Standard Specifications AND Code of Practice FOR Road Bridges

IRC:83 (Part-III)-2018
STANDARD SPECIFICATIONS
AND
CODE OF PRACTICE
FOR
ROAD BRIDGES
SECTION: IX
BEARINGS
PART-III: POT, PIN, METALLIC GUIDE AND
PLANE SLIDING BEARINGS
(First Revision)
Published by
INDIAN ROADS CONGRESS

Kama Koti Marg,
Sector-6, R.K. Puram,
New Delhi-110 022
MAY, 2018
Price Rs. 600/-

(Plus Packing & Postage)
--------------- ---
First Published March,2002

Reprinted December, 2002
Reprinted July, 2006
Reprinted September, 2008
Reprinted January, 2012
Reprinted February, 2016
First Revision May, 2018
(All Rights Reserved. No part of this publication shall be reproduced,

translated or transmitted in any form or by any means without the
permission of the Indian Roads Congress)
Printed by India Offset Press, Delhi- 110064

(500 Copies)
IRG:83 (Part-III)-2018
CONTENTS
S. No. Description Page No.
Personnel of Bridges Specifications and Standards Gommittee .......................................... i-ii
Introduction ............................................................................................................................ 1
1 Scope ........................................................................................................................... 3
2 Terminology .................................................................................................................. 3
3 Symbols and notations ............................................................................................. 10
4 Materials ..................................................................................................................... 13
5 Design ........................................................................................................................ 18
6 Manufacture ............................................................................................................... 42
7 Acceptance specification ........................................................................................... 47
8 Gertification & marking ................................................................................................ 50
9 Installation .................................................................................................................. 50
10 Maintenance .............................................................................................................. 53
Annexure A ......................................................................................................................... 56
Annexure B .......................................................................................................................... 58
Annexure G.......................................................................................................................... 59
Annexure D ......................................................................................................................... 61
Annexure E .......................................................................................................................... 63
Annexure F ......................................................................................................................... 64
Annexure G ........................................................................................................................ 65
PERSONNEL OF THE BRIDGES SPECIFICATIONS

AND STANDARDS COMMITTEE
(as on 23 rd October, 2017)
Kumar, Manoj Director General (Road Development) & Special Secretary to Govt.
(Convenor) of India, Ministry of Road Transport and Highways, New Delhi
2 Singh, B.N. Additional Director General, Ministry of Road Transport & Highways,
(Co-convenor) New Delhi
3 Verma, Dr. S.K. Chief Engineer S&R, Ministry of Road Transport & Highways,
(Member-Secretary ) New Delhi
Members
4 Alam, Pervez Chief Operating Officer, Hindustan Construction Company Ltd.
5 Arora,D.S. Jt. Managing Director (Retd.), UP State Bridge Corporation Ltd.
6 Banerjee, A.K. Member (Technical) (Retd.), National Highway Authority of India
7 Bansal, Shishir Chief Project Manager, Delhi Tourism, DTTDC Ltd.
8 Basa, Ashok Mar,aging Director, CEM Consultant (P) Ltd.
9 Bhowmick, Alok Managing Director, B&S Engineering Consultants Pvt. Ltd., UP
10 Bordoloi, A.C. Commissioner & Spl. Secretary, P.W.B. & N.H. Deptt (Retd.), PWD
Assam
11 Chand, Faqir Advisor, STUP
12 The CMD, (Bakshi, S.P.S.) Engineering Project (India) Ltd., New Delhi
13 The Director General, Border Roads Organization, New Delhi
(Shrivastava, Lt. Gen. S.K)
14 The Director General, Institute for Steel Development & Growth (INSDAG), Kolkata
(Banerjee, Sushim)
15 Dheeraj Superintending Engineer, Ministry of Road Transport and
Highways, New Delhi
16 Dohare, R.D. Chief Engineer (Retd.), Ministry of Road Transport and Highways,
New Delhi
17 The Engineer-in-Chief, Military Engineer Service (MES), New Delhi
(Sharma AVSM, Lt. Gen.
Suresh)
18 Ghoshal, A. Principal Advisor, STUP Consultants (P) Ltd. Kolkata
19 Gupta, Dr. Supratic Asst. Professor, liT, New Delhi
20 Heggade, V.N. Vice President, Gammon Engineers & Contractors, Mumbai
21 Khanna,Shobha Manager, M.P. Metro Rail Corporation
22 Kondai, Bikshapathi Director General, National Academy of Construction, Hyderabad
23 Kumar, Ashwani Superintending Engineer, Ministry of Road Transport and
Highways, New Delhi
24 Kumar, Satander Scientist (Retd.), CRRI
25 Pandey, A.K. Superintending Engineer, Ministry of Road Transport and Highways,
New Delhi
26 Pandey, R.K. Member (Project), National Highway Authority of India (NHAI),

New Delhi
27 Parameswaran, Dr. Lakshmy Chief Scientist (BAS), Central Road Research Institute (CRRI),
New Delhi
28 Patankar, V.L DG(RD)&SS (Retd.), Ministry of Road Transport and Highways,
New Delhi
29 Pateriya, Dr. I.K. Director (Technical), National Rural Road Development Agency,
New Delhi
30 Puri, S.K. DG(RD)&SS (Retd.), Ministry of Road Transport and Highways,
New Delhi
31 Raina, Dr. v.K. Consultant, World Bank
32 Raizada, Pratap S. Senior Vice President, Gammon India Ltd. Mumbai
33 Sharan, G. DG(RD)&SS (Retd.), Ministry of Road Transport and Highways,
New Delhi
34 Sharma, R.S. Managing Director, Mis Sugam Technocrats Pvt. Ltd., New Delhi
35 Shekhar, Saurav Director, SA Infra Consultants Pvt. Ltd.
36 Sinha, N.K. DG(RD)&SS (Retd.), Ministry of Road Transport and Highways,
New Delhi
37 Srivastava, A.K. Chief Engineer, Ministry of Road Transport and Highways,
New Delhi
38 Subbarao, Dr. Chairman & Managing Director, Construma Consultancy (P) Ltd.
Harshavardhan Mumbai
39 Tandon, Prof. Mahesh Managing Director, Tandon Consultants (P) Ltd., New Delhi
40 Verma, G.L. Managing Director, Engineering & Planning Constructions,
New Delhi
Corresponding Members
1 Kand, Sunil C. Director, C.v Kand Consultant, Bhopal
2 Koshi, Ninan DG(RD)&SS (Retd.), Ministry of Road Transport and Highways,
New Delhi
3 Manjure, P.Y. Director, Freyssinet Prestressed Concrete Company Ltd (FPCC), Mumbai
4 Reddi, Dr. S.A. Former JMD, Gammon India Ltd.
5 The Director, CSIR- Structural Engineering Research Centre, T.N.
(Iyer, Prof. Nagesh R)
Ex-Officio Members
1 President, (Pradhan, N.K.)
Indian Roads Congress E-in-C cum Secretary,
Works Department, Odisha
2 Honorary Treasurer, (Kumar, Manoj)
Indian Roads Congress Director General (Road Development) & Spl. Secretary, Ministry of Road
Transport and Highways
3 Secretary General, Nirmal, Sanjay Kumar
Indian Roads Congress
ii
. !
________- -__- =____- - - - - - - -__________________________~I·
1
STANDARD SPECIFICATIONS AND CODE OF

