IRC:112-2020

SECTION 12
SERVICEABILITY LIMIT STATE

12.1 General
(1) In order to verify that the structure and structural elements perform adequately during
service life. The serviceability limit states shall have to be satisfied. The serviceability limit
states are:-
- Stress level
- Crack width
- Deflection
Other limit states such as vibration may be of importance in a particular structure, but are
not covered in this Section.
(2) In calculation of stresses and deflection, the cross-section shall be assumed as uncracked
provided tensile stress in concrete does not exceed fctm or fctm.fl and calculation of minimum
tension reinforcement is also based on the same value of fctm or fctm.fl .Where tensile stresses
exceed fctm or fctm.fl cross-section shall be considered as cracked.

12.2 Stress Limitation

12.2.1 Allowable compressive stress in concrete

(1) Maximum compressive stress in concrete under rare combinations of loads shall be limited
to 0.48 fck, in order to keep the longitudinal cracks, micro cracks or creep within acceptable
limits.
(2) Where compressive stress in concrete under quasi-permanent loads is within 0.36 fcm(t0),
linear creep may be assumed. In case compressive stress exceeds 0.36 fcm(t0), non-linear
creep shall be considered. For stress level in the range of 0.36 fcm(t0) < σc ≤ 0.48fcm(t0), non-
linear creep may be taken into account using the following equation:
φσ (t,t0) = φ (t,t0) exp [1.5 (kσ –0.36)] for 0.36 <kσ≤ 0.48
φσ (t,t0) is the non-linear creep coefficient.
φ (t,t0) is the linear creep coefficient.
c
k 
fcm  to  is the strength ratio.
12.2.2 Allowable tensile stress in steel
In order to avoid inelastic strain and undesirable cracking/deformation of structure, maximum tensile
stress (taking due account of long term creep of concrete) in the reinforcement shall be limited to 0.8
fyk under rare combination of loads. For prestressing steel, in order to avoid inelastic strain, limits
prescribed in Clause 7.9.2 shall be adhered to.

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12.3 Limit State of Cracking

12.3.1 General
Cracking takes place in tensile regions of concrete structures due to load effects, such as bending,
shear, torsion and direct tension. Cracks may also be caused due to internal deformations such as
shrinkage and temperature effects. The intent of the following provisions is to ensure, with acceptable
probability, that the cracks will not impair the proper functioning or durability of the structure or cause
its appearance to be unacceptable. Cracks due to other effects such as expansive chemical reactions
need to be controlled by measures given under Section 14.

12.3.2 Limiting crack width

(1) Due to the random nature of the cracking phenomenon, actual crack width cannot be predicted.
However, a reasonable estimation of crack width can be made using the mathematical
model given in Clause 12.3.4. The crack width, so calculated, shall be restricted to the
values given in Table 12.1 for various conditions of exposure. The decompression limit
check requires that no tensile stresses occur within 100mm of the surface of duct for bonded
prestressing tendons.
This provision of 100 mm is not a cover requirement for prestressing duct, for which
provision has been made in clause 14.3.2.1. In case the duct is closer than 100 mm to
concrete surface the concrete within the cover portion shall be in compression.
Table 12.1 Recommended Values of Wmax

Condition of Exposure As Reinforced members and Prestressed members with

per Clause 14.3.1 prestressed members with un- bonded tendons
bonded tendons
Quasi-permanent load Frequent load combination
combination (mm) (mm)
Moderate 0.3(2) 0.2
Severe 0.3 0.2(3)
Very Severe 0.3 0.2 and decompression(4)
Extreme 0.2 0.2 and decompression(4)
(1) The condition of exposure considered applies to the most severe exposure the surface will be subjected to in service.
(2) For moderate exposure class, crack width has no influence on durability and this limit is set to guarantee acceptable
appearance.
(3) For these conditions of exposure, in addition, decompression should be checked under the quasi-permanent
combination of loads that include DL+ SIDL + Prestress including secondary effect + settlement + temperature
effects.
(4) 0.2 applies to the parts of the member that do not have to be checked for decompression.

(2) For the crack width checks under combinations which include temperature distribution, the
resulting member forces should be calculated using gross section concrete properties. The
effect of self-equilibrating thermal stresses within a section may be ignored.

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(3) For members with only unbonded tendons, requirements for reinforced concrete elements
apply. For members with a combination of bonded and unbonded tendons, requirements for
prestressed concrete members with bonded tendons apply.
(4) Crack width may be calculated according to Clause 12.3.4. Alternatively, limiting maximum
bar size or spacing as per Clause 12.3.6 may be deemed to satisfy crack control criteria for
reinforced concrete members.

12.3.3 Minimum reinforcement for crack control

(1) A minimum amount of untensioned reinforcement is required to control cracking in areas
where tension due to external loadings or external restraints is expected. The amount of such
reinforcement may be estimated from equilibrium between the tensile force in concrete just
before cracking and tensile force in steel at yielding.
(2) Minimum area of reinforcement may be calculated as follows. In profiled cross sections like
T-beams and box girders, minimum reinforcement should be determined for the individual
parts of the section (webs, flanges).
As.min σs=kc k fct, eff Act Eq 12.1
where
As,min is the minimum area of reinforcing steel within the tensile zone
Act is the area of concrete within tensile zone. The tensile zone is that part of the section
which is calculated to be in tension just before formation of the first crack.
In the flanged cross sections such as T-beams and box girders the division into parts should
be as indicated in Fig. 12.1.

fct.eff fct.eff

σc.web

Fig. 12.1 Typical Division of a Flanged Cross-Section for Analysis of Cracking

σs is the absolute value of the maximum stress permitted in the reinforcement

immediately after formation of the crack. This may be taken as the yield strength of
the reinforcement, fyk. A lower value may, however, be needed to satisfy the crack
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width limits according to the maximum bar size or the maximum bar spacing [refer
Clause 12.3.6 (2)].
fct.eff is the mean value of the tensile strength of the concrete effective at the time when the
cracks may first be expected to occur fct.eff = fctm or lower, fctm(t), if the minimum area
of reinforcement is to be calculated for control of cracking earlier than 28 days.
In calculating the minimum reinforcement to cater for shrinkage fct,eff should be taken as the
greater of 2.9 MPa or fctm (t).
k is the coefficient which allows for the effect of non-uniform self equilibrating stresses,
which lead to a reduction of restraint forces
= 1.0 for webs with h < 300 mm or flanges with widths less than 300 mm
= 0.65 for webs with h > 800 mm or flanges with widths greater than 800 mm.
Intermediate values may be interpolated.
kc is a coefficient which takes account of the stress distribution within the section just
prior to cracking and of the change of the lever arm:
For pure tension kc = 1.0
For bending or bending combined with axial forces:
- For rectangular sections and webs of box sections and T-sections:
 c 
kc  0.4 1  1

 k1  h / h * f ct ,eff 
 Eq. 12.2
- For flanges of box sections and T-sections:
Fcr
 kc 0.9  0.5
Act fct ,eff
 Eq. 12.3
Where
σc is the mean stress of the concrete acting on the part of the section under consideration:
N
 c  Ed
bh  Eq. 12.4
NEd is the axial force at the serviceability limit state acting on the part of the cross-section
under consideration (compressive force positive).
NEd should be determined under the relevant combination of actions considering the
characteristic value of prestress and axial forces.
k1 is a coefficient considering the effects of axial forces on the stress distribution:
k1 = 1.5 if NEd is a compressive force
2h *
k1 
3h if NEd is a tensile force
h* =h for h < 1.0 m
h* = 1.0 m for h ≥ 1.0 m
Fcr is the absolute value of the tensile force within the flange just prior to cracking due to
the cracking moment calculated with fct,eff

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(3) Contribution of prestressing steel towards minimum reinforcement for crack control
shall be ignored.
(4) In prestressed members, no minimum reinforcement is required in sections where the
concrete is in compression under the rare combination of loads and the characteristic value
of prestress.
However minimum reinforcement for other considerations such as, early thermal and
shrinkage cracking, prior to application of prestressing, shall be provided as per Section 16.

12.3.4 Calculation of crack width

(1) Crack width varies between the reinforcement bars depending upon the spacing of the bars.
The crack width, Wk, may be calculated from Eq.12.5.
Due account should also be taken of the effects of restrained thermal and shrinkage effects.
Wk = Sr, max (εsm - εcm) Eq 12.5
Where
sr, max is the maximum crack spacing (Refer Eq.12.8, 12.11 or 12.12)
εsm is the mean strain in the reinforcement under the relevant combination of loads,
including the effect of imposed deformations, restrained thermal and shrinkage effects
and taking into account the effects of tension stiffening. For prestressed members
only the additional tensile strain beyond the state of zero strain of the concrete at the
same level is considered
εcm is mean strain in the concrete between cracks
(2) εsm - εcm may be calculated from:
fct .eff
sc  kt
 p.eff
1  e p.eff  sc
 sm  cm  0.6  Eq. 12.6
Es Es
Where
σsc is the stress in the tension reinforcement assuming a cracked section.
α e is the ratio Es/Ecm
ρp,eff = As / Ac,eff Eq 12.7
Ac,eff For rectangular section it is the effective area of concrete in tension surrounding the
reinforcement of depth hcef, where hcef is the lesser of 2.5(h-d);(h-x)/3; or h/2 (refer
Fig. 12.2)
For circular section a thin slice in the plane of bending through diameter having width
equal to spacing of reinforcement bars may be taken and analyzed. Ac,eff , hcef and ρp.eff
shall be calculated for this slice taking d as the effective depth of reinforcement in this
width.
kt is a factor dependent on the duration of the load which may be taken as 0.5.

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Fig. 12.2 Effective Tension Area (Typical Cases)

(3) In situations where spacing of bonded reinforcement within the tension zone is reasonably
close (i.e. ≤ 5(c+φ/2)), the maximum final crack spacing may be calculated from Eq. 12.8.
0.425 k1 k2
Sr.max
 3.4c 
  .eff
 Eq. 12.8
where
φ is the bar diameter. Where bars of different diameters are used in a section, an
equivalent diameter, φeq, should be used. For a section with n1 bars of diameter φ1 and
n2 bars of diameter φ2, the Eq. 12.9 should be used.
n1 12  n2 22
eq 
n11  n22  Eq. 12.9
c is the clear cover to the longitudinal reinforcement. Wherever the clear cover exceeds
50 mm a value of 50 mm shall be used in the calculation.
k1 is a coefficient which takes account of the bond properties of the bonded reinforcement:
= 0.8 for deformed bars
= 1.6 for bars with an effectively plain surface
For epoxy coated bars, the above values shall be increased by 25 percent.
k2 is a coefficient which takes account of the distribution of strain:
= 0.5 for bending
= 1.0 for pure tension
For cases of eccentric tension or local areas, intermediate values of k2 should be used
which may be calculated from Eq. 12.10:

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   
k2  1 2
21  Eq. 12.10
Where ε1 is the greater and ε2 is the lesser tensile strain at the boundaries of the section
considered, assessed on the basis of a cracked section.
For the case of deformed bars associated with pure bending
3.4c  0.17
Sr.max 
  ,eff
 Eq. 12.11
Where the spacing of the bonded reinforcement exceeds 5(c+φ/2) or where there is no
bonded reinforcement within the tension zone, an upper bound limit to the crack width may
be found by assuming maximum crack spacing:
Sr.max= 1.3(h-x)
Eq. 12.12
Where ‘h’ is the effective depth and ‘x’ is depth of neutral axis from the compression face.
(4) Where the angle between the axes of principal stress and the direction of the reinforcement,
for members reinforced in two orthogonal directions ‘y’ & ‘z’, is significant (>15°), then
the crack spacing Sr,max may be calculated from the following expression:
1
Sr ,max 
cos  sin 

Sr ,max. y Sr ,max.z
 Eq. 12.13
Where
θ is the angle between the reinforcement in the y direction and the direction of the
principal tensile stress.
Sr,max,y Sr,max,z are the crack spacings calculated in the y and z directions respectively,
according to Clause 12.3.4 (3).
Note: Where simplified methods of calculating crack width are used they should be based on the
properties given in this Code or substantiated by tests.

