 DVVLJQHGWRHDFK RIWKHP7KHYDULRXVFRPSRQHQWVRIDEULGJHLQVHTXHQFHDUH L IRXQGDWLRQVDQGIORRULQJLIDQ\ LL PDVRQU\FRQFUHWHLQVXEVWUXFWXUH LLL WUDLQLQJDQGSURWHFWLYHZRUNVLIDQ\ LY EHGEORFNV Y EHDULQJVDQGH[SDQVLRQDUUDQJHPHQWV YL VXSHUVWUXFWXUH*LUGHUV$UFK3LSH6ODEHWF YLL WUDFNVWUXFWXUH F 7KH&51LVDOORWWHGWRHDFKRIWKHDERYHFRPSRQHQWVEDVHGRQ WKHLUFRQGLWLRQDWWKHWLPHRILQVSHFWLRQXVLQJWKHIROORZLQJVFDOH Condition RatingNo. Condition of bridge component (CRN)  $FRQGLWLRQZKLFKZDUUDQWVUHEXLOGLQJUHKDELOLWDWLRQ LPPHGLDWHO\  $FRQGLWLRQZKLFKUHTXLUHVUHEXLOGLQJUHKDELOLWDWLRQ RQDSURJUDPPHGEDVLV  $FRQGLWLRQZKLFKUHTXLUHVPDMRUVSHFLDOUHSDLUV  $FRQGLWLRQZKLFKUHTXLUHVURXWLQHPDLQWHQDQFH  $VRXQGFRQGLWLRQ  1RWDSSOLFDEOH  1RWLQVSHFWHG G :KHQDQ\FRPSRQHQWLQDEULGJHLVPRUHWKDQRQHLQQXPEHU &51 LV DVVLJQHG WR HDFK RI WKHP DQG WKH ORZHVW YDOXH XVHG )RU H[DPSOHLIDEULGJHKDVILYHSLHUVDQGWZRDEXWPHQWVDQGWKHVHDUH JLYHQ WKH &51 RI  WKHQ WKH &51 IRU WKH VXEVWUXFWXUH FRPSRQHQWRIWKHEULGJHZRXOGEHPLQLPXPRIWKHDERYHLH H ,ILQDQ\EULGJHRQHRUPRUHFRPSRQHQWVGRQRWH[LVWWKH&51 IRUVXFKFRPSRQHQWVVKDOOEHVKRZQDV INDIAN RAILWAYS BRIDGE MANUAL 84 CHAPTER -  INSPECTION OF BRIDGES I )URPWKH&51VIRUGLIIHUHQWFRPSRQHQWVRIDEULGJHDQRYHUDOO 5DWLQJ1XPEHU 251 IRUWKHEULGJHDVDZKROHLVWKHQJLYHQ7KH251 LVWKHORZHVWRIWKHVHYHQ&51VRIDEULGJHH[FHSW J )RUDPDMRUEULGJHWKH851ZRXOGFRPSULVHRIHLJKWGLJLWVWKH ILUVWGLJLWLQGLFDWLQJWKH251DQGWKHIROORZLQJVHYHQGLJLWVWKH&51VRI HDFKRILWVDERYHVHYHQFRPSRQHQWVLQVHTXHQFH )RUH[DPSOH851RIDPDMRUEULGJHZRXOGLQGLFDWHWKH IROORZLQJ Digit No. Value Indication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 INSPECTION OF BRIGES a) The Assistant Engineer should make an extract of the orders under "Action taken column" and send the same to the Permanent Way Inspector / Inspector of Works / Bridge Inspector concerned for compliance with a copy to the Divisional Engineer. Arrangements should be made to carry out the repairs as soon as defects are noticed without waiting for the completion of inspection of other bridges. b) If it is not possible to make complete inspection of any bridge owing to the presence of standing water, the fact should be so stated. The inspection of foundations should be made no sooner water dries up or conditions make it possible to do so and results recorded as supplementary entries in the register. c) All the bridge components which have Condition Rating Number (CRN) as zero should be inspected by the Assistant Engineer at the earliest. 8. Certificate by the Assistant Engineer a) On completion of his annual bridge inspection, the Assistant Engineer shall certify at the end of the register as follows : "I have personally inspected all the bridges shown in this register during the year ending December.... and have issued detailed orders in writing to the Inspectors concerned, except the following. Bridge No...... are referred to for further orders. Bridge No......... have one or more CRN as 0 during more than one consecutive inspections". All registers should be sent to the Divisional Engineer by a specified date. They may be sent in a regular flow as and when bridge inspection on a section is over without waiting for the completion of inspection of all the bridges. 1RWH : Divisional Engineers include such Sr. Divisional Engineers who have same duties as that of Divisional Engineer in a Division.  %\ 'LYLVLRQDO (QJLQHHUV DQG &KLHI %ULGJH (QJLQHHU1RPLQDWHG6$*RIILFHUQ+HDGTXDUWHUV V $&6GWG  1. Details of inspection : a) The Divisional Engineer shall carefully scrutinise the Assistant Engineer's Bridge Inspection Register and inspect all INDIAN RAILWAYS BRIDGE MANUAL 186 CHAPTER - 11  INSPECTION OF BRIGES important bridges and such bridges as called for his inspection. He shall record his orders regarding the points which require as decision by him and initial against every bridge in token of scrutiny. b) He will complete his inspections and scrutiny by a specified date. 2. Certificate by Divisional Engineer. He should endorse on each register, below the Assistant Engineer's certificate as follows: "I have personally scrutinised this register and inspected all Important bridge and bridges referred to me and have issued orders regarding all essential points requiring a decision by me. The following points are submitted to Headquarters for orders. Bridge No (s) require rehabilitation. Bridge No (s) have ORN 1 or 2 Bridge No (s) have one or more CRN as 0 for more than one consecutive inspection.'' $&6GWG 3. The Divisional Engineer shall inspect all those bridges for which the ORN is 1, 2 or 3 and revise/confirm the rating given by the ADEN. Bridges having ORN 1or 2 after review shall be inspected more frequently at various levels and to be placed under close watch. The schedule and level of inspection of such bridges shall be decided by the Chief Bridge Engineer depending upon severity of the defects noticed. $&6GWG 4. Action by Divisional Engineer: He should then send the register to the Assistant Engineer for noting his orders with instructions to return them within ten days. The Assistant Engineer should then extract the orders issued by the Divisional Engineer, intimate the same to the Inspectors concerned and ensure expeditious compliance. 