PRACTICE FOR ROAD BRIDGES
SECTION: IX
BEARINGS
PART-III: POT, PIN, METALLIC GUIDE AND
PLANE SLIDING BEARINGS
INTRODUCTION
The Standard Specifications and Code of Practice for Road Bridges, Section IX-POT,
POT-CUM-PTFE, PIN and Metallic Guide Bearings, Part-III based on working stress method
was first published in March, 2002. Thereafter, unprecedented growth of knowledge in the
field of Bridge Bearing Design, Manufacturing & Installation, Acceptance Specifications,
Certification & Marketing and Development of high performance materials took place in the
past 15 years. Hence, a need was f~lt by B-6 committee (2012-2014) to revise this document
based on Ultimate Limit State (ULS) condition and to include Plain sliding bearing. The
reconstituted B-6 Committee in 2015 assigned the task of preparing the initial revised draft to
Shri S. Majumdar and Dr. M.V.B Rao. The revised draft "Standard Specifications and Code of
Practice for Road Bridges, Section IX - Part III - POT, PIN, Metallic Guide and Plane Sliding
Bearings" was circulated among the members of B-6 Committee for inviting comments from
its Members. Members submitted their comments on the circulated draft document to B-6
Committee. The B-6 Committee constituted a Sub-Committee comprising of the following
members to incorporate the comments in the revised draft document appropriately:
(i) Shri A.K. Banerjee, Convener;
(ii) Shri H.C. Arora;
(iii) Shri Alok Bhowmick;
(iv) Col. Ashok Bhasin;
(v) Dr. S.S. Gaharwar.
The Sub-committee finalized the revised draft document and submitted it to B-6 Committee.
The B-6 Committee discussed and approved the document in its meeting held on
15th September, 2017 for placing it in the Bridges Specifications and Standards (BSS)
Committee. The BSS Committee approved the document in its meeting held on 23 rd October,
2017. Subsequently, the Executive Committee approved the document on 2nd November,
2017 for placing it before the IRC Council. Finally, the document was considered by the
IRC Council in its meeting held on 3rd November, 2017 during the Annual Session held at
Bengaluru (Karnataka) and was approved for publication.
1
The Bearings, Joints and Appurtenances Committee (B-6) of the Indian Roads Congress
was constituted in 2015 with the following personnel:
Puri, S.K.
Convenor
Arora, H.C.
Co-Convenor
Gaharwar, Dr. S.S.
Member Secretary
Members
Bagish, Dr. B.P.
Kurian, Jose
Banerjee, A. K.
Majumdar, Santanu
Bhasin, Col. Ashok
MandaI, Anirban
Bhowmick, Alok
Ninan, R.S.
Ghosh, Prof. Achyut
Pandey, R.K.
Gupta, Ujjwal
Rao, Dr. M.V.B.
Gupta, Vinay
Rathore, Jitendra
Indoria, R.p.
Ray, Nilanjan
Khaira, Virender Singh
Sharan, G.
Kumar, Ashok
Sharma, R.S.
Kumar, Manoj
Verma, Sanjeev
Corresponding Members
Manjure, P.Y.
Khanna, Shobha
Kumar, Satander
Deshpande, v.P.
Marwah, M.P.
EX-Officio Members
President, IRC
DG(RD) & SS MORTH
(Pradhan, N.K.)
(Kumar, Manoj)
Secretary General, IRC

(Nirmal, S.K.)
2
1 SCOPE
This section of the specification (referred to as 'code' hereinafter) deals with requirements for
the materials, design, manufacture, testing, installation and maintenance of Pot, Pin, Metallic
Guide and Plane Sliding bearings for road bridges. The provisions of this code are meant
to serve as a guide to both design and construction engineers, but mere compliance with
the provisions stipulated herein will not relieve them in any way of their responsibility for the
stability and soundness of the structure designed and erected.
This part of code specifies the requirements for the design and manufacture of pot bearings
which will be used for operating temperatures between - 20 DC and 50 DC.
Pot bearings with confined elastomeric pressure pads up to 1500 mm diameter are within the
scope of this code.
High performance elastomeric pressure pad in combination with specific internal seal and
sliding material (e.g. UHMWPE) can be used subjected to availability of approval document
from international approving bodies like ETA, FHWA or similar acceptance by other leading
international Specifications.
Bearings which are subjected to tensile loads are beyond the scope of this code.
Bearings which are subjected to rotations greater than 0.03 radians are beyond the scope of
this code.
Sliding surfaces with a diameter of the circumscribing circle of single or multiple PTFE sheets
or other approved sliding materials e.g. UHMWPE approved through ETA, FHWA or similar
acceptance by other leading international Specifications, less than 75 mm or greater than
1500 mm, are outside the scope of this code. Sliding elements for use as temporary devices
during construction, for example during launching of the superstructure, are also outside the
scope of this code.
For demanding application in situations beyond the limitations stated above, specialist
literatures and international codes shall be followed. In such situations, only specialist
manufacturers, having proven experience of designing and supplying similar bearings in
similar situations, shall be engaged.
2 TERMINOLOGY
2.1 Pot Bearing
A bearing consisting of a metal piston supported by a disc of unreinforced elastomer that is

confined within a metal cylinder for allowing rotational movement about any axis in horizontal
plane and to bear and transmit vertical load. Pot bearings may be provided with sliding
assembly (with or without restraint in the form of guide along a desired direction to bear and
transmit horizontal force) comprising of stainless steel plate attached to metal backing plate
,---- ------
____________ I
~l,
!
sliding in horizontal plane over sliding material confined in recess(s) on the piston which shall
be termed as Sliding / Guided Pot bearings. Depending on the desired degree of freedom Pot
bearings may be of three types as follows:
2.1.1 Fixed Pot Bearing:
A type of Pot bearing which along with vertical load, bears and transmits horizontal force in
any direction and allows rotation about any axis in horizontal plane without permitting any
movement in horizontal plane (Fig. 2.1).
Free to rotate about any axis in the horizontal plane
Piston
Ili====t--------- External Seal
-- Internal Seal
---10-:::=------------ Confined Elastomeric
Pressure Pad
L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~======j_------- Cylinder -
Fig. 2.1 Fixed Pot Bearing
2.1.2 Sliding Pot Bearing:
A type of Pot bearing which bears and transmits vertical load and allows movement in any
direction in the horizontal plane and accommodates rotation about any axis in horizontal
plane (Fig. 2.2).
------- -
Free to slide along any direction in the horizontal plane
Sliding Top Plate

Stainless Steel Plate
Wiper Seal
'----;:===::1------ Sliding material
-jt:~~1--------- External Seal
<>-- Piston
- - - f - - - - - - - - - Internal Seal
Confined Elastomeric
Pressure Pad
.-----+---- Cylinder
Fig. 2.2 Sliding Pot Bearing
2.1.3 Guided Pot Bearing:
A type of Pot bearing which along with vertical load bears and transmits horizontal force in
one direction only and allows movement perpendicular to that direction and allows rotation
about any axis in horizontal plane (Fig. 2.3).
4
Sliding restrained along this direction
Sliding Top Plate With

Side Guides
r-r==ifuF;=::::Z=============~==:;:;:::::;;;;;;;=a=Ft--F=='-- Stainless Steel Plate
Wiper Seal
Sliding material
-t:::::::~----- External Seal
-- Piston
Internal Seal
i I - - - - - - t - - - - - - - Confined Elastomeric
Pressure Pad
.------+---------------- Cylinder
a) With Side Guide

1- -I
~=====!=~~~;;;;~
-
___
- - 1 - - - - - Sliding Top Plate

Wiper Seal
Sliding material
External Seal
Piston With Central Guide
;;R-----+------ Internal Seal

Confined Elastomeric
Pressure Pad
Cylinder
b) With Central Guide
Fig. 2.3 Guided Pot Bearing
2.2 Sliding Assembly
A bearing consisting of a sliding assembly (with or without restraint in the form of guide along
a desired direction to bear and transmit horizontal force) comprising of stainless steel plate
attached to a metal backing plate sliding in horizontal plane over sliding material confined in
recess(s) on a fixed plate. Sliding assemblies are capable to bear and transmit vertical load
but are not capable to accommodate rotational movement unless provided with additional
arrangement. Depending on the desired degree of freedom Sliding assemblies may be of
two types as follows:
2.2.1 Free Sliding Assembly
A type of Sliding Assembly which bears and transmits vertical load and allows movement in
any direction in the horizontal plane (Fig. 2.4).
5
- --
Free to slide along any direction in the horizontal plane