12.3.5 Control of shear cracks within webs

Where it is considered necessary to check shear cracking, particularly for prestressed
members, the reinforcement required for crack control can be determined as follows:
(1) The directionally dependent concrete tensile strength fctb within the webs should be
calculated from:
  
fctb 1  0.8 3  fctk ,0.05
 fck 
 Eq. 12.14
where
fctb is the concrete tensile strength prior to cracking in a biaxial state of stress in webs.
σ3 is the larger compressive principal stress, taken as positive.
σ3 < 0.6 fck

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fctk.0.05 is lower characteristic tensile strength (Table 6.5)
(2) The larger tensile principal stress in the web σ1 is compared with the corresponding strength
fctb obtained from Eq. 12.14.
If σ1 < fctb , the minimum reinforcement in accordance with Clause 12.3.3 should be provided
in the longitudinal direction.
If σ1 ≥ fctb, the crack width should be controlled in accordance with Clause 12.3.6 or
alternatively calculated and verified in accordance with Clause 12.3.4 taking into account
the angle of deviation between the principal stress and reinforcement directions.

12.3.6 Control of cracking without direct calculation

(1) The rules given in Section 12.3.4 may be presented in tabular form by restricting the bar
diameter or spacing as a simplification.
(2) Table 12.2 gives maximum bar diameter subjected to different stress levels of steel under
relevant combination of load for which crack width is to be controlled. Table 12.3 gives the
maximum spacing of bars in mm for two crack widths for similar condition.
(3) The values in the tables are based on the following assumptions:
c=40mm; fct.eff =2.8 MPa; hcr = 0.5; (h-d) = 0.1h; k1=0.8; k2=0.5; kt=0.5 and k=1.0
(4) Where the minimum reinforcement given by Clause 12.3.3 is provided, crack widths are
unlikely to be excessive if:
- for cracking dominantly caused by restraint, the bar sizes given in Table 12.2 are not
exceeded where the steel stress is the value obtained immediately after cracking (i.e
σs in Eq. 12.1).
- for cracks caused mainly by loading, either the provisions of Table 12.2 or Table
12.3 shall be complied with. The steel stress should be calculated on the basis of a
cracked section under the relevant combination of actions.
(5) For pre-tensioned concrete, where crack control is mainly provided by tendons with direct
bond, Table 12.2 or Table 12.3 may be used with a stress equal to the total stress minus
prestress.
(6) For post-tensioned concrete, where crack control is provided mainly by untensioned
reinforcement, the tables may be used with the stress in this reinforcement calculated with
the effect of prestressing forces included.

Table 12.2 Maximum Bar Diameters φs for Crack Control

Steel stress [MPa] Maximum bar size [mm]
Wk = 0.3 mm Wk = 0.2 mm
160 32 25
200 25 16
240 16 12
280 12 -
320 10 -

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Table 12.3 Maximum Bar Spacing for Crack Control

Steel stress [MPa] Maximum bar spacing [mm]

Wk = 0.3 mm Wk = 0.2 mm
160 300 200
200 250 150
240 200 100
280 150 50
320 100 -
Note: Table 12.2 and 12.3 are applicable for circular section also.
(7) It should be noted that there are particular risks of large cracks occurring in locations where
there are sudden changes of stress, e.g.
- at changes of section
- near concentrated loads
- at positions where bars are curtailed
- at areas of high bond stress, particularly at the ends of laps
Care should be taken at such locations to minimize the stress changes wherever possible.
However, the rules for crack control given above will normally ensure adequate control
at these points provided that the rules for detailing reinforcement given in Section 16 are
complied with.

12.4 Limit State of Deflection

12.4.1 General
Cable supported bridges are not in the purview of this Code, for which specialist literature may be
followed.
(1) The deflections/deformations of a member or structure shall not be such that it adversely
affects its proper functioning or appearance. In some cases, expected deflections may need
to be adjusted in the structural geometry by pre-cambering, so as to attain the requisite
profile at the time of placing expansion joints and wearing course.
(2) Appropriate limiting values of deflection taking into account the nature of the structure,
bridge deck furniture and functional needs of the bridge, should be established. In the
absence of other criteria, the following deflection limits for live load under frequent load
combination may be considered.
Vehicular : Span/800,
Vehicular and pedestrian or pedestrian alone : Span/1000,
Vehicular on cantilever : Cantilever Span/300, and
Vehicular & pedestrian and pedestrian only on : Cantilever Span/375
cantilever arms

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Mn Cr+Mo+V Ni+Cu
C.E=C+ + + shall not be more than 0.53 percent, when microalloys/low alloys
6 5 15
are used. When microalloys/low alloys are not used, carbon equivalent using the formula:
Mn
C.E C 
6
shall not be more than 0.42 percent.
Reinforcement bars/wires with carbon equivalent above 0.42 percent should, however
be welded with precaution. Use of low hydrogen basic coated electrodes with matching
strength bars/wires is recommended.
(3) Welding shall conform to IS 2751 and IS 9417 except as provided herein.
(4) Generally, shop welding in controlled conditions is to be preferred, where feasible. Site
welding where necessary shall, however, be permitted when the facilities, equipment,
process, consumables, operators, welding procedure are adequate to produce and maintain
uniform quality at par with that attainable in shop welding to the satisfaction of the engineer.
(5) Welding may be carried out by metal arc welding process. Oxyacetylene welding shall not
be permitted. Any other process may be used subject to the approval of the engineer and
necessary additional requirements to ensure satisfactory joint performance. Precautions on
over heating, choice of electrode, selection of correct current in arc welding etc., should be
strictly observed.
(6) All bars shall be butt welded except for smaller diameter bars with diameter of less than 20
mm which may be lap welded. Single-V or Double-V butt joints may generally be used. For
vertical bars single bevel or double bevel butt joints may be used.
(7) Welded joints shall be located well away from bends and not less than twice the bar diameter
away from a bend.
(8) Joint welding procedures which are to be employed shall invariably be established by
a procedure specification and shall be qualified prior to use by tests as prescribed in IS
2751. All welders and welding operators to be employed shall have to be qualified by tests
prescribed in IS 2751. Inspection of welds shall conform to IS 822 and destructive or non-
destructive testing may be undertaken when deemed necessary. Joints with weld defects
detected by visual inspection or dimensional inspection shall not be accepted.

15.2.5.3 Splicing by mechanical devices

(1) Bars may be spliced with mechanical devices, e.g. by special grade steel sleeves swaged on
to the bars in end to end contact or by threaded couplers. A mechanical splice including its
connecting elements shall develop, in tension or compression, at least 125 per cent of the
characteristic strength fy.
(a) For established systems the design shall be based on manufacturer’s test certificate
of ultimate strength with appropriate safety factor to be selected by the designer. In
addition, field testing on selected samples from actual supply at site shall be carried
out, both for acceptance and as quality control tool.
(b) For new systems acceptance testing shall be carried out in laboratories. In addition,
field testing on selected samples from actual supply at site shall be carried out, both
for acceptance and as quality control tool.

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(2) At location of mechanical splices reduction in minimum cover may be accepted but should
not be less than 30 mm.

15.2.6 
Additional rules for high yield steel deformed (HYSD) bars exceeding 32 mm in diameter

15.2.6.1 General
(1) The rules given below are complementary to those given in Clause 15.2.3.
(2) Splicing by lapped joints shall not be used either for tension or compression bars.
(3) Bars of φ>32 mm shall be used only in elements whose minimum depth is not less than 15
times, the diameter of the bar.
(4) When large bars are used, adequate crack control shall be ensured either by using
surface reinforcement as per Clause 16.3.4(3), or by calculation as per Section 12.
(5) Splitting forces are higher and dowel action is greater with the use of large diameter bars.
Such bars should be anchored with mechanical devices. As an alternative they may be
anchored as straight bars, but links should be provided as confining reinforcement.
(6) Generally large diameter bars should not be lapped. Exceptions include sections with a
minimum dimension 1.0 m or where the stress in steel is not greater than 80 percent of the
design ultimate strength.
(7) Transverse reinforcement, additional to that for shear, should be provided in the anchorage
zones where transverse compression is not present.
(8) For straight anchorage lengths (see Fig. 15.6 for the notation used) the additional
reinforcement referred to in (7) above should not be less than the following:
- in the direction parallel to the tension face:
Ash = 0.25 As.n1 Eq. 15.4
- in the direction perpendicular to the tension face:
Asv = 0.25 As.n2 Eq. 15.5
where
AS is the cross sectional area of an anchored bar,
n1 is the number of layers with bars anchored at the same point in the member
n2 is the number of bars anchored in each layer.
(9) The additional transverse reinforcement should be uniformly distributed in the anchorage
zone and the spacing of bars should not exceed 150 mm.
(10) For surface reinforcement provisions of Section (16.5.4) applies.
The area of surface reinforcement should not be less than 0.01 Act, eff where Act,eff is the area
of cover portion outside the stirrups/links.

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Fig.15.6 Additional Reinforcement in an Anchorage for

Large Diameter Bars where there is no Transverse Compression

15.2.7 Bundled high strength deformed bars

15.2.7.1 General
(1) Bundle of same Types of Bars
Unless otherwise stated, the rules for individual bars also apply for bundles of bars. In a
bundle, all the bars shall be of the same characteristics, type and grade, and preferably of
same dia. Bars of different diameters can be bundled provided the ratio of diameters does
not exceed 1.7.
(2) Equivalent Diameter
In design, the bundle is replaced by a notional bar having the same sectional area and the
same centre of gravity as the bundle.
The ‘equivalent diameter’ φn of this notional bar is such that:
n  nb  55mm
  Eq. 15.6
where nb is the number of bars in the bundle, which is limited to:
- Four for vertical bars in compression and for bars in a lapped joint for lap length
portion.
- Three for all other cases.
(3) Use of Equivalent Diameter
For a bundle, provision of Section 15.2.1 applies using the equivalent diameter φn, in
place of φ. Where two touching bars are positioned one above the other, and where bond
conditions are favourable, such bars need not be treated as a bundle.
(4) Minimum Concrete Cover and Spacing of Bar
The equivalent diameter φn, is taken into account in evaluation of the minimum cover and

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spacing between bundles. However, the minimum cover and spacing are measured from the
actual outside contour of the bundle of bars.

15.2.7.2 Anchorage of bundled bars

(1) Bundles of bars in tension may be curtailed over end and intermediate supports. Bundles
with an equivalent diameter of less than 32 mm may be curtailed near a support without the
need for staggering bars. Bundles with an equivalent diameter of equal to or more than 32
mm which are anchored near a support should be staggered in the longitudinal direction as
shown in Fig. 15.7.
(2) For bars anchored with widely spaced anchor points (E) [Fig. 15.7], the diameter of the
individual bar may be used in assessing lo.

lo lo lo

Widely Spaced Cut-off Points (E) spaced at >1.3 lo.

Fig. 15.7 Anchorage of Bundles of Bars

(3) For compression anchorages, bundled bars need not be staggered. For bundles with an
equivalent diameter ≥32 mm, at least four links having a diameter of ≥12 mm should be
provided at the ends of the bundle within distance of 0.33 lo. One number of further link
should be provided just beyond the end of the curtailed bar.

Fig. 15.8 Lap Joint in Tension including a Fourth Bar

15.2.7.3 Lapping of bundled bars

(1) The lap length should be calculated in accordance with Clause 15.2.7.1 using equivalent
diameter of bar.
(2) Bundles which consist of two bars with an equivalent diameter<32 mm may be lapped
without staggering individual bars. In this case the equivalent bar diameter should be used
to calculate lo.
(3) For bundles which consist of two bars with an equivalent diameter of ≥32 mm, or of three
bars, individual bars should be staggered in the longitudinal direction by at least 1.3 lo. For

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this case the diameter of a single bar may be used to calculate lo. Care should be taken to
ensure that there are not more than four bars in any lap cross section.