5. Scrutiny by Chief Bridge Engineer/Nominated SAG officer in Headquarters and action thereon: The registers should then be forwarded by the Divisional Engineer to Bridge Branch in Headquarters by a specified date. All the registers of major and important bridges sent by divisions should INDIAN RAILWAYS BRIDGE MANUAL 187 CHAPTER - 11  INSPECTION OF BRIGES be examined by CBE. The minor bridge registers sent by a division may be examined by a SAG officer in Headquarters nominated by PCE for this purpose. Chief Bridge Engineer/ Nominated SAG officer in Headquarters will issue orders regarding matters referred to them duly endorsing the registers to the effect. However, observations of inspecting officers in respect of minor bridges which have been assigned ORN as 1, 2 or 3 and cases where bridge matters are referred by DEN/Sr. DEN to Headquarters should also be seen by CBE after examination by nominated SAG officer. The registers should then be returned to the Divisional Engineer latest by a specified date. Subsequent action taken on the nominated SAG officer's and Chief Bridge Engineer’s orders should be entered in the register by the Assistant Engineers. $&6GWG %\$VVLVWDQW(QJLQHHU'LYLVLRQDO(QJLQHHU %ULGJH  1. The officer nominated for the purpose of maintenance and inspection of steel work of bridges shall scrutinise the registers sent by Bridge Inspector and endorse the registers below the Bridge Inspector's certificate and forward it through the concerned Divisional Engineer by a specified date to the Dy. Chief Engineer/ (Bridges) nominated by Chief Bridge Engineer. 2. He will inspect: a) Bridges which have been referred to him, b) Bridges which call for the inspection after scrutiny of the Bridge Inspector's registers, and c) All the overstressed girders where camber loss is noted. 1 He will test check 10% of the inspection work carried out by the Bridge Inspector. 2 Certificate of Inspection: After scrutiny of the registers and inspection of bridges the nominated officer will append a certificate on each register to the effect: "I certify that I have personally scrutinised this register and issued instructions on essential points requiring a decision by me. I have carried out test checks as required during the year and the following points are referred to the Dy. Chief Engineer/ (Bridges) for orders". %\'\&KLHI(QJLQHHU %ULGJHV  1. Scrutiny of the register : The nominated Dy. Chief Engineer (Bridges) shall examine the entries in the Bridge Inspector's register INDIAN RAILWAYS BRIDGE MANUAL 188 CHAPTER - 11  INSPECTION OF BRIGES and record his orders on the points referred to him by the Divisional Engineer (Bridges) / Assistant Engineer (Bridges). The registers should be returned by a prescribed date with necessary endorsements to the Bridge Inspectors through the nominated officer for taking prompt action thereon. 2. Details of Inspection : He shall inspect the steel work of such bridges, a) as called for his inspection after scrutiny of the registers, b) as directed by the Chief Bridge Engineer and enter his notes and ensure prompt action thereon. "He will list out the defects considered sufficiently important and bring them to the notice of the Chief Bridge Engineer." $&6GWG '(7$,/62)%5,'*(,163(&7,216 7KH'HWDLOHG,QVSHFWLRQ2I$%ULGJH,QFOXGHV([DPLQDWLRQ RI 1. Flooring and foundations : a) To ascertain whether: i) scour has taken place particularly around the piers and near abutments and also along curtain walls and down stream of drop walls, ii) there is any settlement or undermining of the foundations. b) The conditions of the flooring, drop walls, curtain walls, apron and pitching should be examined. c) At specified bridges soundings should be taken during floods vide instructions contained in para 711.1 and annual survey of scour holes vide para 712.2 2. Masonry in substructure: a) To ascertain whether: i) the masonry is in any way cracked, shaken or crushed, particularly under the