Wiper Seal
Sliding Top Plate
'---------+------
Sliding material
L-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _----"'==d---- Fixed Bottom Plate
Fig. 2.4 Free PTFE Sliding Assembly
2.2.2 Guided Sliding Assembly:
A type of Sliding Assembly which along with vertical load bears and transmits horizontal force
in one direction and allows movement perpendicular to that direction (Fig. 2.5).
1---1
r------------------------;::::====t-_ Sliding Top Plate With
'
L
---, 'r~R=============+==FI
IUhr
Side Guides
m t - - t - - - - Stainless
Wiper SealSteel Plate
Sliding material
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _---.J
Fixed Bottom Plate
a) With Side Guide

..-- -l
Sliding Top Plate
-1=====~=~~~~-------:---- Stainless Steel Plate

Wiper Seal
'--------+---~-- - - Sliding material
___________~_________~____________~=t--------- Fixed Bottom Plate
b) With Central Guide
Fig. 2.5 Guided PTFE Sliding Assembly
2.3 Pin Bearing

A bearing consisting of a metal pin provided within a metal cylinder to bear and transmit
horizontal force along any direction in the horizontal plane and accommodating rotational
movement about any axis. Pin bearings cannot bear or transmit any vertical load (Fig. 2.6).
- - - - - Anchors (See Fig. 2.8)
0-------;=====1--- Pin 1
--------- External Seal \

1
Elastomeric Pad
(Non-Load Bearing)
Cylinder \
Fig. 2.6 Pin Bearing
1
6 1
t
'1_I
,\
I
IRC:83 (Part-II 1)-2018
2.4 Metallic Guide Bearing
A bearing consisting of a sliding assembly with restraint along a desired direction to bear and
transmit horizontal force and capable of allowing movement in a direction perpendicular to
the direction of horizontal force. Metallic Guide bearings are capable of allowing rotation only
about an axis perpendicular to the plane of sliding. Metallic Guide bearing cannot bear or
transmit any vertical load (Fig. 2.7).
F! 2
l I I J
I
I I p
'--- '---
I
,
i
I
I
I I ! 1
Plane of Free Sliding
~::l ~::"'"'
Plane of FreE) Rotation

--~..------~- Anchors (Fig. 2.8)
Top 'U'
Wiper Seal
Sliding material
Stainless Steel
'- - - _______---'_====~I---- - Bottom T

i I
j
Sec A-A
Fig. 2.7 Metallic Guide Bearing
2.5 Cylinder
A metallic cylindrical component provided with a base plate which houses the elastomeric
pressure pad and piston for pot bearings and the pin for Pin bearings.
l
2.6 Piston
The metallic component of a Pot bearing which is housed inside the cylinder and confines the
elastomeric pressure pad. For sliding or guided type Pot bearings the piston is provided with
recess(s) at the top to accommodate and confine sliding material.
2.7 Confined elastomeric pressure pad
A disc of unreinforced elastomer that is confined within the cylinder by the piston of Pot
bearings for accommodating rotational movement about any axis in horizontal plane and to
bear and transmit vertical load.
2.8 Sliding component
A component comprising of stainless steel plate attached to a metal backing plate for sliding
over sliding material.
2.9 Accumulated slide path
The sum of the relative movements between the internal seal and the pot wall resulting
from variable Rotations OR the sum of relative movements at sliding interface for variable
translation.
2.10 Guide
Metallic projection either from the piston which fits into a corresponding recess in the sliding
component or from the sliding component parallel to two opposite edges of the piston, to bear
and transmit horizontal force along a direction.
2.11 Internal seal
A sealing arrangement may be provided for preventing ingress of moisture and debris through
the gap between the piston and cylinder for Pot bearings and that through the gap between
the pin and cylinder for Pin bearings.
2.12 External seal
A sealing arrangement provided for preventing ingress of moisture and debris through the
gap between the piston and cylinder for Pot bearings and that through the gap between the
pin and cylinder for Pin bearings. The detail of external seal shown in Figs. 2.1 to 2.3 and )
2.6 are indicative and actual arrangement / detail may differ depending upon manufacturer's
design.
I
2.13 Wiper seal I
A sealing arrangement provided for retaining the lubrication and preventing contamination of
the sliding surfaces. Use of wiper seal is optional.
II
8
1
i
1
2.14 Anchoring arrangement
An arrangement provided to fix the bearing to the structure (Fig. 2.8) .
. Anchor Sleeve
Anchor Bolt (with Nut &
Elastomeric Washer
Washers) -- Anchor Screw
(with Washer)
~~1
a:p
.ci
Oi
ANCHORING ARRANGEMENT ~i
-II
FOR STEEL STRUCTURE ... ~ ~ ANCHORING
... "0 'ci ARRANGEMENT FOR
m 2i
'- (/); CONCRETE STRUCTURE
..c CUi
f-- LL I
a) Anchoring Arrangement with Bolt-Nut I Screw-Sleeve System
IT IT
= -0
=
::J
.-.~: T,J ii5. -:~ ~----- Tension Anchor
(5
! .c
-
I OJ --- Shear Stud
-
c
OJ
~
I ....J
• Top Backing Plate
Anchor Bolt (with Nut

,- & Washers)
. .. .-,-- Bottom Backing Plate

..-or
I .
I
IT . IT
Vl'
b) Anchoring Arrangement with Shear Studs And Tension Anchors
Fig. 2.8 Anchoring Arrangement
9
2.15 Pre-set
Setting of sliding component to a predetermined position with respect to its mean position.
3 SYMBOLS AND NOTATIONS
3.1 Symbolic Representation of Bearing Function
Symbol Bearing Resists Direction of Direction Direction

Type Vertical restraining of allowing of allowing
Load horizontal force translation rotation
Fixed Yes Any No Any
0 Pot
Free Sliding
~~
Yes No Any Any
Pot
t
Guided Yes Unidirectional Unidirectional Any
~~ Sliding Pot
Free Sliding Yes No Any No
? Assembly
Guided Yes Unidirectional Unidirectional No

~ Sliding
Assembly
.A Pin No Any No Any
\~
Metallic No Unidirectional Unidirectional Uni-directional

~CJ~ Guide
3.2 Notations
3.2.1 Latin Upper Case Letters
A = gross cross section area

Aco = loaded area for no eccentricity
AC1 = is the maximum design distribution area with a similar shape to Aco
Ar = reduced area
As = tensile area of bolt
o = diameter of anchor sleeve, in mm
Op = largest plan dimension of piston or outer diameter of pot cylinder, whichever is
smaller, in mm
L = length of anchor sleeve, in mm
10
Ecm = short term static modulus of elasticity of concrete

Es = static modulus of elasticity of steel, in MPa
F ien = design tensile force per stud
FRdu = resistance offered by concrete in ULS
F v,Rd = design shear resistance of single anchor
Fw = resistance of weld, in MPa
FXY = applied horizontal Force in N
Ku = thickness of guide
Lu = effective length of guide
Me,d = induced moment due to tilting stiffness, in N-mm
M Rd = induced moment due to frictional resistance, in N-mm
MT,d = total induced moment, in N-mm
N = axial forces, in Newton
NRk = characteristic value of resistance of the elastomeric pad
P R,d = design shear resistance of single shear stud
R = radius of curvature of the curved contact surface of piston and cylinder for Pot
bearing, in mm
S = shape factor
Sa = accumulated slide path
SAd = actual Accumulated slide path
V = total transverse or shear force, in N
V' = total transverse or shear force per unit length, in N per millimetre
Ve = shear force due to elastomer pressure, in N
VPd = design value of anchorage resistance in Shear
3.2.2 Latin Lower Case Letters
di = diameter of confined elastomeric pressure pad, in mm

e = eccentricity i
!
= permissible direct compressive strength of concrete
= characteristic compressive strength of the 28 day concrete cube
= design contact strength of elastomer, in MPa I
= characteristic compressive strength 1
i
11
tu = ultimate strength of material, in MPa

tUb = ultimate Tensile Strength of bolt
tv,wd = the design shear strength of the weld
ty = yield strength of material, in MPa
h = projection of PTFE/UHMWPE above the recessed portion
ha = height of line of application of design horizontal force for guide
he = height of cylinder wall of Pot and Pin bearing, in mm
he = thickness of confined elastomeric pressure pad, in mm
hp = height of piston, in mm
hse = length of stud including head
kb = thickness of base of Pot and Pin bearing, in mm
k 1,k2 = constants for determining induced moments due to tilting stiffness of confined
elastomeric pressure pad
nv = number of vehicle (Lorries)
tp = thickness of sliding material
w = width of contact surface of the piston for Pot bearing and the pin for Pin bearing,
in mm
we = effective width of contact surface of piston and cylinder for Pot bearing and pin
and cylinder for Pin bearing, in mm
3.2.3 Greek Letters