15.3 Prestressing Units

15.3.1 Arrangement of the prestressing tendons/cable ducts
15.3.1.1 General
(1) The spacing of cable-ducts or pre-tensioned tendons shall be such as to ensure that placing
and compacting of the concrete can be carried out satisfactorily and good bond can be
attained between the concrete and tendons/ducts.
(2) In case of post tensioned bonded cables, bundles of more than two ducts are not permitted.
A pair of ducts placed horizontally or vertically touching each other may be permitted only
in the straight portion of the cable subject to limitations given below and Fig. 15.9.
- Two cables can be grouped horizontally provided each duct diameter is not more than
50 mm.
- Two cables can be grouped vertically provided each duct diameter is not more than
110 mm.
- Two cables shall not be bundled over the curved length of cable in the plane of
curvature.
- In case of precast segmental construction, grouping of cables is not permitted. The
minimum clear distance between the ducts shall be greater of 100 mm or the outer
diameter of the duct.
(3) In case of post tensioned bonded cables, the minimum horizontal and vertical clear spacing
of cables as given in Fig. 15.9 shall be followed for major lengths of the cables.
These requirements can be relaxed locally near transition lengths of the cable, provided the
minimum clear spacing between the adjacent cables along the line joining the centers of
two cables is maintained as Min [φduct or 50 mm].

15.3.1.2 Concrete cover

The concrete cover between the inner surface of the formwork and either a pre-tensioned tendon or a
duct shall be fixed with due regard to the size of the tendons or of the duct, as well as the durability
requirements. Minimum cover for pre-tensioned tendons shall be not less than the maximum of the
diameter of tendon, nominal aggregate size plus 10 mm, and durability requirement as per Clause
14.3.2.1. The minimum cover for post tensioned ducts shall not be less than 75 mm. Local reduction in
cover at externally jointed locations of ducts is acceptable.

15.3.1.3 Horizontal and vertical spacing between cables ducts/tendons

1) Post Tensioning
The minimum clear spacing between individual ducts :
- Between single ducts vertical spacing; ≥ φduct or 50 mm

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- Between pair of ducts & next pair ≥ φduct or 50 mm or single duct;
where φduct denotes the outer diameter of the duct (local reduction in spacing at externally jointed
locations of ducts is acceptable).

dg+10mm
Ø
50mm

dg+10mm
Ø
50mm
dg+10mm
Ø
50mm

Note: Where φ is the diameter of post-tension duct and dg is the maximum size of aggregate
Fig. 15.9 Minimum Clear Spacing between Ducts

(2) Unbonded Embedded Cables

Spacing and cover requirements for embedded but unbonded post tensioned tendons are the
same as those for bonded cables.
(3) Pre-Tensioning
The minimum clear horizontal and vertical spacing of individual tendons is given in Fig.
15.10.

Note: Where φ is the diameter of pre-tensioned tendon and dg is the maximum size of Aggregate
Fig. 15.10 Minimum Clear Spacing between Pre-tensioned Tendons

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15.3.1.4 Cable spacing for thin sections and curved portions of cables
Refer Clause 7.10 for special checks and additional recommendations.

15.3.2 Anchorages and couplers for prestressing tendons

15.3.2.1 Post-tensioning systems

(1) The anchorage devices used for post-tensioned tendons and the anchorage lengths in the
case of pre-tensioned tendons shall be such as to enable the full design strength of the
tendons to be developed.
(2) Anchorages for post-tensioned tendons shall meet the requirements of Clause 13.2. The
specification 13.2.4 are mandatory for new systems. For the established systems, the client/
owner may at his discretion ask for fresh tests to verify the suitability of the system.
(3) Where couplers are used, these shall be so placed that they do not adversely affect the
load carrying capacity of the member and that any temporary anchorage which may be
needed during construction can be introduced in a satisfactory manner. The requirements
of minimum concrete cover over couplers and reinforcement for bursting and spalling shall
be as per the specifications of manufacturers and should be subjected to acceptance tests
similar to those covered in 13.2.4 for anchorages.
(4) In general, couplers should be located away from intermediate supports.
(5) The use of couplers for more than on 50 percent of the tendons at any cross-section should
be avoided.
The distance between any two successive sections at which cables are coupled should not
be closer than 1.5 m. for structural members where depth is less than 2.0 m and not closer
than 3.0 m. for members of depth greater than 2.0 m.
(6) If tendons are anchored at a construction joint or within a concrete member (whether on
an external rib, within a pocket or entirely inside the member), it should be checked that
a minimum residual compressive stress of at least 3 MPa is present in the direction of the
anchored prestressing force, under the frequent load combination. If the minimum residual
stress is not present, reinforcement should be provided to cater for the local tension beyond
terminated tendon near the anchor. The check for residual stress is not required if the tendon
is coupled at the anchorage considered.
(7) Anchorage of tendons in top surface of deck shall not be permitted.
(8) For tendons anchored in the deck slab and soffit slab, local thickening or blisters shall be so
provided that minimum cover to anchorage shall not be less than 200 mm.

15.3.2.2 Pre-tensioning systems

(1) Anchorage of pre-tensioned tendons In anchorage regions for pre-tensioned tendons, the
following length parameters should be considered, Refer Fig. 15.11.
(a) Transmission length lpt over which the prestressing force (Po) is fully transmitted to
the concrete.
(b) Dispersion length, ldisp over which the concrete stresses gradually disperse to a linear

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distribution across the concrete section, is as per Eq. 15.11
(c) Anchorage length, lbpd , over which the tendon force Fpd in the ultimate limit state is
fully anchored in the concrete; see Section 15.3.2.2(3) (d).

ldisp σpd
σpt

lpt
lpt lbpd
ldtsp

Fig. 15.11 Transfer of Prestress in Pre-tensioned Elements; Length Parameters

(2) Transfer of Prestress

(a) At release of tendons, the prestress may be assumed to be transferred to the concrete
by a constant bond stress fbpt
where:
fbpt = ηp1 η1 fctd(t) Eq. 15.7
where
ηp1 = is a coefficient that takes into account the type of tendon and the bond situation at
release.
ηp1 = 2.7 for indented wires
ηp1 = 3.2 for 3 and 7-wire stands.
η1 = 1.0 for good bond conditions.
= 0.7 otherwise.
fctd(t) = is the design tensile strength at time of release 't' (Refer Clause 6.4.2.3), taken as 0.7
fctm(t) / γc
Note: Values of ηp1 for types of tendons other than those given above may be obtained by actual testing.
(b) The basic value of the transmission length lpt is given by:
1 2 pm.o
lpt 
fbpt  Eq. 15.8
Where
α 1 = 1.0 for gradual release
= 1.25 for sudden release
α 2 = 0.25 for tendons with circular cross section
= 0.19 for 3 and 7-wire strands
φ = is the nominal diameter of tendon

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σpm.o = is the tendon stress just after release
(c) The design value of the-transmission length should be taken depending on the design
situation, given in Eq. 15.9 and 15.10.
lpt,1 = 0.8lpt Eq. 15.9
OR
lpt, 2 = l.2lpt Eq. 15.10
Note: The lower value is used for verifications of local stresses at release, the higher value for ultimate limit states
(shear, anchorage etc.).
(d) Concrete stresses may be assumed to have a linear distribution outside the dispersion
length.
2 2
ldisp
 l pt  d (Refer Fig. 15.11) Eq. 15.11
(e) Alternative build-up of prestress may be assumed, if adequately justified and if the
transmission length is modified accordingly.
(3) Anchorage of Tensile Force for the Ultimate Limit State
(a) The anchorage of tendons should be checked in sections where the concrete tensile
stress exceeds fctk,0.05. The tendon force should be calculated for a cracked section,
including the effect of shear according to Section 10.3.3.3(6). Where the concrete
tensile stress is less than fctk,0.05 no anchorage check is necessary.
(b) The bond strength for anchorage in the ultimate limit state is:
fbpd = ηp2 η1 fctd Eq. 15.12
where
ηp2 is a coefficient that takes into account the type of tendon and the bond situation
at anchorage
= 1.4 for indented wires or
= 1.2 for 7-wire strands
η1 is as defined in Eq. 15.7.
(c) Due to increasing brittleness with higher concrete strength, fctk,0.05 should here be
limited to the value for M75.
(d) The total anchorage length for anchoring a tendon with stress σpd is:
lbpd = lpt2 + α2φ (σpd - σpm.∞)/fbpd Eq. 15.13
where
l pt2 is the upper design value of transmission length = 1.2 lpt
α2 as defined in Clause 15.3.2.2 (2)
σpd is the tendon stress corresponding to the force described in (a).
σpm.∞ is the prestress after all losses.
(e) Tendon stresses in the anchorage zone are illustrated in Fig. 15.12.
(f) In case of combination of ordinary and pre-tensioned reinforcement, within the same
zone of concrete the anchorage capacities of each may be separately calculated and
added for design verification.

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Fig. 15.12 Stresses in the Anchorage Zone of Pre-Tensioned Members:

Curve (1) At Release of Tendons, Curve (2) At Ultimate Limit State.

(4) Deviators
(a) A deviator shall satisfy the following requirements:
- Withstand both longitudinal and transverse forces that the tendon applies to it
and transmit these forces to the structure;
- ensure that the radius of curvature of the prestressing tendon does not cause any
overstressing or damage to it.
(b) In the deviation zones the tubes forming the sheaths shall be able to sustain the radial
pressure and longitudinal movement of the prestressing tendon, without damage and
without impairing its proper functioning.
(c) The radius of curvature of the tendon in a deviation zone shall not be less than 40
times the diameter of wire/strand.
(d) Designed tendon deviations up to an angle of 0.01 radians may be permitted without
using a deviator. The forces developed by the change of angle shall be considered in
design.

15.4 Coated Steels

For coated steel, the bond is affected by coating system and the details of manufacture. The following
values may be used:
(1) For fusion bonded epoxy coated high strength deformed steel (HSD) and prestresssing
tendons, bond values given in previous Sections shall be reduced by 20 percent, and
anchorage and lap lengths increased by 25 percent.
The factor of 0.7 for reduction of above modified lap length to account for hooks and
bends, shall remain unchanged.
(2) For galvanised and stainless steel, the bond is to be taken the same as for non-galvanised
steel.

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SECTION 16
DETAILING REQUIREMENTS OF STRUCTURAL MEMBERS

16.1 General
(1) Detailing requirements given below are in addition to those given in Section 15.
(2) Minimum areas of reinforcement are given in order to prevent a brittle failure, wide cracks
and also to resist forces arising from restrained actions.
(3) In addition to the detailing of reinforcement and prestressing steel, the dimensional
restrictions on various types of elements are also covered.

16.2 Columns of Solid Section

16.2.1 Sectional dimensions

(1) These Clauses deal with columns of any cross-sectional shape for which the larger dimension
of solid concrete section is not greater than 4 times the smaller dimension of the concrete
section.
(2) For purpose of this Section, columns are classified in two types (i) Pedestal columns and
(ii) Other columns.
Pedestal columns are defined as those columns for which ratio of length/least radius of
gyration is less than 12.

16.2.2 Longitudinal reinforcement

(1) Longitudinal reinforcement for pedestal columns shall not be less than 0.15 percent of
cross-sectional area of concrete.
(2) For other columns, bar diameter shall not be less than 12 mm and spacing measured along
periphery of column, not more than 200 mm.
(3) For other columns, the minimum cross-sectional area of total longitudinal reinforcement
As.min should be derived from the following condition:
0.10 N ED
As.min  or 0.002Ac which ever is greater,
f yd

where
fyd is the design yield strength of the reinforcement,
NEd is the design axial compression force.
Ac is the gross cross-sectional area of concrete.
(4) The maximum cross-sectional area of reinforcement, outside lap portion shall not be more
than 0.04 Ac. At lap section, it shall not be greater than 0.08 Ac.
(5) The longitudinal bars should be distributed around the periphery of the section. For columns
of circular cross-section the minimum number of bars is six. For columns having a regular

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polygonal cross section or having two adjacent surfaces meeting at any angle, at least one
bar shall be placed near the junction of the two surfaces.