bed blocks in the ballast walls, abutments and piers, ii) there is any bulging, shearing, tilting (out of plumb) and apparent signs of movement in abutments, wing and return walls, iii) there is any deterioration due to weathering or any damage to the stone or brick or leaching of the mortar in the joints. INDIAN RAILWAYS BRIDGE MANUAL 189 CHAPTER - 11  INSPECTION OF BRIGES b) Seepage of water through the joints in the masonry should be looked for. Brick masonry and other soft stone should be tapped with a light hammer for detecting "drummy'' places. c) Cracks in the masonry must be marked by red paint for their entire lengths and dated tell-tales placed at their extremities and numbered. This will enable cracks to be readily located and any extension detected. Where extensive cracks are noticed, sketch of the cracks should be kept in the Bridge Inspection Register with the details like length, depth, width, location, etc. d) Under-water substructure inspection: The sub-structure of the bridges which are normally underwater should be inspected by adopting suitable methods which may include engaging of divers and special equipments: i) Routine/swim by inspection should be done once a year ii) Detailed inspection should be done once in five years. iii) Special inspection-as considered necessary” $&6GWG e) In the case of arch bridges, the following points may be examined during inspection : i) longitudinal cracks (cracks parallel to the direction of traffic) in arch barrel, due to settlement below, ii) horizontal crack and bulging of spandrel wall. iii) sliding forward of spandrel wall, iv) transverse or diagonal cracks in arch intrados which may or may not be accompanied by crushing of bricks, or stone masonry, v) Cracks in the vicinity of the crown of the arch, vi) leaching out of mortar, vii) weathering of masonry, viii) loosening of key stone and voussoirs of arch, ix) adequacy of cushion, x) adequacy of weep holes and drainage, xi) presence of cracks in parapet wall/leaning of parapet wall. 3. Protective works and water ways: INDIAN RAILWAYS BRIDGE MANUAL 190 CHAPTER - 11  INSPECTION OF BRIGES a) To ascertain whether : i) the protective works such as pitching, toe wall, flooring, drop/ curtain walls, guide bunds, launching aprons, spurs/groynes, approach banks, marginal bunds, are in sound condition and adequate, ii) the waterway is adequate and clear of obstruction, iii) the pitching reserves as per schedule are available and are adequate. b) The marginal embankments maintained by the State Governments should be inspected and deficiencies noticed advised to concerned authority. c) It should be examined whether there has been any disturbing influence noticed like excessive velocity, parallel flow, heavy afflux, tank bursts in catchments and increase in spill from adjacent catchment. 4. Girder alignment and seatings: a) To ascertain whether: i) the position of girders in respect of line and level relative to the piers and abutments is correct, ii) the bearings are fully and evenly seated on the bed blocks and the holding down bolts are in position and anchored in the bed blocks, iii) the bed blocks are cracked, crushed, shifted or shaken, particularly under the bearings, iv) the rollers and the sliding plates provided at the expansion ends to permit expansion and contraction are well greased, free of dust and working freely, v) the date of lubrication of girder bearings is conspicuously painted, vi) the metal bearings are cracked or corroded, vii) bed timbers where provided, are crushed or decayed, viii) the elastomeric bearings are cracked or are showing signs of excessive deformation beyond the normal visible corrugations, ix) the bearings provided with oil bath are covered free of dust and proper oil level is maintained. INDIAN RAILWAYS BRIDGE MANUAL 191 CHAPTER - 11  INSPECTION OF BRIGES b) Where possible, girders should be observed under train load for any abnormal movement or evidence of settlement. If a girder lifts off its bearings and ""hammers'' this must be specially reported. 