Ym = partial safety factor
Ym2 = partial safety factor for bolts, weld
Yv = partial safety factor shear Stud
YJl = partial safety factor for friction
f) = design rotation angle, in radian
f}max = calculated value of resultant rotation angle, in radian
f}p = calculated value of resultant rotation angle due to permanent actions and long
term effects, in radian
f}v = calculated value of resultant positive rotation angles due to variable actions, in
radian
f}Iv = calculated value of resultant negative rotation angles due to variable actions, in
radian
f}v,range = range of rotation angles due to extreme positions of variable actions, in radian
12
Ji = coefficient of friction at sliding material-stainless steel sliding interface
Jifr = coefficient of friction at secondary sliding interface

Ji k = characteristic value of friction coefficient between bearing and adjacent
structure
v = Poisson's ratio
(J = average pressure on sliding material
3.2.4 Subscripts
d = design value
Rd = design resistance
Sd = design internal forces and moments from actions
u = ultimate limit state
3.2.5 Abbreviations
POM = polyoxymethylene (acetal)

PTFE = polytetrafluoroethylene
UHMWPE = Ultra High Molecular Weight Polyethylene
4 MATERIALS
4.1 Steel
4.1.1 Mild steel to be used for the main components of the bearings shall generally
comply with grade E350BR (minimum) of IS: 2062 or equivalent. However, sub quality C
of IS: 2062 or equivalent shall be used for sub-zero condition. For other components, e.g.
transportation clamps etc., the grade of steel should be E250BR minimum.
4.1.2 Cast steel shall generally comply with Grade 340-570W of IS: 1030 or equivalent.
Use of cast steel in sub-zero condition is allowed with Charpy Impact value similar to sub
quality C of IS: 2062. Alternatively, for sub-zero condition, cast steel of suitable grade
conforming to IS: 4899 may also be used.
4.1.3 The steel for forging to be used for the components of the bearings shall comply
with Class 3, 3A or 4 of IS: 1875 and steel forgings shall comply with Class 3, 3A or 4 of IS:
2004 or equivalent grades of BS: 970.
4.1.4 Stainless steel shall conform to AISI 316 or AISI 316L.
4.2 Low Friction Thermo-Plastic Sliding Material (PTFE or UHMWPE)
The material shall be either polytetrafluoroethylene (PTFE) free sintered without regenerated
13
material or Ultra High Molecular Weight Polyethylene (UHMWPE) having high material
strength and low frictional properties. The pattern of dimples shall be as described in Fig. 4.1.
13.5 ±O,5. 13.5 ±O.5
Direction of main sliding
0111
-td-=?;
Fig. 4.1 Pattern of Dimples in Sliding Material
4.2.1 The mechanical and physical properties of PTFE shall comply with Table 4.1
Table 4.1 Mechanical and Physical properties of PTFE
Property Testing standard Requirement
Mass density EN ISO 1183 (all parts) Pp =2140 to 2200 kg/m3

Tensile strength EN ISO 527-1 and 3 fptk =29 to 40 MPa
Elongation at break EN ISO 527-1 and 3 (5p ~ 300 %
Ball hardness EN ISO 2039-1 H132/60 =23 to 33 MPa

4.2.2 Use of modified sliding material (UHMWPE) having frictional properties superior
to that of PTFE combined with enhanced load bearing capacity and ability to provide high
velocity displacement with longer service life can be considered for both horizontal and vertical
sliding surfaces. Use of UHMWPE shall be subjected to availability of approval document
from international approving bodies like ETA, FHWA or similar acceptance by other leading
International Specifications, reference of its usage in the bearing.
14
ial 4.3 Composite Material

1.
For guides of Pot / Sliding bearings composite material (CM 1) may be used. This is a composite
material consisting of three layers: a bronze backing strip and a sintered interlocking porous
matrix, impregnated and overlaid with a PTFE / lead mixture.
The material shall conform to the characteristics listed in Table 4.2. In addition, the condition
of the material and its surface finish shall be checked visually.
Table 4.2 Characteristics of CM1
Bronze backing Material: CuSn 6

Thickness: 2.1 ±0.15 mm
Hardness HB - EN ISO 6506 (all parts): 80 to 160
Bronze interlayer Material: CuSn 10

Saturation with PTFE-Pb: ~ 25%
Thi~kness: 0.25+ 0.15 mm
0.0
Composite material surface Material: PTFE + Pb

layer Composition by mass: Pb 49 to 62%, remainder PTFE
Thickness: 0.01 +0.02 mm
0.0
Overlay adhesion - EN ISO 2409: minimum GT 2
Total thickness 2.48 ± 0.015 mm
4.4 Elastomer
The elastomer to be used for the components of bearings shall generally be made of
Chloroprene Rubber (CR) or Natural Rubber (NR). The confined elastomer of Pot bearings
shall have the properties specified in Table 4.3.
Table 4.3 PhYSical Properties of Confined Elastomer
Properties Unit Requirement Test methods
Hardness IRHD 50 ± 5 ISO 48
Minimum tensile strength MPa 16 ISO 37 type 2

- Moulded test piece
Minimum elongation at break % 450 ISO 37 type 2

- Moulded test piece
15
!I
I
11 4.3 Composite Material
Forguides of Pot! Sliding bearings composite material (CM1) may be used. This is a composite
material consisting of three layers: a bronze backing strip and a sintered interlocking porous
matrix, impregnated and overlaid with a PTFE / lead mixture.
The material shall conform to the characteristics listed in Table 4.2. In addition, the condition
of the material and its surface finish shall be checked visually.
Table 4.2 Characteristics of CM1
Bronze backing Material: CuSn 6

Thickness: 2.1 ±0.15 mm
Hardness HB - EN ISO 6506 (all parts): 80 to 160
Bronze interlayer Material: CuSn 10

Saturation with PTFE-Pb: ~ 25%
Thir:kness: 0.25+ 0,15 mm
0,0
Composite material surface Material: PTFE + Pb

layer Composition by mass: Pb 49 to 62%, remainder PTFE
Thickness: 0.01 +0,02 mm
0,0
Overlay adhesion - EN ISO 2409: minimum GT 2
Total thickness 2.48 ± 0.015 mm
4.4 Elastomer
The elastomer to be used for the components of bearings shall generally be made of
Chloroprene Rubber (CR) or Natural Rubber (NR). The confined elastomer of Pot bearings
shall have the properties specified in Table 4.3.
Table 4.3 Physical Properties of Confined Elastomer

Minimum tear resistance ISO 34-1 trouser

-CR method A
-NR kN/m 7
5
Maximum compression set (%)