16.2.3 Transverse reinforcement

Concrete columns shall have transverse reinforcement to hold the longitudinal reinforcement in place
and avoid its buckling. The transverse reinforcement shall be in the form of lateral ties (polygonal
links), circular rings, helix and open ties, used singly or in combination as required.
(1) Helical reinforcement intended for making use of increased load capacity by confinement
of concrete, shall satisfy requirements in (i) & (ii) in addition to other requirements given
in (2) to (9).
(i) The end of helical reinforcement consisting of evenly spaced helical turns shall be
properly anchored. The splicing of the helical turns shall be made by welding or by a
lap of one and a half turns.
(ii) The pitch of the helical turns shall not be more than 75 mm nor more than one sixth
the diameter of the core of the column.
(2) The diameter of the transverse reinforcement shall not be less than 8 mm or one quarter of
the maximum diameter of the longitudinal bar, whichever is greater.
(3) The transverse reinforcement shall be adequately anchored.
(4) The spacing of the transverse reinforcement along the column axis shall not exceed the
lesser of the following:
- 12 times the minimum diameter of the longitudinal bars,
- the least dimension of the column,
- 200 mm
(5) At location of laps, the transverse reinforcement shall satisfy requirements of Clause
15.2.5.1.(3).
(6) Where the direction of the longitudinal bar changes (e.g. at changes in column size), the
spacing of transverse reinforcement should be calculated, taking account of the lateral
forces involved. These effects may be ignored if the change of direction is less than or
equal to 1 in 12.
(7) At the location of change in dimension of concrete section (e.g. flaring of section) transverse
reinforcement should be provided to balance internal transverse tensile stresses in concrete.
(8) Every longitudinal bar (or group of longitudinal bars) placed at a corner should be held
in two directions by transverse reinforcement. The included angle between these two
directions should not be more than 135 degrees.
(9) A maximum of 3 bars on one face and not more than 5 bars on two faces meeting at each
corner including the corner bar, can be secured against buckling by any one set of transverse
reinforcement. The distance of the farthest bar thus supported from the corner of column
shall not be more than 150 mm.
(10) No bar within a compression zone should be further than 150 mm from a restrained bar.

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16.3 R.C. Walls and Wall Type Piers
(1) These clauses deal with reinforced concrete walls of which the larger dimension measured
horizontally is more than four times the smaller dimension.
(2) The amount and proper detailing of reinforcement may be derived from FEM analysis or
strut-and-tie model within the dispersal zone of concentrated loads. For walls subjected to
predominantly out of plane bending, the rules of slab apply if they are more severe.

16.3.1 Vertical reinforcement

(1) The diameter of bar should not be less than 12 mm.
(2) The total area of the vertical reinforcement should be between 0.0024Ac and 0.04Ac outside
the locations of laps of vertical steel.
(3) This reinforcement should be provided at two faces taking into account the direct axial
force and biaxial bending, but shall not be less than 0.0012 Ac on either face.
(4) The distance between two adjacent vertical bars shall not exceed 200 mm.

16.3.2 Horizontal reinforcement

(1) Horizontal reinforcement running parallel to the faces of the wall should be provided and
arranged at each surface between the vertical reinforcement and the nearest surface. The
area of total horizontal reinforcement should not be less than 25 percent of the area of total
vertical reinforcement or 0.001Ac whichever is greater.
(2) The spacing between two adjacent horizontal bars shall not be more than 300 mm.
(3) The diameter shall not be less than one quarter of that of the largest diameter of vertical
bars, nor less than 8 mm.

16.3.3 Transverse reinforcement

If the area of the load carrying vertical reinforcement in two faces exceeds 0.02 Ac this reinforcement
should be enclosed by stirrups in accordance with Clause 16.2.3 for columns.

16.4 Hollow Piers/Columns

Hollow piers/columns shall satisfy all of the following conditions:
(1) The largest overall dimension is not greater than four times the smallest overall dimension.
(2) The height is such that the ratio of effective length to radius of gyration is not less than 12.
(3) The two ends are capped by solid structural members of sufficient thickness to ensure
that for unit as a whole, the plane sections remain plane under action of axial load and
bending. A solid reinforced concrete slab, having thickness not less than one-third the size
of clear inside dimension of the hollow section in the direction of spanning of the slab and
integrally connected to the walls of the hollow pier/column, may be considered to fulfil the
requirement.
(4) The wall thickness shall not be less than 300 mm.

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16.4.1 Detailing rules IRC:112-2011
(1) For wall type pier of non-circular hollow section with length less than four times the width,
the rules for solid columns stipulated in Clause 16.2 will apply.
(2) For wall type pier of non-circular of hollow section with length more than 4 times the
width, the rules as per Clause 16.3 will apply.

16.5 Beams

16.5.1 Longitudinal reinforcement

16.5.1.1 Minimum and maximum reinforcement percentage
(1) The effective cross-sectional area of the longitudinal tensile reinforcement should be not
less than that required to control cracking (Section 12), nor less than AS.min where,
fctm
As.min  0.26 b d, but not less than 0.0013 btd Eq. 16.1
f yk t
Where
bt denotes the mean width of the tension zone; for a T- beam or L-beam with the flanges in
compression, only the width of the web is taken into account in calculating the value of bt.
fctm should be determined with respect to the relevant strength class.
(2) The cross-sectional areas of the tension reinforcement shall not be greater than 0.025Ac at
sections other than at laps. The total of tension and compression reinforcement shall not
exceed 0.04Ac at a section.

16.5.1.2 Tensile steel in flanged section

The total amount of tensile reinforcement As of a flanged cross-section (e.g. at intermediate supports
of continuous T-beam) may be divided approximately equally over the effective width of the flange
(Refer Fig. 16.1).

Fig. 16.1 Internal and External Parts of a T-Beam

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16.5.1.3 Length of the longitudinal tension reinforcement and anchorage in tension Zone
The curtailment of longitudinal steel and anchorage of the same in tension zone is done as described
below with help of Fig. 16.2.
(1) Fs is the tensile force in the longitudinal reinforcement obtained by a cross-section analysis
according to Sections 8 & 9 including effect of axial force in member, if any.
(2) For members with shear reinforcement the additional tensile force in the longitudinal
reinforcement due to shear shall be provided in the tensile chord and should be calculated
from ∆Ftd = 0.5.VED (Cot θ-Cot α).
M M
The total force zEd  Ftd should be taken not greater than Edz.max where MEd.max is the
maximum moment along the beam.
In the case of prestressed member the spare capacity in the prestressing cable if available
can be used for this requirement.
(3) For members without shear reinforcement ∆Ftd may be estimated by shifting the moment
curve a distance al=d in unfavourable direction according to Clause 10.3.2(6). This ‘shift
rule’ may also be used as an alternative for members with shear reinforcement,
Where

 cot   cot  
aai l z    Eq. 16.2
 2 

where θ is the angle of the concrete strut with the longitudinal axis for the shear reinforcement
calculated according to the variable strut inclination method, as per Section 10.
The additional tensile force is illustrated in Fig. 16.2.
(4) The envelope line of the tensile force carried by the longitudinal reinforcement is obtained
by a horizontal displacement ‘al‘ of the envelope line of Fs.
(5) The resistance of bars within their anchorage lengths may be taken into account, assuming
a linear variation of force as shown in Fig. 16.2. As a simplification this contribution may
be ignored.
(6) For reinforcement in the flange, placed outside the web al should be further increased by
the distance equal to the distance of the bar from the web. (distance x1, x2 in Fig. 16.1).
(7) Curtailed reinforcement should be effectively anchored beyond point where it is no longer
required. The anchorage length (lα) should not be less than larger of distance ‘d’ or lb.net
where ‘d’ is the effective depth of member and lb.net is calculated as per Eq. 15.2 of Section
15.
(8) The diagram of the resisting tensile forces should lie outside the envelope line of the acting
tensile force, displaced as described.
(9) The anchorage lengths of bent-up bars which contribute to the resistance to shear should be
not less than 1.3 lb.net when anchored in the tension zone and 0.7 lb.net when anchored in the
compression zone.

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Ftd

Fig. 16.2 Curtailment of longitudinal reinforcement

16.5.1.4 Anchorage of span reinforcement at an end support

(1) Over supports with little or no end fixity it is necessary to retain not less than one-quarter
of the maximum reinforcement in the span.
(2) The anchorage of the reinforcement should be capable of resisting a tensile force of:
1
Fs VEd .  N Ed
d  Eq. 16.3
Where NEd denotes the design axial force taken by the steel, and VEd as defined in Section
10, and a1 as defined in Clause 16.5.1.3. NEd is taken as positive if it is tensile and negative
if it is compressive.
(3) (a) For a direct support [Refer Fig. 16.3(a)] the anchorage length is measured from the
2
line of contact between the beam and its support. It should be minimum as lb,net .
3
(b) For an indirect support [Refer Fig. 16.3(b)] lb,net is taken from distance from the
face of support, where w is total width of the support with lb,net taken according to Eq.
15.2 of Section 15.

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Fig. 16.3 Anchorage End Supports

16.5.1.5 Anchorage of span reinforcement at intermediate supports

(1) Amount of span reinforcement (steel for sagging moment) carried upto and over intermediate
support should not be less than one quarter of steel present in span.
(2) Anchorage should have a length of not less than 10 φ for straight bars or not less than the
diameter of the mandrel for hooks and bends, as shown in Fig. 16.4.

Fig. 16.4 Anchorage at Intermediate Supports

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16.5.2 Shear reinforcement
(1) The shear reinforcement should form an angle of 45° to 90° with the longitudinal axis of
the structural element.
(2) The shear reinforcement may consist of a combination of
(a) Links enclosing the longitudinal tensile reinforcement as well as the compression
zone of concrete,
(b) Bent-up bars;
(c) Shear assemblies in the form of cages, ladders etc. of HYSD bars which do not enclose
the longitudinal reinforcement, but are properly anchored both in the compression
and tension zones.
(3) At least 50 percent of the necessary shear reinforcement should be in the form of links.
(4) Links should be effectively anchored. A lap joint may be allowed in web only for high yield
strength deformed bars.
(5) The shear reinforcement ratio is given by Eq. 16.4
ASW
w 
 s.bw .sin    Eq. 16.4
The minimum value ρw.min for ρw is as given by:

 w.min 
 0.072 fck 
f yk
 Eq. 16.5
In above equations:
ρw = is the shear reinforcement ratio.
Asw = is the area of shear reinforcement within lengths.
s = is the spacing of the shear reinforcement, measured along longitudinal axis of the
member.
bw = is the minimum breadth of the web of the member.
α = is the angle between the shear reinforcement and the longitudinal axis (i.e. for
vertical stirrups α = 90° and sin α = 1).
(6) The minimum clear distance between vertical legs of shear reinforcement should be largest
of :
• dg + 10 mm
• 40 mm
• 2φ of shear Reinforcement.
(7) The maximum longitudinal spacing sl.max of successive series of stirrups or shear assemblies
should not exceed sl.max , where,
sl.max =0.75d (1+ cot α) Eq, 16.6
(8) The maximum longitudinal spacing of bent-up bars should not exceed sb.max where,

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Fig. 16.10 Edge Sliding Mechanism

16.12 Forces Associated with Change in Direction

IRC:112-2011
At points where considerable changes in the direction of the internal forces occur in concrete, reinforcing
steel or prestressing steel, the associated forces in direction normal to the same shall be resisted by
means of suitably anchored additional reinforcement. Refer Clause 7.10.1 for requirements of curved
tendons.