5. Structural condition of girders: i) In case of girders having High Strength Friction Grip (HSFG) Bolts: L ,QVSHFWLRQ The inspection of HSFG bolts shall be done visually for broken and loose bolts. Hitting HSFG bolts to check looseness is not allowed. Looseness of bolts shall be seen by rust appearing beneath the bolt head/washer/nut etc or marks left by water or apparent relative movement between the steel parts joined by the HSFG bolts. The broken/loose bolts if any, shall be marked by a round circle all around and shall be replaced expeditiously by new HSFG bolts of same specifications properly tightened Retightening of loose bolts found during inspection is not allowed in any case. LL 8VHRI+6)*EROWVIRUUHSDLUUHKDELOLWDWLRQZRUNV Where any girder component/ joint is to be replaced, HSFG bolts shall be used as follows: (a) Complete joint shall have HSFG bolts. HSFG bolts cannot be used for replacement of isolated loose rivets. (b) Proper surface preparation shall be done and joint design shall be done based on design provisions as per para 7 12 of Steel Bridge Code. Particular care shall be taken regarding use of appropriate slip factor for the surface preparation done.. $&6GWG $& $&66GWG a) To ascertain whether the structural condition is satisfactory. b) In triangulated spans, the following points should be observed: i) loss of camber in the main girders assessed from comparative readings, ii) distortion of members, iii) high incidence of loose rivets. c) The following girder members should be examined for distortion: i) bottom chord members especially the unbraced sections near the ends of the span, ii) top chord members with insufficient restraint by bracings, iii) diagonal web members and tension members made up of flats, INDIAN RAILWAYS BRIDGE MANUAL 192 CHAPTER - 11  INSPECTION OF BRIGES iv) top flanges of plate girders. d) (i) To ascertain tightness of rivets by a sample test, the rivets are to be tested as per the procedure outlined in Annexure 11/ 12. Rust streaks close to rivets usually denote looseness, ii) In the case of plate girders, loose and distorted rivets should be looked for at the connections of the main angles to the web plates below the sleepers and also at the ends of the girder. iii) In triangulated spans field rivets should be examined at end connections of stringers to cross girders, cross girders connections to main girder, end connections of cross and lateral bracings, and chord joints and web member connections. e) To ascertain whether inspection gangways have been provided on triangulated girder spans, where necessary. f) In the case of welded girders, the girders shall be inspected over the entire length. Some of the weld details and critical locations, which should be given special attention during the inspection are: i) butt welds in tension flange or tension member, ii) welds at ends of transverse and longitudinal stiffeners and welds of attachments to web and tension flange or tension member, iii) ends of welded cover plates, iv) intersecting weld, v) locations having sudden change in cross section or configuration leading to stress concentrations, vi) re-entrant corners and copes vii) weld repairs and tack welds viii) visible notches such as flame cut edges and mechanical indentations, ix) splice joints, x) bracing and cross frame connections with stiffeners, xi) connections transmitting heavy torsional or in plane moments to members, i.e. stringer to cross girder and cross girder to main girder connections, xii) ends of welds and weld craters, xiii) unusual type connections, INDIAN RAILWAYS BRIDGE MANUAL 193 CHAPTER - 11  INSPECTION OF BRIGES xiv) bearings and their connections, xv) members damaged or bent during transit, erection or in service, xvi) structural details which are known to have exhibited fatigue problems on other bridges, xvii) locations having corrosion, pitting, etc. and loss of section. g) In case of composite girders the junction between concrete slab and steel girder shall be inspected for: i) shear connector and girder connections, ii) any vertical separation between girder and slab and also the critical locations mentioned in sub-para 5(f) as applicable to the composite girder. h) In the case of overstressed girders, the joints where the stresses in rivets in shear and bearing as per stress sheets are higher than the permissible working stresses should be examined. 