(24 h, 70° ± 1°C) % 15 ISO 815
-CR % 30 <1>29 x 12.5mm
-NR Spacer: 9.38-25%
Accelerated Ageing
(Maximum change from unaged value)
Hardness IRHD ISO 48
- NR 7 d, 70°C -5, +10 ISO 188
- CR 3 d, 100°C %
Tensile strength ±5
- NR 7 d, 70°C ±15
- CR 3 d, 100°C ±15
Elongation at break %
- NR 7 d, 70°C ±25
- CR 3 d, 100°C ±25
Ozone Resistance
Elongation: 30 % - 96 h, 40°C ± 2°C No cracks ISO 1431-1
- NR 25 pphm
- CR 100 pphm
4.5 Internal seal
To prevent the extrusion of confined elastomer, under load, between piston and cylinder
of Pot bearing, internal seal shall be provided. The following seals can be considered as
suitable, according to the state of the art.
4.5.1 Brass seal
The internal brass seal shall be fitted into a formed recess in the upper edge of the elastomeric
pad and shall consist of a number of split rings formed to the internal diameter of the pot.
When fitted, the gap between the ends of the ring shall not exceed 0.5 mm and the gaps in
adjacent rings shall be equally disposed around the perimeter of the pot. Where possible no
gap should coincide with the point of maximum rotation movement on the pot wall.
16
The material used for the brass seal shall be grade CuZn37 or CuZn39Pb3, as specified in
EN 12163 and EN 12164 respectively or CuZn37 1CuZn40 as per IS: 410 and in accordance
with Clause 6.2.4.
4.5.2 paM seal
paM (Poly Oxy Methylene) sealing chain shall consist of individual interlocking elements
made of moulded polyoxymethylene, which can adapt easily to deformation. Material
properties of paM sealing chain shall be as specified in Table 4.4.
Table 4.4 Physical and Mechanical Properties of POM
Property In accordance with Requirements
Density ISO 1183 1410 kg/m3 ± 20.0 kg/m3
Melt flow index MFI 190/2, 16 ISO 1133 10 g/min ± 2.0 g/min
Ultimate tensile strength ISO 572-2 ~ 62 MPa
Ultimate strain ISO 572-2 ~30%
4.5.3 Carbon filled PTFE seal
The material composition of carbon filled PTFE seal shall consist of PTFE + 25 % carbon.
The material properties shall be in accordance with the requirements of Table 4.5 below.
Table 4.5 Physical and Mechanical Properties of carbon filled PTFE seal
Properties In accordance with Requirements
Density ISO 1183 2100 kg/m3 to 2150 kg/m3
Ultimate tensile strength EN ISO 527-2 ~ 17 MPa
Ultimate strain EN ISO 527-1 ~80%
Ball hardness EN ISO 2029-1 ~ 40 N/mm
The material properties shall be verified on samples taken from finished tubes at 23°C
and 50% humidity. The ultimate tensile strength and the ultimate strain shall be determined
with a speed C = 50 mm/min on test samples with a PTFE thickness of 2 mm ± 0.2 mm in
accordance with EN ISO 527-2. The ball hardness shall be determined on samples with a
minimum thickness of 4.5 mm.
17
Minimum tear resistance ISO 34-1 trouser

-CR method A
-NR kN/m 7
5
Maximum compression set (%)

(24 h, 70° ± 1°C) % 15 ISO 815
-CR % 30 <1>29 x 12.5mm
-NR Spacer: 9.38-25%
Accelerated Ageing
(Maximum change from unaged value)
Hardness IRHO IS048
- NR 7 d, 70°C -5, +10 ISO 188
- CR 3 d, 100°C %
Tensile strength ±5
- NR 7 d, 70°C ±15
- CR 3 d, 100°C ±15
Elongation at break %
- NR 7 d, 70°C ±25
- CR 3 d, 100°C ±25
Ozone Resistance
Elongation: 30 % - 96 h, 40°C ± 2 °C No cracks ISO 1431-1
- NR 25 pphm
- CR 100 pphm
4.5 Internal seal

To prevent the extrusion of confined elastomer, under load, between piston and cylinder
of Pot bearing, internal seal shall be provided. The following seals can be considered as
suitable, according to the state of the art.
4.5.1 Brass seal
The internal brass seal shall be fitted into a formed recess in the upper edge of the elastomeric
I
1
pad and shall consist of a number of split rings formed to the internal diameter of the pot.
When fitted, the gap between the ends of the ring shall not exceed 0.5 mm and the gaps in
adjacent rings shall be equally disposed around the perimeter of the pot. Where possible no I
I
,I
gap should coincide with the point of maximum rotation movement on the pot wall. '1
16
t
I
The material used for the brass seal shall be grade CuZn37 or CuZn39Pb3, as specified in
EN 12163 and EN 12164 respectively or CuZn37 1 CuZn40 as per IS: 410 and in accordance
with Clause 6.2.4.
4.5.2 POM seal

POM (Poly Oxy Methylene) sealing chain shall consist of individual interlocking elements
made of moulded polyoxymethylene, which can adapt easily to deformation. Material
properties of POM sealing chain shall be as specified in Table 4.4.
Table 4.4 Physical and Mechanical Properties of POM
Property In accordance with Requirements
Density ISO 1183 1410 kg/m3 ± 20.0 kg/m3
Melt flow index MFI 190/2, 16 ISO 1133 10 g/min ± 2.0 g/min
Ultimate tensile strength ISO 572-2 ~ 62 MPa
Ultimate strain ISO 572-2 ~30%
4.5.3 Carbon filled PTFE seal
The material composition of carbon filled PTFE seal shall consist of PTFE + 25 % carbon.
The material properties shall be in accordance with the requirements of Table 4.5 below.
Table 4.5 Physical and Mechanical Properties of carbon filled PTFE seal
Properties In accordance with Requirements
Density ISO 1183 2100 kg/m3 to 2150 kg/m3
Ultimate tensile strength EN ISO 527-2 ~ 17 MPa
Ultimate strain EN ISO 527-1 ~80%
Ball hardness EN ISO 2029-1 ~ 40 N/mm
The material properties shall be verified on samples taken from finished tubes at 23°C
and 50% humidity. The ultimate tensile strength and the ultimate strain shall be determined
with a speed C = 50 mm/min on test samples with a PTFE thickness of 2 mm ± 0.2 mm in
accordance with EN ISO 527-2. The ball hardness shall be determined on samples with a
minimum thickness of 4.5 mm.
17
4.5.4 Stainless steel seal
The sealing ring shall be made from stainless steel strip formed into an equal or unequal
angle section inserted between the elastomeric pad and the pot wall.
The material used for the stainless steel seal shall be as per AISI 316 or AISI 304LN.
4.6 External seal
External seal of suitable profile made of silicone rubber or chloroprene rubber shall be
provided for preventing ingress of moisture and debris through the gap between the piston
and cylinder for Pot bearings and that of the pin and cylinder for Pin bearings.
4.7 Wiper seal
Wiper seal of suitable profile made of Chloroprene Rubber (CR) or Nitrile Butadiene Rubber
(NBR) may optionally be provided for retaining the lubrication and preventing contamination
of the sliding surfaces.
4.8 Fasteners
Bolts, screws, nuts and lock nuts shall generally conform to IS:1363, IS:1364, IS:1365,
IS:2269, IS:3138, IS:6761, IS:6639 or equivalent as appropriate with mechanical properties
conforming to IS: 1367 or equivalent. Threads shall generally conform to IS: 4218 or equivalent.
Washers shall conform to IS: 2016, IS: 6610 or equivalent as appropriate.
4.9 Shear Stud
Shear studs shall conform to SD1 / SD2 of ISO 13918.
5 DESIGN
5.1 General
5.1.1 Local effects of load / force and movements to be considered in designing the
bearings shall be determined by suitable global analysis of the structure with idealised
boundary condition under any critical combination of loads and forces that can coexist in
accordance with the requirements of IRC:6.
5.1.2 Resistance due to friction at the sliding interface of the bearing, if any, shall be
ignored for idealising the boundary conditions in global analysis of the structure. However,
induced force generated due to friction at sliding interface shall be considered in the design
of bearings and adjacent (supported/supporting) structures.
5.1.3 Load / movement data for design of bearings shall be furnished in SLS-ULS format
as per Annexure A, 'Typical Format of Furnishing Data for Design of Bearings'.
5.1.4 For design of Pot bearings or part thereof the design horizontal force to be
18
considered shall be the resultant of the coexisting active horizontal forces, determined from
global analysis, and induced horizontal forces, generated due to friction at sliding interface (if
any).
5.1.5 For design of bearings or part thereof and the adjacent structures the resultant of
the coexisting moments (MT,d) produced due to design horizontal force and that induced due
to resistance to rotation shall be considered.
5.1.5.1 For the verification of the adjacent structural parts, the maximum value of the
restraint moment, i.e. the induced moment resulting from resistance to rotation due to the
effect of tilting stiffness of elastomeric pressure pad (Me,d) shall be determined as per either
of the following methods:
Method 1 (Applicable when Type test data are available):
Me,d= 32 x dP x (Fo + (F1 x epJ + (F2 x eJ)