16.13 Indirect Supports

(1) In the case of a connection between a supporting beam and a supported beam, ‘suspension’
reinforcement designed to resist the total reaction from supported beam, shall be provided
in addition to shear reinforcement.
(2) The suspension reinforcement should consist preferably of links surrounding the principal
reinforcement of the supporting member. Some of these links may be distributed outside
the volume of concrete which is common to the two beams, as indicated in Fig. 16.11.

Fig. 16.11 Extent of the Inter-Section Zone (in Plan) for the
Connection of Secondary Beams

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16.14 Anchorage Zones for Post Tensioning Forces
Anchorage zone is defined as the zone within which the concentrated forces of post tensioned anchorages
disperse and spread over the full section of the prestressed structural element.
For the design and amount of reinforcement for the full section and for the local effects, refer Section
13. This reinforcement should be detailed to meet requirements of Clause 13.5 as well as to satisfy the
following rules. Extra reinforcement over and above the calculated amount as per Clause 13.5 shall be
provided, if needed, to satisfy these rules.
(1) Anchorage zones should always be provided with distributed reinforcement near all surfaces
in the form of an orthogonal mesh.
(2) Where groups of post-tensioned cables are located at a certain distance from each other,
suitable links should be arranged at the ends of the members, as a protection against splitting
away of groups.
(3) All reinforcement should be fully anchored.
(4) Where a strut and tie model has been used to determine the transverse tensile force, the
following detailing rules shall be followed:
(a) The steel area actually required to provide the tie force, acting at its design strength,
shall be distributed in accordance with the actual tensile stress distribution, i.e. over
a length of the block approximately equal to its greatest lateral dimension.
(b) Closed stirrups should be used for anchorage of ties.

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SECTION 17
DUCTILE DETAILING FOR SEISMIC RESISTANCE

17.1 General
(1) Ductile detailing shall be carried out for bridges located in zones III, IV and V of seismic
zone map of IRC:6, if they are designed for Response reduction factor R>1.0
(2) The rules of this Section apply to bridges designed for ductile behaviour for improving
their seismic resistance and aim to ensure a minimum level of curvature/rotation ductility
at the plastic hinges. These are supplementary to the rules given in Sections 15 & 16 which
remain applicable, unless specifically modified in this Section.
(3) In general, plastic hinge formation is not allowed in the superstructure. Therefore there is
no need for application of detailing rules of this Section for the superstructure.
(4) Bridge foundation system shall be designed, as far as practicable, to remain elastic under
design seismic action and foundations shall not be intentionally used as a means of energy
dissipation through phenomenon of hysteresis.
(5) The bridge shall be proportioned and detailed in such a manner that plastic hinges can
occur only at pre-determined locations and not at any other locations.
(6) Where longitudinal reinforcement is curtailed potential of formation of hinge shall be
avoided just beyond the point of curtailment. Not more than 1/3 of longitudinal reinforcement
available at the section shall be curtailed.

17.2 Concrete Piers/Columns

17.2.1 Confinement
17.2.1.1 General requirements
(1) Within the potential plastic hinge regions, ductile behaviour of the compression zone of
concrete shall be ensured by providing confinement of concrete.
(2) Confinement is implemented through rectangular hoops and/or cross-ties or through circular
hoops or spirals.
(3) In potential hinge regions where the normalised axial force ηk exceeds the limit,
N ED
nk  0.064, Eq. 17.1
Ac fck
confinement of the compression zone in accordance with Clause 17.2.1.4 shall be provided.
(4) The required quantity of confining reinforcement expressed as ratio ωwd is calculated as per
Eq. 17.2 and shall satisfy the requirements of Clause 17.2.1.2:
 w . f yd
wd 
fcd  Eq. 17.2
where
(a) In rectangular sections:
ρw is the volumetric ratio of transverse reinforcement defined as:

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A
 w  sw
S L .b  Eq. 17.3
where
A sw = is the area of the stirrups and ties in one direction of confinement.
SL = is the spacing of hoops or ties in the longitudinal direction
b = is the dimension of the concrete core perpendicular to the direction of the
confinement under consideration, measured to the outside of the perimeter hoop.
(b) In circular sections:
Volumetric ratio ρw of the hoops/spiral reinforcement relative to the concrete core is
given by Eq. 17.4:
4 Asp
w 
D .S
sp L  Eq. 17.4
where
Asp is the area of the spiral or hoop bar
Dsp is the diameter of the spiral or hoop
SL is the spacing of these bars
Note: Bars inclined at an angle a to the transverse direction shall be assumed to contribute to the
total area Asw or Asp in Eq. 17.3 by their area multiplied by (cos α)

17.2.1.2 Minimum confining reinforcement

(1) Confinement is provided by use of rectangular loops and/or cross ties for rectangular
sections or through circular hoops or spirals for circular sections.
(2) For rectangular stirrups and cross-ties, the minimum design confining reinforcement is the
greater of two values given in Eq.17.5.
The minimum reinforcement condition shall be satisfied in both directions.
wd  max .req ;0.12
 Eq. 17.5
AC f yd
w.req 0.37 k  0.13   L  0.01
ACC fcd  Eq. 17.6
where
Ac is the area of the gross concrete section;
ACC is the confined (core) concrete area of the section within the outside dia of hoop.
ηk Normalised axial force (Clause 17.2.1.1);
ρL is the reinforcement ratio of the longitudinal reinforcement.
(3) Interlocking spirals/hoops are quite efficient for confining approximately rectangular
sections. The distance between the centres of interlocking spirals/hoops shall not exceed
0.6Dsp where Dsp is the diameter of the spiral/hoop (Refer Fig. 17.1).

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Fig. 17.1 Typical Confinement Detail in Concrete Piers

Using Interlocking Spirals/Hoops

(4) For circular sections, the minimum confining reinforcement provided by hoops/spiral is
determined as the higher of two values given in Eq. 17.7
ωwd.c ≥ max (1.4ωw.req; 0.18) Eq. 17.7
(5) When rectangular hoops and cross-ties are used, the minimum reinforcement condition
shall be satisfied in both transverse directions

17.2.1.3 Spacing of ties/hoops/spirals

(1) The spacing of hoops or ties in the longitudinal direction, SL shall satisfy both of the
following conditions:
SL ≤ 5 times the diameter of smallest longitudinal bar.
SL ≤ 1/5 of the smallest dimension of confined concrete core for rectangular section or
1/5th of the diameter of confined core of concrete for circular section, both
measured upto hoop centre line.
(2) For rectangular section, the transverse distance sT between hoop legs or supplementary
cross-ties, shall not exceed 1/3 of the smallest dimension of the concrete core or 200 mm
whichever is less (Refer Fig. 17.2).

17.2.1.4 Extent of Confinement - Length of Potential Plastic Hinges

(1) When the design length Lh of potential plastic hinges shall be estimated as
the larger of the following two values:
- the depth of the pier section within the plane of bending (perpendicular to the axis of
rotation of the hinge);
- the distance from the point of maximum design moment to the point where the design
moment is 80 percent of the value of the maximum moment.
(2) When 0.48 ≥ ηk > 0.24 the design length of the potential plastic hinges as determined in (1)
shall be increased by 50 percent.
(3) The design length of plastic hinges (Lh) estimated above should be used exclusively for
detailing the reinforcement of the plastic hinge. It should not be used for estimating the

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plastic hinge rotation.

A: 4 closed overlapping stirrups

B: 3 closed overlapping stirrups plus cross-ties
C: closed overlapping stirrups plus cross-ties
Fig. 17.2 Typical Confinement Details in Concrete Piers with Rectangular Section using Overlapping
Rectangular Stirrups and Cross-Ties

(4) When confinement is required, the reinforcement specified in Clause 17.2.1.2 shall be
provided over the entire length of the plastic hinge. Outside the length of the hinge, the
transverse reinforcement may be gradually reduced to that required by other criteria. The
amount of transverse reinforcement provided over an additional length Lh adjacent to
the theoretical end of the plastic hinge, shall not be less than 50 percent of the confining
reinforcement required in the region of plastic hinge.

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(5) The confinement shall extend at least upto the length where the value of the compressive
strain exceeds 0.5 εcu2.

17.2.2 Buckling of longitudinal compression reinforcement

(1) Buckling of longitudinal reinforcement shall be avoided along the length of the potential
hinge areas, even after several hysterics cycles in post-yield region of stress-strain diagram
of steel.
To meet this requirement all main longitudinal bars should be restrained against out
ward bucking by transverse reinforcement (hoops or crossties for rectangular section and
though circular hoops or spirals for circular section) perpendicular to the longitudinal bars
at a (longitudinal) spacing SL not exceeding five times dbL, the diameter of the smallest
longitudinal bars.
(2) Along straight section boundaries, restraining of longitudinal bars should be achieved in
either one of the following ways:
(a) Through a perimeter tie engaged by intermediate cross-ties at alternate locations of
longitudinal bars, at transverse (horizontal) spacing St not exceeding 200 mm. The
cross-ties shall have 135° hooks at one end, and 135º or 90º bend at the other end.
Bends of 90º are not permitted if ηk is greater than 0.24. Cross ties having 135º on
both ends may consist of two lapped spliced pieces. In sections of large dimensions
the perimeter tie may be spliced using appropriate lapping length combined with
hooks; or
(b) Through overlapping closed ties arranged so that every corner bar and at least every
alternate internal longitudinal bar is engaged by a tie leg. The transverse (horizontal)
spacing of the tie legs should not exceed 200 mm.
(c) The minimum amount of transverse ties shall be determined as follows:
{ }= (mm2/m)
 Eq. 17.8
where
Al is the area of one tie leg, in mm2.
SL is the spacing of the legs along the axis of the member, in m;
ΣAS is the sum of the areas of the longitudinal bars in outer layer restrained by tie at
any one end, in mm2;
fyt is the yield strength of the tie; and
fys is the yield strength of the longitudinal reinforcement.
(d) The steel As shall be determined for different situations for Al as follows:

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As for determining Al = 0.5 As1 + As2 + 0.5 As3

As for determining Al1 = 0.5 As1 + As2

Al2 = As3

When Al is at any inclination to the transverse outer tie, then the As shall be divided
by the Sine of the angle between the outer transverse tie and this tie, e.g. in case Al is
inclined at 45 degrees to the outer tie, then As shall be divided by Sin 45, hence As =
√2 x (0.5 As1 + As2 + 0.5 As3)
(3) Along Circular section boundaries, restraining of longitudinal bars should be achieved
through circular ties determined by :
(mm2/m)
 Eq. 17.9
where
Al is the area of one circular tie, in mm2.
SL is the spacing of the circular tie along the axis of the member, in m;
ρl is the reinforcement ratio of the longitudinal steel;
D is the Diameter of the Circular section in mm
fyt is the yield strength of the tie; and
fys is the yield strength of the longitudinal reinforcement.

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17.2.3 Other rules
(1) Due to the possibility of loss of concrete cover in the plastic hinge region, the confining
reinforcement shall be anchored by 135° hooks around a longitudinal bar. Where 90º bend
is used as per Clasue 17.2.2(2), the bar shall extend by minimum 10 diameters into the core
concrete.
(2) Similar anchoring or a full strength weld is required for the lapping of spirals or hoops
within potential plastic hinge regions. In this case laps of successive spirals or hoops, when
located along the perimeter of the member, should be staggered.
(3) Splicing by lapping or welding of longitudinal reinforcement is not allowed within the
plastic hinge region.
(4) The confinement steel and buckling preventing reinforcement shall not be added together.
(5) The buckling prevention and confinement steel may be provided through a set of hoops or
single leg cross ties. The hoops shall engage the longitudinal bars only, while single leg
ties shall engage both the longitudinal bars and the transverse hoops in the manner shown
below at the 135 Degree bent hook. Such ties need not comply with cover requirements at
such engagement locations.