6. The condition of steel work : a) Action may be taken to ascertain whether the condition of paint is satisfactory and that no corrosion is taking place. b) The following part of steel work which are prone to corrosion should be specially examined. i) where water is likely to collect or parts where alternate wetting and drying can take place, ii) where longitudinal timbers are carried in channel stringers and in the troughing of ballasted deck, iii) steel work of girders and the under side of over bridges which are liable to corrosion by the action of fumes from engines and whether they are protected by smoke guards, iv) seatings of wooden floors or treads of foot over bridges, v) steel column footings of over bridges where buried in ground, vi) around bearings of girders where debris can collect, vii) inaccessible parts of structures like the inside of box girders with insufficient clearance between the flanges and behind bends of joggled stiffeners. c) It is difficult to detect cracks in steel work as they are likely to be covered by a film of paint or corrosion and a careful inspection is INDIAN RAILWAYS BRIDGE MANUAL 194 CHAPTER - 11  INSPECTION OF BRIGES necessary for their timely detection. Locations which must receive attention are : i) roots of flanges and angles where defects in rolling can initiate cracks, ii) joints where heavy shear is transmitted, iii) badly corroded members, iv) bent plates, if shaped at an inadequate and low temperature and subjected to heavy and repeated dynamic loads. d) Steel work in wrought iron or manufactured before 1905 (i.e. early steel) requires greater attention in regard to the existence of cracks. e) Once cracks are detected, their likely cause should be investigated. If the investigations indicate certain deficiencies, girders of the same design and vintage must be closely examined at corresponding locations. 7. Track on the bridge approaches : The following points should be kept in mind while inspecting the track on the bridge proper : a) General condition of track : i) it should be ascertained whether it is central to the rail bearers and the main girders are in good line and level, ii) departure from line is caused by incorrect seating of girders, shifting of girders laterally or longitudinally, incorrect seating of sleepers on girders and rails on sleepers, varying gauge or creep. iii) departure from level is caused by errors in level of bed blocks or careless sleepering. The adequacy of clearances of running rails over ballast walls or ballast girders at the abutments and the condition of timbers and fastening on the run off and skew spans should be checked. b) Sleepers : The condition of sleepers and fastenings should be checked. The spacing of sleepers should not exceed the limits laid down in para 273 (1) and 273 (3) of IRPWM-1986. Squareness of sleepers shall be ensured. Sleepers requiring renewals should be marked with paint, and renewals carried out. End bolts should be provided on sleepers which have developed end splits. INDIAN RAILWAYS BRIDGE MANUAL 195 CHAPTER - 11  INSPECTION OF BRIGES c) Hook bolts : Hook bolts should be checked for their firm grip. Position of arrows on top of the bolts should be at right angles to the rails pointing towards the rail. Hook bolts should be oiled periodically to prevent rusting. d) Creep and joint gaps should be checked and rails pulled back wherever necessary. Rail fastenings should be tight. Defective rails should be replaced. Where switch expansion joints are provided on the girder bridge, it should be ensured that free movement of the switch is not hindered. e) Guard rails : i) adequacy of guard rail arrangements should be checked, ii) correct distance between the running rails and the guard rail and the clearance of guard rails over the ballast walls should be checked, iii) correct flaring and burial at the ends of the guard rails should be examined. iv) wooden block, where provided, should be examined for their soundness, v) it should be checked whether angle iron/tie bar runners and foot walk are provided and fixed properly. f) The gauge and level of track should be checked. g) Track on approaches : The following points need attention, while inspecting the approaches of the bridge : i) track geometry on the approaches should be maintained to the best possible standards, ii) rail joints should be avoided within three metres of a bridge abutment, iii) the condition of the ballast wall should be checked, iv) full sections of ballast should be maintained for atleast 50 metres on the approaches. This portion of the track should be well anchored. h) Rail joints : It should be checked whether any rail joint is existing on girder bridges of 6.1 m span and less and on arch bridges having insufficient cushion. In the case of bridges consisting INDIAN RAILWAYS BRIDGE MANUAL 196 CHAPTER - 11  INSPECTION OF BRIGES of two or more spans, the rail joints shall be placed as far as practicable over the piers. 