Fo' F1 & F2 shall be taken from certified Type test data. Type test shall conducted in laboratory
of international repute eligible to test in accordance with annex D of EN 1337-5.
di =diameter of elastomeric pressure pad in mm

ep = Resultant rotation angle due to permanent actions and long term effects, in radian
(Fig. 5.2).
Bv = Resultant positive rotation angles due to variable actions, in radian (Fig. 5.2).
Method 2 (Applicable when Type test data are not available):
Me, d =dP x (k1·e p

+ k2 .ev ) , where,
k1 and k2 shall be as per Table 5.1. Intermediate values may be obtained by linear interpolation.
Table 5.1 Values of Constants k1 and k2
di I he k1 k2
15 2.2 101
12.5 1.8 58.8
10 1.5 30.5
7.5 1.1 13.2
di=diameter of elastomeric pressure pad in mm

Bp = Resultant rotation angle due to permanent actions and long term effects, in radian
(Fig. 5.2)
Bv =Resultant positive rotation angles due to variable actions, in radian (Fig. 5.2).
19
5.1.5.2 Induced moment resulting from resistance to rotation caused by the friction at the
piston-cylinder contact surface due to coexisting horizontal force from permanent action shall
be determined as follows:.
MR,d = 0.2 x C x Vd where,

C = the perpendicular distance from the pOint of action of horizontal force on cylinder wall to
the axis of rotation in mm. (Fig. 5.1).
Vd =Coexisting horizontal force in N
Direction of Horizontal Force

Axis of Rotation
Diameter
Fig. 5.1 Moment Arm for Rotation Resistance due to Friction

1
Note: This moment however may be ignored for transient horizontal forces, as change in
rotation is not likely to occur instantaneously during application of transient horizontal force. il
5.1.6 For Pot bearings total induced moment will be
total induced moment will be M Td = MR,d
M Td = ME,d + MR,d and for Pin bearings
I
I
I
5.1.7 The relationship between the permanent and variable rotation angles is shown in
Fig. 5.2.
j
20 I
(
1
2 1
"
"
Fig. 5.2 Diagramatic Representation of Rotation Angles
1 Starting position (after installation),
2 Position due to rotation 8p caused by permanent actions
Bv = positive rotation angles due to variable actions.

B'v = negative rotation angles due to variable actions.
B
v,range
= B
v
+ B'v = range of rotation angles due to extreme positions of variable actions.
Bmax = Bp + Bv
Under the frequent combination of actions the difference in rotation Bv,range shall not exceed
0.005 rad.
The design rotation (8) shall be determined by as follows B= Bmas + 0.005 radians. Maximum
value of design rotation shall not exceed 0.03.
5.1.8 Variable rotations result in an accumulated slide path, which affects the durability
of the internal seal.
When required the actual accumulated slide path SA,d shall be calculated with data provided
by the bridge designer using the following formula:
di
SAd =n v x Bv,range x -
2
SAd::; 5 xST' where
SAd =actual accumulated slide path due to characteristic traffic loads
21
n v = number of vehicles for the intended life of bearing

ST = accumulated slide path
= 500 m for Stainless Steel seal

= 1000 m for Brass seal
= 2000 m for POM seal and Carbon filled PTFE seal
It is advised that e
v,range
is determined using an appropriate single vehicle model (Lorries /
trucks).
5.1.9 Design horizontal displacement for both Pot and Metallic Guide Bearings shall
be increased by ± 20 mm in both the directions of movement. However, a minimum total
displacement of ± 50 mm in the longitudinal direction and ± 20 mm in the transverse direction
shall be considered. The values are not applicable if the bearings are mechanically restrained.
They shall not be used where stresses are being calculated.
In addition, for Metallic Guide Bearings, the vertical design movement capacity shall be at
least the following:
- 15 mm upwards
- 10 mm downwards
5.1.10 The line of action of resultant horizontal force shall be considered at the middle of
the contact width (Clauses 5.3.1.4.1 and 5.3.1.4.2) of the piston and cylinder for Pot bearings
and that of the pin and cylinder for Pin bearings.
5.2 Design Parameter
5.2.1 Desig(] resistance of the adjacent concrete structure
5.2.1.1 The load transfer from the Bearing to the adjacent structure shall be concentrated
but uniformly distributed load for which the resistance of the adjoining concrete structure in
ultimate load condition is to be determined which shall meet or exceed the acting load values.
The resistance of the concrete structure shall be calculated from the expression below.
Design resistance may further be enhanced taking into account the effect of reinforcement
as per discretion of structural engineer. Concrete zones below and adjacent to the bearing
shall be designed as per Clause 16.11.2 of IRC: 112.
For a uniform distribution of load on an area Aco (Fig. 5.3) the concentrated resistance force
may be determined as follows:
I
i
FRdu = resistance offered by concrete in ULS condition loading I
22
I
i
t
fCd = permissible direct compressive strength of concrete, calculated as:

_ 0.67 x ick
fcd
Yc
fCk = characteristic compressive strength of the 28 day concrete cube
Yc = 1.5 for concrete
Aco = loaded area

AC1 = the maximum design distribution area with a similar shape to Aco
The design distribution area AC1 required for the resistance force FRdu should correspond to
the following conditions:
the height for the load distribution in the load direction should correspond to the conditions
given in Fig. 5.2
the centre of the design distribution area AC1 should be on the line of action passing
through the centre of the loaded area Aco
-7~
h
I Id, ~ 3d.
~- line of action
I - .
/
II ;::: (b2 - bd and

~ (dJ - dl)
~.... /
Fig. 5.3 Pattern of Load Dispersion and Distribution Area
5.2.1.2 Effect of eccentricity (e) due to induced moment and horizontal force in critical
combination of load shall be taken into account considering reduced contact loaded area
(Ar), determined from Annexure B. In case of separation of parts due to eccentricity, special
measures shall be taken. e.g., specially designed tension anchors as per ACI 318M or CENI
T8 1992-4-1 may be provided.
23
5.2.1.3 Limiting strain for concrete in ULS condition shall be considered as 0.0035.
5.2.2 Yield strength and UTS values of different grade steel as per their thicknesses
shall be considered as per IS: 2062 or equivalent International standard for rolled steel and
IS: 1030 or equivalent International standard for cast steel.
Limiting strain for steel in ULS condition shall be considered as 0.002 + 1.:; Es
5.2.3 Particular recommendations for confined elastomeric pressure pad
5.2.3.1 Design resistance of confined elastomeric pressure pad depends on the

effectiveness of the internal seal preventing it from extruding between the piston and the
cylinder wall and as such shall be verified by load testing of assembled bearing.
5.2.3.2 The design maximum axial force NSd in ULS condition shall meet the following
condition under the critical combination of actions:
Where:
NRk
N Rd = Ym is the design value of resistance of the elastomeric pad
NRk is the characteristic value of resistance of the elastomeric pad
The characteristic value of the resistance shall be determined from:
NRk -- x d'I X fe.k' were.