17.2.4 Hollow piers

(1) The ratio of the clear width b to the thickness h of the walls, in the plastic hinge region
(length Lh in accordance with Clause 17.2.1.4) of hollow piers with a single or multiple box
cross-section, should not exceed 8.
(2) For hollow cylindrical piers the ratio of clear inside diameter, to thickness of wall shall not
exceed 8.
(3) In piers with simple or multiple box section and when the value of the ratio ηk does not
exceed 0.16, there is no need for verification of the confining reinforcement in accordance
with Clause 17.2.1, provided that the requirements of controlling buckling of longitudinal
bars given in Clause 17.2.2 are met.

17.3 Foundations

17.3.1 General
Spread foundations (such as footings, rafts), wells, box-type caissons, etc. shall not enter the plastic
range under the design seismic action and hence do not require any special ductile detailing of
reinforcement.

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17.3.2 Pile foundations
(1) When it is not feasible to avoid localised hinge formation in the piles by designing pier to
form hinges earlier (capacity protection method), integrity and ductile behaviour of piles
shall be ensured as given below.
(2) The following locations along the pile should be treated as potential plastic hinges.
(a) At the pile heads adjacent to the pile cap, when the rotation of the pile cap about a
horizontal axis transverse to the seismic action is restrained by the large stiffness of
the pile group.
(b) At location of maximum bending moment in piles taking into account soil-pile
interaction, using appropriate stiffnesses of both pile, pile cap and soil.
(c) At the interfaces of soil layers with markedly different shear deformability (e.g.
change of strata).
(3) At location of type 2(a), confining reinforcement of the amount specified in Clause 17.2.1.1
along a vertical length equal to 3 times the pile diameter, shall be provided.
(4) Unless a more accurate analysis is made, longitudinal as well as confining reinforcement
of the same amount as that required at the pile head, shall be provided over a length of two
pile diameters on each side of the point of maximum moment at location of type 2(b) and
of each side of the interface at locations of type 2(c).

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SECTION 18

MATERIALS, QUALITY CONTROL AND WORKMANSHIP

18.1 General
This Section gives specifications of materials to be used in construction of new concrete bridges and
standards to which they should conform. For new construction, the Indian Standards, referred below or
any specific international standards governing these materials, shall be the latest revisions thereof. The
tables and notes below table given in this Section are reproduced for ready reference from the relevant
IS Codes listed in Annexure A-3.
For assessment of properties of materials in existing bridges, the standards in force at the time of their
construction or the actual standards used for procurement, shall be referred to. The time dependency of
properties shall also be taken into account in such cases.

18.2 Untensioned Steel

18.2.1 Specification and grades

Reinforcement shall consist of hot rolled, thermo-mechanical or heat-treated rods, de-coiled rods, or
cold worked steel conforming to relevant Indian Standards. The main definitive properties and grades
are given in Table 18.1. Steel conforming to any other international standard may be used provided
its strength, elongation, chemical composition and bond in concrete, are not inferior to those of Indian
Standards. The grade designations are as adopted by the relevant standards.
The minimum strength, as specified in relevant BIS Standards, which is either the yield strength in
case of mild steel or 0.2 percent proof strength in case of high yield steel is notionally taken as the
characteristic strength fyk.

18.2.2 Other characteristics

Other important characteristics such as bendability (established by bend and re-bend test), weldability
(established by equivalent carbon content) and bond characteristics in concrete should be as specified
in IS:432 and IS:1786.
The dimensional tolerances and characteristics of ribs for HSD steel should be as per IS:432 and
IS:1786.

18.2.3 Products with improved corrosion resistance

Reinforcing steel bars with corrosion resistance improved by any of the following methods, can be used
as untensioned reinforcement, provided they meet the minimum strength, proof stress and elongation
characteristics as specified for untensioned reinforcement.

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Table 18.1 Reinforcing Steel

Relevant BIS
Type of Steel

Yield Stress/

proof stress/
0.2% proof-

actual 0.2%
Designation

but not less

as % of the

yield stress
Minimum

elongation
Minimum

stress ƒyk
Standard

Strength,

Min. %
Grade /

Tensile

than
Bars upto & including
IS:432 410 MPa 23
20mm dia. = 250 MPa
Mild Steel Grade-I (Part-1)-
1982 20mm ≤dia 50mm
410 MPa 23
240 Mpa
110% (not less than
Fe 415 14.5
485MPa)
IS:1786 415 MPa 112% (not less than
Fe 415D 18.0
500MPa)
Fe 415S ≥ 125% 20.0
108% (not less than
Fe 500 12.0
545MPa)
High Strength
IS:1786 500 MPa 110% (not less than
Deformed Steel Fe 500D 16.0
565MPa)
(HSD Steel)
Fe 500S ≥ 125% 18.0
106% (not less than
Fe 550 10.0
585MPa)
IS:1786 550 MPa
108% (not less than
Fe 550D 14.5
600MPa)
106% (not less than
Fe 600 IS:1786 600 MPa 10.0
660MPa)

Note:
1. Elongation on a gauge length of 5.65√A, where A is the cross-sectional area of the test
piece, when tested in accordance with IS:1608.
2. For seismic zones III, IV & V, HSD steel bars having minimum elongation of 14.5% and
conforming to other requirements of IS:1786 shall be used.
3. For seismic zones III, IV and V, HSD steel bars shall possess following properties:
a. The actual 0.2% proof strength of steel bars based on tensile test must not exceed
their characteristic 0.2% proof strength by more than 20 percent.
b. The ratio of the actual ultimate strength to the actual 0.2 percent proof strength/yield
strength shall be at least 1.15.

18.2.3.1 Galvanised reinforcement

Galvanising of reinforcing steel is achieved by hot dipping process in which steel reinforcement is
dipped in a bath of molten zinc at about 450°C and cooled in a controlled manner. The coating is
chromate treated to avoid reaction between zinc and fresh cement paste. The requirements of coating
are as per IS 12594-1988. In this process, zinc is chemically bonded with steel surface in layers with
varying percentage of zinc contents, from maximum of 100 percent (i.e. free) zinc as the outermost

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layer, to a minimum 72-79 percent of zinc as the innermost layer above the base steel. These layers
increase the corrosion resistance of steel.
The strength as well as elongation and bond properties are not adversely affected by galvanising.

18.2.3.2 Epoxy-coated reinforcement

Reinforcing bars conforming to IS 1786 can be coated by fusion bonded epoxy conforming to IS
13620-1993.
The fusion-bonded epoxy coating forms a continuous layer (free of holidays) which has high electrical
resistance and prevents setting up of corrosion cells between steel and the surrounding electrolytic
micro-environment of moist concrete. It also provides physical barrier between steel and the harmful
elements from environmental sources, controlling their rate of penetration. On the other hand, the
discontinuities in the barrier (holidays) have the tendency to concentrate the corrosion currents in
these areas, leading to faster localised corrosion. The overall effect of coating is, however, beneficial in
increasing the corrosion resistance of the structure, provided the occurrence of holidays is controlled.
The bond between reinforcement and concrete is lowered by upto 20 percent of the bond without such
coating. In detailing of steel, the lap lengths and anchorage lengths shall be increased by 25 percent.

18.2.3.3 Stainless steel reinforcement

Stainless steel reinforcement shall conform to IS:16651.
Properties of stainless steel reinforcement shall not be inferior to those of carbon steel reinforcement
of corresponding strength class.

18.3 Prestressing Steel

18.3.1 Specification and grades

Prestressing steel in the form of plain or indented wires, stress-relieved multi-ply strands, or high
tensile steel bars, shall conform to standards given in Table 18.2 subject to the stipulations given in
Clause 18.3.2.

Table 18.2 Types of Prestressing Steel

Type BIS Standard

Plain Cold Drawn Stress-relieved Wire IS:1785 (Part-I)
Indented hard-drawn stress-relieved wires IS: 6003
Stress relieved multi-ply strands of normal relaxation IS: 6006
Stress-relieved multi-ply strands of low relaxation IS:14268
High Tensile Steel Bars IS: 2090

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18.3.2 Nomenclature, grade designation, strength, elongation and relaxation
The following grades of steel having characteristics as mentioned in Table 18.3 to 18.5, are permitted
for use in bridges designed for normal life.
For other bridges mentioned in Clause 5.8.1 wires/strands having smaller diameters than those given in
the Tables, but otherwise meeting the requirements of Indian Standards mentioned therein, can be used.

Table 18.3 Hard Drawn Stress Relieved Wires

Diameter, mm Minimum Tensile Minimum Elongation

strength, MPa at fracture, %
Plain Wires 4 1715 3.0
5 1570 4.0
7 1470 4.0
8 1375 4.0
Indented Wires 4 1715 3.0
5 1570 4.0
Notes:
(1) Percent elongation is measured on 200 mm gauge length.
(2) The 1000 hour relaxation tested at initial load of 0.7 UTS at 20°C shall not be more than 5 percent of 0.7
UTS.
(3) For plain wires of 5 mm, 7 mm and 8 mm, higher minimum strengths of 1715 MPa, 1570 MPa & 1470 MPa
respectively, may also be manufactured as per IS:1785 (Part-1).
(4) For acceptance of test results from a lot, a value calculated as (arithmetic mean minus 0.6 of the range of
test results) shall be more than the minimum strength and elongation specified as per IS 1785.
(5) 0.2 percent proof stress shall not be less than 85 percent of minimum tensile strength.

Table 18.4 Stress Relieved Strands

Class Designation Nominal Normal relaxation Low relaxation

area, mm2 Breaking 0.2% Proof Breaking 0.2% Proof
Load, kN Load, kN Load, kN Load, kN
I 11.1 mm 7 ply 70.0 124.54 105.86 120.1 108.00
12.7 mm 7 ply 92.9 166.18 139.6 160.1 144.1
15.2 mm 7 ply 139.0 226.86 192.83 240.2 216.2
II 11.1 mm 7 ply 74.2 137.89 117.21 137.9 124.1
12.7 mm 7 ply 98.8 183.71 156.11 183.7 165.3
15.2 mm 7 ply 140.0 261.44 222.23 260.7 234.6
Notes:
(1) Elongation measured just before fracture of any of the constituent wires on gauge length of 600 mm, shall
not be less than 3.5 percent.
(2) The 1000 hour relaxation value shall not be more than 5 percent and 2.5 percent of 0.7 UTS for normal and
low relaxation steel respectively, tested at 0.7 UTS and 20°C.

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(3) For acceptance, all samples tested from a batch shall meet requirement of minimum breaking load and
proof load as per IS 6006 and IS 14268.

Table 18.5 High Tensile Bars

Sizes in mm Minimum Specified Tensile Minimum 0.2% proof

Strength strength

10, 12, 16, 20, 22, 25, 28, 32. 980 MPa 80% of specified tensile
strength

Notes:
(1) Elongation at failure shall not be less than 10 percent measured on gauge length of 5.65 √A where A is the
area of cross-section of steel bar.
(2) The 1000 hour relaxation when tested at 70 percent of UTS shall not be more than 49 N/mm2.
(3) For acceptance of test results from a lot, a value calculated as arithmetic mean minus 0.6 of the range of test
results shall be more than the minimum strength and elongation specified as per IS 2090.
(4) 0.2 percent proof stress shall not be less than 85 percent of minimum tensile strength.

18.3.3 Other properties

18.3.3.1 Ductility
The requirements of ductility at fracture are deemed to be satisfied by use of steel having the minimum
elongations specified in Clause 18.3.2.
The wires/strands shall pass the bendability test (reverse bending test) as specified in relevant Indian
Standards.

18.3.3.2 Tolerance on size/diameter

The relevant Indian Standards specify the manufacturing tolerances on diameters/size of various
products, which remain valid for general acceptance of the material and for qualifying the source of
supply.

18.3.4 Coated wires/strands

The wires/strands conforming to Indian Standards can be provided with protective coatings,
like galvanising or epoxy coating, carried out in specialised manufacturing units. However, if the
technological processes affect any of the mechanical and physical properties, such modified properties
should be taken into account in design.