8. Trolley and safety refuges : Trolley refuges should be checked to ascertain : a) Whether these are structurally in good condition. b) Whether they have been provided : i) on bridges with main span of less than 100 metres, at every 100 metres, ii) on bridges with main spans of 100 metres and more, a refuge over each pier. 9. Foot paths : a) To ascertain whether the foot paths are properly supported. b) To check up whether all girder bridges situated within station limits are provided with foot paths for the convenience of the railway staff. c) Whether long unballasted girder bridges located between stations are provided with foot paths for the convenience of Engineering staff. 10. Painting, marking HFL and Danger level, providing foundation particulars and bridge name boards : It should be ascertained whether: a) The date of last painting has been conspicuously painted on the girder and recorded in the Bridge Inspection Register. b) The Highest Flood Level and the year in which the flood had occurred has been marked and recorded in the Bridge Inspection Register. c) The danger level has been fixed and marked on the pier/ abutment as envisaged in Para 703 and recorded in the Bridge Inspection Register. d) The direction of the flow has been distinctly marked on the abutment or pier. e) The plaque showing particulars of foundation have been fixed over every abutment and pier in accordance with instructions in Annexure 11/7. f) Name boards have been fixed at either approach of INDIAN RAILWAYS BRIDGE MANUAL 197 CHAPTER - 11  INSPECTION OF BRIGES important bridge. g) The Full Supply Level (FSL) has been marked distinctly at all canal crossings in the same way as the HFL for other bridges. h) The Bridge Number Tablets have been provided on the parapet walls of bridges as per Annexure 2/1 j) The flood gauges have been provided at important bridges for recording flood levels and afflux. Any increase in HFL during the previous monsoon should be reported to the Divisional Engineer. 11. Flood records at important bridges. a) It should be ensured that the following flood records are maintained as detailed in para 710 and as specified for each bridge. i) soundings around piers and abutments during and after high floods' ii) gauge readings of flood level during monsoon, iii) observations of afflux and velocity during monsoon' iv) cross sections of river during and after floods, v) survey of the river course after monsoon, vi) cross section of guide banks/protection works and aprons, vii) annual survey of scour holes. b) It should be checked whether River and Flood Registers are being maintained for large alluvial and other specified rivers and kept upto date. 12. Precautions against damage by fire : It should be ensured : a) That the precautions against damage by fire are adequate. b) That the sand bins on long girders are kept filled. 13. Equipment of watchman : To check up: a) Whether the watchman posted at bridge site is having the necessary equipment as envisaged in Para 705 and whether they are in satisfactory condition. b) Whether the watchman's knowledge of rules is satisfactory. INDIAN RAILWAYS BRIDGE MANUAL 198 CHAPTER - 11  INSPECTION OF BRIGES 14. Road over/under bridges: a) Road over bridges : They should be inspected : i) to ascertain whether the structures are on sound condition, ii) to check the vertical clearance available is as per schedule of dimensions, iii) to check the thickness of road way to ensure that the dead load on the bridge does not exceed the maximum permissible, iv) to ascertain as to whether in electrified areas, safety or protective screens of approved designs (side claddings) are provided for the ROBs/FOBs, v) to examine the condition and adequacy of smoke guards, vi) to examine the condition of the deck slab for spalling or deterioration of concrete, vii) to check the condition of any waterproofing or any preservative treatment given to concrete deck, viii) to check whether at the expansion joints provided, adequate gap is available for the joint to function and for looseness and vertical displacement of one part of the deck relative to the adjoining part, ix) whether speed breakers have been provided on either side of weak Road Over Bridge and where speed restriction is imposed for vehicular traffic. b) Road under bridges: i) to check up whether height gauges are provided, ii) to check up whether the bottom of girders have been covered by suitable and approved means to prevent droppings, falling from passing trains on road users. 