h .
2
4'rr
di is the diameter of elastomeric pad (mm)
fe.k is the characteristic contact strength of the elastomer given by fe.k =60 N/mm 2
The partial factor Ym = 1.3
NOTE 1: The compressive resistance fe .k of the elastomer in pot bearings, that leads to N Rk is
limited by the effectiveness of the seal preventing the elastomer from extruding between the
piston and the pot wall.
NOTE 2: Elastomeric pad including internal seal having higher characteristic contact strength
(fe) may be used subjected to the availability of approved documents from International
Approval bodies like ETA, FHWA or similar acceptance by other leading International
Specifications, reference of its usage in the bearing application, satisfactory and proven test
and performance records etc.
5.2.3.3 Minimum average stress in confined elastomeric pressure pad of Pot bearing,
under any critical combination of loads and forces that can coexist in SLS condition, shall in
no case be less than 2 MPa.
24
..
5.2.3.4 The dimension of the confined elastomeric pressure pad shall be such that at
design rotation the deflection at the perimeter shall not exceed 15% of the pad thickness.
(Fig. 5.4).
l····
Q)
..c.:
.l~.
di
<r·' he x 0.15 Rotation 0

1 r
Q)
],'"'~"~""~~~ll==""~~":{:: . ~
i \
..c.:
.J~..~. .,. ". ,.~. . .,.
Fig. 5.4 Pattern of load dispersion and distribution area
5.2.3.5 The minimum thickness of the confined elastomeric pressure pad shall not be less
th
than 1115 of its diameter or 16 mm, whichever is higher and the diameter shall not be less
than 150 mm.
5.2.4 Particular recommendations for confined Sliding Material
5.2.4.1 The permissible combination of the materials (sliding material and mating surfaces)
to be used for sliding interfaces shall be as given in Table 5.2. The Sliding material surface
shall be lubricated in accordance with clause 6.3.2.
Table 5.2 Sliding Surfaces
Flat Sliding Surface Guides
PTFE (Unfilled and Stainless Steel (SS) PTFE (Unfilled) / Stainless Steel (SS)
dimpled) / UHMWPE UHMWPE
(Dimpled) Composite Material
(CM1)
5.2.4.2 Sliding material shall be located into recess of a sufficiently rigid metal backing
plate by confinement and shall be in form of dimpled large sheets. The thickness of the
Sliding material and its protrusion from the recess should be related to its maximum plan
dimension in accordance with Table 5.3.
25 ~
..
'?'",,"\
f
II
Table 5.3 Thickness 't p ' and protrusion 'h' of Sliding Surfaces
Design values Flat sliding surfaces Guides
PTFE PTFE CM1
Thickness \' in mm 2.2h:::; tp ± 8.0 5.5 2.5
Protrusion 'h' in mm L 2.3 ± 0.2 1 ± 0.1

h = 1.75 + 1200 ~ 2.2
'L' diameter or diagonal distance

of sliding material in mm
The tolerance on the protrusion 'h' is ±0.2 mm for 'L' less than or equal to 1200 mm and
±0.3 mm for 'L' greater than 1200 mm. The protrusion "h" shall be verified at marked measuring
points, where the corrosion protection coating shall not exceed 300 I-lm. There shall be at
least two measuring points, suitably located.
5.2.4.3 Sliding Surface for Guides (PTFE)
Dimensions 'a' shall not be less than 15 mm and the modified shape factor shall be greater
than 4 (Fig. 5.5).
Ap tp-II
s=-
uxii
x --'where
II '
h = Projection of PTFE above the recessed portion
u = Perimeter of PTFE free to bulge.

Ap =Area of sliding surface (PTFE) in contact i.e. under load.
:j I
I
I
Ap
r-
Ap /2 Ap /2
~l
j
~I
t
I
~
L 10±5 •
10±5
... L ... 10±5 1
i
Fig. 5.5 Examples of Recessed Sliding Surface for Guides
5.2.4.4 Composite materials shall only be used where self-alignment between the mating
parts of the bearing is possible. Width "a" shall be equal to or greater than 10 mm.
I
,I
'I
26 I
I
l
_______......i.i.
..
It
5.2.4.5 The characteristic compressive strengths of Sliding materials are given in

Table 5.4
Table 5.4 Characteristic Compressive Strength (fk) of Sliding Material
Material Application Condition fk (MPa)

PTFE (Unfilled) Main bearing Surface and guides 90
CM1 Guides
200
These values are valid for temperatures up to 30° C for PTFE. For bearing exposed to a
maximum temperature in excess of mentioned respective values, the values shall be reduced
by 2 percent per degree in order to reduce creep effects of the PTFE respectively. No such
correction is required for composite material CM1.
5.2.4.6 The design maximum axial force NSd in ULS condition shall meet the following
condition under the critical combination of actions:
Where:
NSd is the design value of the axial force due to the design values of action
fk is the characteristic compressive strength given in Table 5.4.
Ar is the reduced contact area of the sliding surface whose centroid is the point through which
NSd acts with the total eccentricity e, which is caused by both mechanical and geometrical
effects. Arshall be calculated on the basis of Annexure B. Separation of part is not allowed
for sliding material.
For guides eccentricity can be neglected.
NOTE: The recommended value is 1m= 1.4
5.2.4.7 For bearing with sliding surface as given in Table 5.5, the co-efficient offriction f.1max'
for verification of the bearing and the structure in which it is incorporated shall be calculated
as per expression below. The effect of friction at the sliding interface shall not be used to
relieve the effects of externally applied horizontal forces.
Coefficient of friction for PTFE.
For flat sliding interfaces combined with dimpled and lubricated PTFE sheets and stainless
steel, the co-efficient of friction Il max is determined as a function of the average pressure a p
(MPa) under maximum vertical load in ULS condition, as follows
12
0.03 :5 f.1max =10 +. (Jp :5 0.08
NOTE 1: For zones where the minimum effective bearing temperature doesn't fall below
_5° C the coefficient of friction values for PTFE sliding surfaces as worked out from the above
27
expressions may be multiplied by a factor of 2/3.

For guides with a combination of sliding materials given in Table 5.5, the coefficient of friction
shall be considered to be independent of contact pressure and the following values shall be
used.
Table 5.5 Co - efficient of Friction (Jl fr) for Secondary Sliding Surfaces
Application Sliding Interface

SS - PTFE 0.08
Guides
SS - Composite Material (CM1) 0.20
NOTE: For guides, effect of induced frictional force due to resistance to translation shall not
be applicable for transient force.
5.2.4.8 When UHMWPE is used as sliding material, relevant ETA / FHWA documents
shall be referred to determine the parameters described in Clause 5.2.4.1 to 5.2.4.7.
5.3 Design Philosophy
5.3.1 Particular recommendations for design of Pot bearings

Stress distribution through the bearing component adjacent to the (supported/supporting)
structure as well as on the structure itself due to active load, force and induced force and
moment produced due to resistance to movement and rotation in ULS condition shall be
determined with due considerations to the relative stiffness and interaction of the bearing
component and the adjacent structure by a suitable method e.g. three dimensional finite
element (3D-FEM) method of analysis. In absence of elaborate 3D-FEM analysis, design
procedure specified in Clause 5.3.1.2 may be adopted to determine the dimensions of
bearing components. However for Pot bearings of vertical load capacity 10,000 kN or higher
in SLS condition or if horizontal load is more than 25% of vertical load in SLS condition,
the pot cylinder shall always be analysed by three-dimensional finite element method of
analysis. Only internationally accepted, authentic software shall be used for carrying out
3D-FEM analysis.
5.3.1.1 To carry out 3D-FEM analysis, bearing component and the adjacent structure
shall be modelled together. For concrete structure, a block of concrete shall be considered
for modelling together with the adjacent bearing component. The area of the block shall be
i
. i
geometrically similar to the contact area and also the largest area that can be contained in
the plane of contact of bearing and structure. The depth of the concrete block shall be equal
to the minimum available depth of the adjacent component of the concrete structure over
the area of the block. The depth of concrete block need not exceed the largest dimension
(diameter or diagonal) of the bearing component along the contact plane.
28
5.3.1.1.1 For concrete elements, Poisson's ratio (v) may be assumed as 0.2, and modulus
of elasticity (Ecm) may be considered as per IRC: 112 depending upon the concrete strength
class.
For steel elements, static modulus of elasticity, Es ' may be considered as 2 x 10 5 Mpa and
the poisson's ratio (v) may be considered as 0.3.
Non-linear analysis is preferred while carrying out FEM.
5.3.1.1.2 The confined elastomeric pressure pad to be considered to act as fluid exerting
fluid pressure under vertical load. In addition, design horizontal force that may coexist shall
be taken into account for carrying out 3D-FEM analysis.
5.3.1.1.3 Maximum strain in bedding grout / concrete shall not exceed the limiting strain of
concrete (refer CI. 5.2.1.3) under any critical load combination in ULS condition.
5.3.1.1.4 For steel bearing components of Pot, maximum strain under any critical load
combination shall not exceed limiting strain (refer CI. 5.2.2) in ULS condition.
5.3.1.2 Simplified Design Rule