18.4 Material Ingredients of Concrete

The concrete shall be prepared by using ingredients given in this Clause.

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18.4.1 Cement
The cement shall be any of the following. The selected type should be appropriate for the intended use.

Type BIS Standard

(a) Ordinary Portland Cement 33 Grade conforming to IS 269
(b) Ordinary Portland Cement 43 Grade conforming to IS 269
(c) Ordinary Portland Cement 53 Grade conforming to IS 269
(d) Rapid Hardening Portland Cement conforming to IS 8041
(e) Sulphate Resistant Portland Cement conforming to IS 12330
(f) Portland Pozzolana Cement conforming to IS 1489 (Part-I)
(g) Portland Blast Furnace Slag Cement conforming to IS 455
(h) Low Heat Portland Cement conforming to IS 12600

If any other cement conforming to other International Standards is used, it shall be corresponding to
one of the types listed above and shall meet the minimum specifications of the Indian Standards.

18.4.2 Chemical admixtures

Chemical admixtures and superplasticisers conforming to IS:9103 may be used. Compatibility of the
superplasticiser with the cement and any other pozzolanic or hydraulic additives as covered in Clause
18.4.3 being used, should be ensured by trials, so that the following problems are avoided:
• Large dosage of superplasticiser required to achieve the desired workability,
• Excessive retardation of setting,
• Excessive entrainment of large air bubbles,
• Unusually rapid stiffening of concrete,
• Rapid slump loss, and
• Excessive segregation and bleeding.

18.4.3 Mineral admixtures

The following mineral admixtures may be used in concrete to improve its performance:
(a) Fly ash conforming to Grade-I of IS 3812. The proportion should not be less than 20 percent
nor should exceed 35 percent of the total mass of Ordinary Portland Cement and fly-ash.
(b) Ground Granulated Blast-Furnace Slag (GGBS) conforming to IS 12089. The proportion
should not be less than 50 percent nor should exceed 70 percent of total mass of Ordinary
Portland Cement and GGBS.
(c) Silica fume conforming to IS 15388. Silica fume should be very fine, non-crystalline SiO2,
obtained as a by-product of Silicon or Ferro-Silicon alloy industries.

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18.4.4 Aggregates

18.4.4.1 General
All coarse and fine aggregates shall conform to IS:383 and shall be tested to conform to IS:2386 Parts
I to VIII.

18.4.4.2 Coarse and fine aggregates

(1) Coarse aggregates shall consist of clean, hard, strong, dense, nonporous and durable pieces
of crushed stone, crushed gravel, natural gravel or a suitable combination thereof or other
approved inert material.
(2) The maximum size of the coarse aggregate may be as large as possible within the limits
specified, but in no case greater than (a) one quarter of the minimum thickness of member,
(b) 10 mm less than the minimum lateral clear distance between individual reinforcements
or (c) 10 mm less than the minimum clear cover to any reinforcement.
(3) The preferred nominal size of aggregate is 20 mm for reinforced concrete and prestressed
concrete. However, larger sizes upto 40 mm may be permitted in special cases, when there
is no restriction to flow of concrete in a section.
For plain concrete, preferred nominal sizes may be between 20 mm and 40 mm. However,
larger sizes may be permitted only in special cases, subject to supplemental specifications
and precautions.
(4) Fine aggregates shall consist of hard, strong, durable clean particles of natural sand, crushed
stone or gravel or suitable combination of natural sand and crushed stone or gravel.
(5) The coarse and fine aggregates shall not contain dust, lumps, soft or flaky particles, mica
and other deleterious materials in such quantities as would reduce the strength or durability
of concrete or attack the reinforcement.
(6) Grading of aggregates shall be such as to produce a dense concrete of the specified strength,
which can be worked readily into position without segregation and without the use of
excessive water content.

18.4.5 Water
Water used for mixing and curing shall be clean and free from injurious amounts of oils, acids, alkalis,
salts, sugar, organic materials or other substances that may be deleterious to concrete or steel.
(1) In case of doubt regarding development of strength, the suitability of water for producing
concrete shall be ascertained by the compressive strength and initial setting time tests
specified in (3) & (4).
(2) The sample of water taken for testing shall represent the water proposed to be used for
concreting, due account being paid to seasonal variation. The sample shall not receive any
treatment before testing other than that envisaged in the regular supply of water proposed
for use in concrete. The sample shall be stored in a clean container previously rinsed out
with similar water.

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(3) Average 28 days compressive strength of at least three 150 mm concrete cubes prepared with
water proposed to be used, shall not be less than 90 percent of the average strength of three
similar concrete cubes prepared with distilled water. The cubes shall be prepared, cured and
tested in accordance with the requirements of IS:5l6.
(4) The initial setting time of test block made with the appropriate cement and the water
proposed to be used, shall not be less than 30 minutes and shall not be more than 30
minutes from the initial setting time of control test block prepared with the same cement
and distilled water. The test blocks shall be prepared and tested in accordance with the
requirements of IS 4031 (Part 5).
(5) The pH value of water shall not be less than 6. Potable water is generally considered
satisfactory for mixing concrete. As a guide the following concentrations represent the
maximum permissible values:
(a) To neutralise 100 ml sample of water, using phenolphthalein as an indicator, it should
not require more than 5 ml of 0.02 normal NaOH. The details of test are given in
Clause 8.1 of IS 3025 (Part 22).
(b) To neutralise 100 ml sample of water, using mixed indicator, it should not require
more than 25 ml of 0.02 normal H2SO4. The details of test shall be as given in Clause
8 of IS 3025 (Part 23).
(c) Permissible limits for solids shall be as given in Table 18.6.
Table 18.6 Permissible Limit for Solids

Tested as per Maximum Permissible Limit

Organic IS 3025 (Pt. 18) 200 mg/liter
Inorganic IS 3025 (Pt. 18) 3000 mg/liter
Sulphates (as SO3) IS 3025 (Pt. 28) 400 mg/liter
Chlorides (as Cl–) IS 3025 (Pt. 32) - 2000 mg/liter for concrete work not containing
embedded steel, and - 500 mg/liter for prestressed/
reinforced concrete work
Suspended matter IS 3025 (Pt. 17) 2000 mg/lit.
(6) Mixing or curing of concrete with sea water is not permitted due to presence of harmful
salts in sea water.
(7) Water found satisfactory for mixing is also suitable for curing concrete. However, water used
for curing should not produce any objectionable stain or unsightly deposit on the concrete
surface. The presence of tannic acid or iron compounds in the water, is objectionable.

18.5 Mix Proportions of Concrete

18.5.1 Grade designation

The concrete shall be designated by one of its types as described in Clause 6.4.2 – Ordinary Concrete,
Standard Concrete, or High Performance Concrete and its grade-designation based on characteristic
strength as described in Table 6.8.

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Except ordinary concrete with strength designations of M-15 & M-20, the design mix of standard
concrete and high performance concrete shall be established by laboratory / field testing and controlled
at site by conducting tests to confirm suitability of constituent materials, as per the relevant codes
mentioned in Clause 18.4. The concrete shall meet the acceptance criteria as per Clause 18.6. Mix
design shall be modified if it does not meet the acceptance criteria.

18.5.2 Proportion of ordinary concrete

(1) The proportions of ordinary concrete shall be as per Table 18.7.
(2) Chemical and Mineral admixtures shall not be used for Ordinary Concrete.
Table 18.7 Proportion of Ordinary Concrete

Concrete Total Quantity of dry aggregate by mass Proportion of fine Maximum quantity
Grade per 50 kg of cement to be taken as the sum aggregate to coarse of water per 50kg
of individual masses of fine and coarse aggregate (by mass) of cement (litres)
aggregate (Kg) P.C.C. R.C.C.
M15 350 Generally 1:2, subject 25 -
M20 250 to upper limit 1:1.5 25 22
and lower limit 1:2.5

18.5.3 Requirement of design mixes

(1) Trial Mixes
Trial mixes shall be prepared using sample of approved materials for the initial design.
Additional trial mixes and tests shall be carried out during production in case any changes in the
properties of fresh concrete and/or strength of hardened concrete on the basis of early age tests, are
observed, so as to control and bring the quality of concrete within acceptable limits. In case of any
change in the source of materials, or properties of materials, the design of mix shall be newly established.
(2) Procedure for Design of Mix
Procedures as per any national code or any procedure established by practice for arriving at the suitable
mix design, can be followed. Where earlier experience of concrete made from the selected materials is
available, the same can provide the basis for the start of the mix design.
The target mean strength of concrete shall exceed the specified characteristic strength by at least the
margin (called current margin) taken as 1.645 times the standard deviation of sample test results taken
from at least 30 separate batches of concrete of nominally similar proportions produced at site by the
same plant under similar supervision, over a period exceeding 5 days, but not exceeding one month.
Where sufficient data as above to establish the standard deviation is not available, the current margin
for the initial mix design shall be taken as 10 MPa, (i.e. standard deviation as 6 MPa) for normal and
uniform conditions of quality controls. This initial current margin shall be used only until sufficient
data are available to determine the current margin as described above.

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(3) Mix Design for High Performance Concrete
General: Choice of materials, concrete mix design and field practices are quite critical, so that optimum
performance can be extracted of each of the ingredients. The procedure of mix proportioning of normal
grades of concrete may not be adequate. Relationships between the compressive strength of concrete
and water/cement ratio (or water-cement + cementitious materials ratio, when part of the cement is
replaced by mineral admixtures) and between water content and workability will have to be established
by laboratory trials for the grade of concrete, the materials to be used, and the water-reducing efficiency
of the superplasticiser.
The minimum cement content of concrete, inclusive of any mineral admixtures, shall be not less than
380 kg/m3.
The ratio of water/(all cementitious materials including cement) should generally not exceed 0.33, but
in no case more than 0.40.
Field Trial Mixes: Mix proportions arrived at by laboratory trials shall, in addition, be verified to be
satisfactory under field conditions and necessary adjustments made. Field trial mixes shall be prepared
for all grades of concrete, using samples of approved materials.
The concreting plant and means of transportation employed to make trial mixes and to transport them
to representative distances shall be similar to the corresponding plant and transport to be used in the
works. The optimum sequence of mixing of ingredients shall be established by trials. Mixing time may
be longer than in normal grade concrete mixes.
The temperature of concrete at the time of placement shall not exceed 25°C. The temperature of
concrete at the mixing stage should be lower, to allow for rise in temperature during transport. When
considerable distance of transport is involved, particular attention should be paid to ensure retention of
slump as targeted for placement.
Use of Mock-up Testing: Further mock-up testing may be carried out to ensure that the concrete can
be satisfactorily placed and compacted, taking into account the location of placement and provision
of reinforcement, and adjustments made in concrete mix design and/or detailing of reinforcement
accordingly.

18.5.4 Sampling and testing

(1) General
(a) Samples from fresh concrete shall be taken as per IS 1199 and samples shall be made, cured
and tested at specified number of days in accordance with IS 516. The strength parameters
are based to 28 days strength. Tests at other age shall be performed, if specified.
(b) Where automated batching plant is located away from the place of use or concrete is
supplied from Ready Mixed Concrete (RMC) Plant, and the time gap between production
and placement is more than the initial setting time or where any ingredients are added
subsequent to mixing, separate sets of samples shall be collected and tested at batching
plant and at location of placement. The results shall be compared and used to make suitable

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adjustments at batching plants so that properties of concrete at placement are as per the
requirements.
(c) In order to get a relatively quicker idea of the quality of concrete, optional tests on beams
for modulus of rupture at 72 ± 2 h or at 7 days, or compressive strength tests at 7 days
may be carried out in addition to 28 days compressive strength test. For this purpose,
the acceptable values should be arrived at, based on actual testing. In all the cases, the
equivalent 28 days compressive strength shall be the criterion for the acceptance/rejection
of the concrete.
(d) Additional samples may be required for various purposes such as to determine the strength
of concrete at 7 days or at the time of transfer of prestress or striking the formwork, or to
determine the duration of curing, or to check the testing error. Additional samples may also
be required for testing samples cured by accelerated methods as described in IS 9013. The
specimen shall be tested as described in IS 516.
(2) Test Specimen and Sample Strength
Three test specimens constitute one sample for any type of test at specified age of testing. The average
of these results of three samples constitute the test result of sample provided that the individual variation
is within ±15 percent of average. If variation is larger, the sample shall be discarded.
(3) Frequency of Sampling
The minimum frequency of sampling of concrete of each grade shall be in accordance with Table 18.8.