15. Concrete bridges : a) The condition of bed blocks and bearings, wherever provided should be checked, items of inspection being the same as for steel girders. E 7KHFDPEHURISUHVWUHVVHGFRQFUHWHJLUGHUVKRXOGEHFKHFNHGE\ %5, ZLWKLQ RQH \HDU RI LQVWDOODWLRQ DQG RQFH LQ  \HDUV DIWHUZDUGV E\ E\ DQ\UHOLDEOHPHWKRGDQGUHFRUGHGLQ$QQH[XUHD2QHPHWKRG INDIAN RAILWAYS BRIDGE MANUAL 199 CHAPTER - 11 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c)i) The surface of concrete should be checked by a magnifying glass for any cracks. ii) The location, width and length of crack, type of crack (longitudinal/transverse/horizontal/vertical/diagonal) whether it is active or dormant and its behaviour under live load should be carefully noted and documented. Sketches, preferably photographs should be included. The observation of earlier inspection should be compared for the purpose of determining whether the crack is developing or otherwise. Efforts should be made to determine the probable cause of the cracks. iii) While inspecting one should look for diagonal cracks in the web of main girders near the support, flexural (vertical) cracks especially in the area of tension steel, cracks near the bearings and longitudinal cracks at supports of slabs or beam near junction of main girder with deck slab and at the diaphragms. d) While checking the PSC girders for cracks particular attention should be paid to the bearing area, end blocks, anchorage zone, support of main girders, web near girder ends, diaphragms, junction (interface) of diaphragms with web and at junction of main girder with deck slab. e) It should be checked whether sufficient depth of ballastcushion exists under the track sleepers. The deck slab should be examined after clearing the ballast for any signs of cracking/disintegration and to see whether there is dampness and whether drainage arrangement is functioning. INDIAN RAILWAYS BRIDGE MANUAL 200 CHAPTER - 11  INSPECTION OF BRIGES It should also be checked as to whether water proof layer, if provided is intact. f) It should be examined whether rust streaks / stain marks are visible parallel to reinforcement; spalling and presence of rust streaks are indicators of corrosion. g) It should be checked whether there is spalling, caused by separation of the concrete from the reinforcement. In such cases it should be ascertained as to whether the steel is corroded by exposing the reinforcement. The location, depth and area/size of spalling should be noted. h) It should be examined whether there is scaling, i.e. the gradual and continuing loss of surface mortar and aggregate over an area. Location, area involved and character of scaling should be recorded. j) It should be checked whether there are signs of disintegration of concrete due to poor workmanship, weathering action, attack by chemicals, etc. k) Seepage, leakage and efflorescence should be looked for. 16. Health Monitoring of Very Important Bridges: Health monitoring of very important bridge should be done periodically by an independent agency. Health monitoring will include corrosion monitoring, deterioration of material, system damage, retrofitting, etc. The periodicity of health monitoring is recommended as given below. Aggressive Other than environment Aggressive (Extreme, Very environment (Mild severe & Severe) and Moderate) First Survey 5th year 5th year Subsequent At 5 years At 10 years interval suveys interval interval 6SHFLDO,QVSHFWLRQ'XULQJ0RQVRRQ 1 During floods and/or during spells of heavy rain the Assistant Engineer, Permanent Way Inspector /Inspector of Works should inspect by trolley, foot-plate of the engine or other means the bridges and allied works as frequently as necessary. INDIAN RAILWAYS BRIDGE MANUAL 201 CHAPTER - 11  INSPECTION OF BRIGES 2 Where a strong rush of water and heavy afflux occur, they should look for the presence of eddies and back waters which are signs of danger. When these are observed, soundings with the help of echo sounders or probing with the help of log line with a heavy lead weight, rail piece or probing rod must be taken and if scour is detected, boulders or pitching material should be run out and dumped as necessary. As a precautionary measure, traffic may be suspended if long lengths of track with a large number of bridges experience a flood situation and scour cannot be measured, particularly during night time. (TXLSPHQW5HTXLUHG)RU,QVSHFWLRQRI%ULGJHV The equipment as suggested in Annexure 11/15 may be arranged by the Railways to enable the various officials carry out the inspection of bridges effectively. In the Annexure suggestions have also been made as to the equipment needed at the various levels. The Chief Engineers may add or delete any item from the list based on the site conditions and experience. INDIAN RAILWAYS BRIDGE MANUAL 202 CHAPTER - 11