Table 18.8 Minimum Frequency of Sampling of Concrete

Quantity of Concrete in Work (m3) Number of Samples

1-5 1
6-15 2
16-30 3
31-50 4
51 and above 4 plus one additional sample for each
additional 50 m3 or part thereof.

At least one sample shall be taken from each batch of work. For the purpose of acceptance as per Table
18.8, quantity of concrete represented by a group of four consecutive samples shall include all batches
and single sample shall represent the batch from which it is taken.
Where concrete is provided continuously at site from a batching plant or RMC plant, groups
of four consecutive samples, shall not have overlapping common samples. Irrespective of other
methods of controlling production used at the batching/RMC plant the requirements of this Clause
shall be met.

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18.6 Acceptance Criteria

18.6.1 General
Acceptance or rejection of concrete is mostly based on compressive strength. However, other properties
of the concrete in fresh and hardened states including durability are also important.
Apart from meeting the acceptance criteria given below, concrete is liable to be rejected if it is porous
or honey-combed, its placing has been interrupted without providing a proper construction joint, the
reinforcement has been displaced beyond the tolerances specified, or construction tolerances have
not been met. However, the hardened concrete may be accepted after carrying out suitable remedial
measures.

18.6.2 Compressive strength

When both the following conditions are met, the concrete shall be deemed to comply with the specified
compressive strength:
(a) The mean strength determined from any group of four consecutive non-overlapping samples
shall exceed the specified characteristic compressive strength by 3 MPa.
(b) Strength of any sample is not less than the specified characteristic compressive strength
minus 3 MPa.
Concrete of each grade shall be assessed separately.
If the concrete is deemed not to comply as per the above criteria, the structural adequacy of the bridge
elements affected shall be investigated and any consequential action as needed, shall be taken.

18.6.3 Flexural strength

When both the following conditions are met, the concrete complies with the specified flexural strength:
(a) The mean strength determined from any group of four consecutive non-overlapping samples
exceeds the specified characteristic flexural strength by at least 0.3 MPa.
(b) The strength determined from any sample is not less than the specified characteristic flexural
strength minus 0.3 MPa.

18.6.4 Density of fresh concrete

Where minimum density of fresh concrete is specified, the mean of any four consecutive non-
overlapping samples shall not be less than the specified value and any individual sample result shall
not be less than 97.5 percent of the specified value.

18.6.5 Density of hardened concrete

Where minimum density of hardened concrete is specified, the mean of any four consecutive non-
overlapping samples shall not be less than the specified value and any individual sample result shall
not be less than 97.5 percent of the specified value.

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18.6.6 Chloride content
The chloride content in the concrete can be measured as described in IS 14959 – Part I (for fresh
concrete) or Part II (for hardened concrete). Alternatively it can be calculated, in which case, the
method of calculation shall be based upon the measured chloride-ion contents of all constituents and
the mix proportion of concrete. The chloride-ion content so measured or calculated and expressed
as the percentage of chloride-ion by mass of cement, shall not exceed the value specified in Clause
14.3.2.3.

18.6.7 Durability of concrete

Unlike the tests on concrete described above, there is no specified test method for durability, which
can be completed within a reasonably short time. The requirement of long term durability of concrete
is ‘deemed to be satisfied’ by following the recommended provisions in this Code for maximum
water-cement ratio, minimum cement content, cover thickness, type of cement and amounts of
chlorides and sulphates in concrete etc. All these recommendations taken together tend resulting
concrete being dense, workable, and placeable and having as low permeability as possible under the
given situation.
When durability of concrete is the main reason for adopting high performance concrete, or in other
specific situations, Rapid Chloride Ion Permeability Test (RCPT) as per ASTM C1202 shall be carried
out. Suggested upper limits of values of RCPT for 56 days for various exposure conditions (refer Table
14.1) are:
(1) Extreme 800 Coulombs
(2) Very Severe 1200 Coulombs
(3) Severe 1500 Coulombs
Additional durability tests, such as Water Permeability test as per DIN 1048 Part 5 or Initial Surface
Absorption test as per BS 1881 Part 5 can also be specified. The permissible values in such tests have
to be specified taking into account the severity of the exposure condition. The acceptance criteria shall
be arrived at prior to testing.

18.7 Self-Compacting Concrete

18.7.1 Constituents
In Self-Compacting Concrete, superplasticisers provide the fluidity, and Viscosity Modifying
Admixtures (VMA) are used to help reduce segregation, and sensitivity of the mix due to variations in
other constituents, especially to moisture content. Other materials are as in Clauses 18.4.1 to 18.4.5.
VMA’s are hydrophilic, water-soluble polymers having high molecular weight. Such polymers can
form a network of large molecules extending throughout the mass. The dimensions of the polymers or
particles are in colloidal range; hence these are called ‘colloidal admixtures’. These can also be used
as ‘anti-washout’ admixtures for underwater placement.

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18.7.2 Properties in the Fresh State
The filling ability and stability of self-compacting concrete in the fresh state can be defined by four key
characteristics. Each characteristic can be assessed by one or more test methods (Table 18.9).

Table 18.9. Characteristics of SCC and Tests

Characteristics Preferred Test Method(s) Limit of Test Value
Flowability Slump-flow test 550 – 850 mm
T500 Slump flow test 2 sec
Flowability
V-funnel test 8 – 25 sec
Passing ability L-box test 0.8
Segregation Segregation resistance (sieve) test 15 – 20 per cent
Note: For details of the test methods and limiting test values, as appropriate to placing conditions, amount and
congestion of reinforcement, dimensions of the members, size of aggregate etc., EFNARC Guidelines for
Self-Compacting Concrete, May 2005 may be referred.
Fig. 18.1 gives the dimensions of the test equipment.

Fig. 18.1 (a) Slump Flow Test

Fig. 18 .1 (b) V – Funnel Test

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Fig. 18.1 (c) L Box Test

Fig. 18.1 Test Equipment for SCC

18.7.3 Mix Design

There is no fixed method of mix design for SCC. Mix proportions are to be selected by trials and tests,
till a satisfactory mix is arrived at. EFNARC Guidelines 2005 suggest broad outline, as given below:
• Coarse aggregate content - 750 – 1000 kg per m3 of concrete,
• Total powder content – 380 to 600 kg per m3 of concrete,
• Water/powder ratio by solid volume – 0.85 to 1.10,
• Water content –150 – 210 litres/ m3,
• Paste volume – 300 – 380 litres/ m3,
• Water/cement ratio selected for strength and durability requirements,
• Sand content to balance the remaining volume, usually 48 – 55 % of total aggregate by
weight.

18.8 Grouting

18.8.1 General
Grout is a homogenous mixture of cement and water. It may contain chemical admixtures which
modify the properties of grout in its fluid state. These recommendations cover the cement grouting of
post tensioned tendons of prestressed concrete members of bridges.
The purpose of grouting is to provide permanent protection to the post tensioned steel against corrosion
and to develop bond between the prestressing steel and the surrounding structural concrete. The grout
ensures encasement of steel in an alkaline environment for corrosion protection and by filling the duct
space it prevents water collection and freezing.
A critical feature of grout is that it should remain pumpable for the time required to fully inject the
tendon.

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18.8.2 Materials

(1) Water

Only clean potable water free from impurities conforming to Clause 18.4.5 shall be used. No sea or
creek water is to be used at all.

(2) Cement

The same type of cement as used in construction of prestressed elements, should be used for preparation
of the grout. It should be as fresh as possible and free from any lumps.

(3) Sand

It is not recommended to use sand for grouting of prestressing tendons.

(4) Admixtures

Acceptable admixtures conforming to IS 9103 may be used if tests have shown that their use improves
the properties of grout, i.e. increasing fluidity, reducing bleeding, entraining air or expanding the grout.
Admixtures must not contain chlorides, nitrates, sulphides, sulphites or any other products which are
likely to damage the steel or grout. When an expanding agent is used, the total unrestrained expansion
should not exceed 10 percent. Aluminium powder as an expanding agent is not recommended as doubts
exist about its long term effects.

(5) Ready Mixed grout

Alternatively, the dry materials may be batched in a factory for pre-mixed grout and mixed with the
liquid materials on site as per instructions of the manufacturers.

18.8.3 Use of grout colloidal mixer

It is essential that the grout is maintained in a homogenous state and of uniform consistency so that
there is no separation of cement during the entire grouting process. It is, therefore, necessary that the
grout be continuously mixed in a colloidal mixer with a minimum speed of 1000 RPM and travel of
discharge not exceeding 15 m per second.

18.8.4 Properties of the grout

Before grouting, the properties of the grout mix should be tested. Tests should be conducted for each
job periodically.

(1) Water/cement Ratio

Water/cement ratio should be as low as possible, consistent with workability and should not exceed
0.40.

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(2) Deleterious Materials
No chloride, sulphates shall be separately added to the grout. The constituent may contain chlorides/
sulphates. However, its net effect should not exceed the following limits in the grout:
- Chlorides (Cl-) not more than 0.1 percent by weight of cement.
- Sulphate (SO3) not more than 4 percent by weight of cement.
- Sulphide-ions (S2-) not more than 0.01 percent by weight of cement.
(3) Temperature
The temperature of the grout after accounting for the ambient temperature of the structure, shall not
exceed 25°C.
(4) Compressive Strength
The compressive strength of 100 mm cube of the grout shall not be less than 27 MPa at 7 days or 30
MPa at 28 days. Cubes shall be cured in a moist atmosphere for the first 24 hours and subsequently in
water. These tests shall be conducted in advance to ascertain the suitability of the grout mix. The 7 day
strength is not mandatory if the 28 day strength requirement is met.
(5) Setting Time
Initial setting time of grout shall be more than three hours and less than 12 hours. The final setting time
shall not be less than 24 hours.
(6) Bleeding
Bleeding is the separation of free water from the grout mix. It includes the filtering effect of strands
where the cavities between the wires constituting the strand, block cement particles and permit water
under pressure to move ahead of the grout in the direction of general flow of grout. The bleeding shall
be sufficiently low to prevent excessive segregation and sediment of the grout material. The bleeding
shall not exceed 0.3 percent of volume of the initial volume of grout after three hours kept at rest.
(7) Volume Change
Volume change of the grout at rest for 24 h shall be within the range of - 1 % and + 5 % of the original
volume when tested as per EN 445. It should not be more than +0.2 percent at 28 days.
(8) Fluidity
Fluidity is tested as per EN 445 by a) cone test and b) grout spread test. The time for cone test (as per
Fig 18.2a) shall be less than or equal to 25 seconds. The spread of the grout as per grout spread test (as
per Fig 18.2b) shall be greater than or equal to 140 mm.
For retention of fluidity there shall not be more than 20% reduction in fluidity at 30 minutes when
tested as per EN 445.

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1- Cylinder (steel or plastic tube)

2- Smooth plate
Fig 18.2 (a) – Cone for fluidity test (as per EN 445) Fig 18.2 (b) – Grout spread test (as per EN 445)

(9) Tests for Bleed and Volume Change

Wick Induced Bleed and volume change test shall be as per EN 445. The details of the test are given
in Fig. 18.2 (c).

1- Seal 4- Grout ho- height at to

2- Air 5- Transparent tube ho - height at tn
3 - Water 6- Strand, wires or bar
Fig 18.2 (c) – Wick induced test setup (as per EN 445)

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