5.3.1.2.1 In absence of 3D-FEM analysis, load dispersion angle through bearing
component(s) and to the adjacent structure shall be taken as 45°.
'~ I~~________E__ff_e_c_ti_v_e_c_o_n_t_a_c_t_a_r_e_a________~~I
1- Effective contact area

Fig. 5.6 Load Dispersion through Bearing Components
29
5.3.1.2.2 In absence of 3D-FEM analysis, the dimensions of the cylinder shall be determined
using expressions given in the following.
..c
C """
~C
di
I· ·1 I. di
I. do
.1 do
·1
I. .1
(a) (b)
c..>
~C
..r::::.
I· di
-I i.. di
·1
I. do
.1 do
Do
(e) (d)
Fig. 5.7 Types of Pot Construction
5.3.1.2.3 Pot walls subjected to tensile force
VSd:5 V Rd Where:
Vsd = Ve,sd + VFxy,sd

4XNSd xhe
Ve,Sd Tr x di
Where = AR= (do - di) x hc
5.3.1.2.4 Pot walls subjected to shear force:
V'Sd :5 V'Rd' Where:
fyX(do-di)
V· =...:::...----
2XYm .,[3
Rd x
~.
\
30
L
j 5.3.1.2.5 Pot base subjected to tensile force:
Vsd::; VRd Where:
Vsd -V
- e,sd
+ VFXy,sd
fyXAp
v:Rd -
- -
Ym
Where A p =do x kb
5.3.1.2.6 Full Penetration butt weld connecting the pot base to the pot wall within the pot
wall (Fig. 5.7 (b) and Clause 6.2.1)
VSd ::; VRd Where:

Vsd =Ve,sd + VFxy,sd
tyXAp
v:Rd -
-
-
Ym-
Where Ap = do x kb
Also refer Annexure E.

5.3.1.2.7 Partial penetration butt welds connecting the pot base to the pot wall within the pot-
wall (Fig. 5.7 (c) and Clause 6.2.1)
VSd ::; V
Rd
Where:
V sd = V e,sd + V Fxy,sd
VRd =2 X Fw,Rd. di
Where F w,Rd is Design Resistance of Partial penetration butt Weld calculated as per
Annexure E
5.3.1.2.8 Fillet welds connecting the pot wall to the top of the pot base (Fig. 5.7 (d) and
Clause 6.2.1)
V'Sd ::; V'Rd' Where:
V'Rd = 1[ x F w,Rd (di + do)

Where F w,Rd is Design Resistance of Fillet Weld calculated as per Annexure E
NOTE: The recommended values of partial factor Ym in 5.3.1.2.3 to 5.3.1.2.6 may be
considered as follows:
Ym =1.1 for cast steel

= 1.0 for rolled steel
31
5.3.1.3 Thickness of pot base shall not be less than 2.5% of the inner diameter of the pot
cylinder. Thickness of the steel backing plate of stainless steel for sliding component shall
not be less than 4% of the maximum dimension (diameter or diagonal) in plan. However,
minimum thickness of any steel component or part thereof shall in no case be less than
12 mm.
5.3.1.4 The contact face of the piston may be designed as flat in accordance with Clause
5.3.1.4.1 provided that the width of the piston contact face, w, is less than 15 mm (Fig. 5.8).
---------+-
-+-_-=--_
....
_V_Fxy_,_Sd_ _ _ --+'_~-_-~_--~_-~_-------"'- / ) Break edge
Fig. 5.8 Details of Flat Piston Contact Face
The mechanical resistance of contact faces shall be verified for the fundamental combination
of actions in accordance with Clause 5.3.1.4.1 or 5.3.1.4.2.
5.3.1.4.1 Flat contact surface
Flat contact faces shall be verified, so that:
VSd ~ V Rd Where:
VSd is the design value of the horizontal force (N)
w = width of piston face in mm,
fy = yield strength of material, in MPa
di = inner diameter of pot in mm
Ym = 1.1 for cast steel

5.3.1.4.2 Curved contact surface
Curved contact surfaces shall have a radius R (Fig. 5.9), of not less than 0.5 x di or 100 mm,
whichever is the greater.
32
>t ------------------1------------------
II _ VFxy, Sd I R____~I
r,
n
di
Fig. 5.9 Details of Curved Piston Contact Face
They shall be verified, so that
_ 15xf~xRXdi
VRd - Es xy2m
1.5xV FXySdXR
We = 3.04 Esxdi and we + () X di $; W
R = radius of curvature of the curved contact surface in mm

we = effective contact width
e = design rotation
Es = design modulus of elasticity of steel in MPa
di = inner diameter of pot in mm
fu = ultimate tensile strength of the steel material of piston or cylinder, whichever is lower,
in MPa

NOTE 1: The ability of curved surfaces and plates to withstand deformation under load is
dependent upon the hardness of the material from which they are made. There is not a direct
relationship between hardness and yield stress of steel but there is relationship between
hardness and ultimate strength. Consequently the above expressions are based on the
ultimate strength of the material.
NOTE 2: A force concentration factor 1.5 is included in the factor 15.

5.3.1.5 Additional geometrical conditions for required rotation capacity
For the fundamental combination of action it shall be shown that:
- The edge of the piston/elastomer contact face remains within the cylindrical recess formed
by the pot wall around the whole circumference (Fig. 5.10).
33
..--------------------------------------~-------- -
- There is no contact between the top of the pot wall and any other metallic component
(Fig. 5.10).
The above conditions are satisfied when:
he - he - (w - we) x 0.5 - (8 x 0.5 x di) ;::: (5
hp - (he - he) - (8 x 0.5 x Dp);:: (5
For flat contact surfaces we =w

Where, 8= 0.01 x di or 3 mm whichever is greater, but not exceeding 10 mm. (Fig. 5.10).
DeSIgn
". /
rotatIOn
,
Op
di
Fig. 5.10 Geometrical Conditions for Rotation
5.3.1.6 For sliding components, stainless steel sheet shall be attached to its backing plate
by continuous fillet welding along the edges. This welding is, however, not to be considered as
structural welding. The stainless sheet may also be attached to its backing plate by screwing
or riveting but the thickness of the stainless steel sheet shall be at least 2.5 mm in that case.
When attaching the stainless steel sheet by screwing or riveting, corrosion resistant fasteners
compatible with the stainless steel sheet shall be used for securing its edges. They shall be
provided at all corners and along the edges outside the area of contact with the PTFE sheet.
Care shall be taken to ensure that the stainless steel sheet is fully in contact with the backing
plate over the area which will be in contact with the PTFE sheet. The stainless steel surface
shall always overlap the sliding material even when the extreme movement occurs.
5.3.1.7 Minimum required thickness of stainless steel is 1.5 mm when the stainless steel
is attached by continuous fillet welding. When the stainless sheet is attached to its backing
plate by screwing or riveting, the thickness of the stainless steel sheet shall be at least
2.5mm.
5.3.1.8 Guides shall be designed in accordance with Clause 5.3.5.
5.3.1.9 Anchoring arrangement shall be designed in accordance with Clause 5.3.6.
34
..
5.3.2 Particular recommendations for design of sliding assemblies
5.3.2.1 PTFE is commonly used as plane sliding element at the interface capable to
cater for translational movements. UHMWPE (if supported by independent certification
like ETA / FHWA / similar certifying authority) can also be provided as may be required.
Sliding assemblies should not be used to accommodate rotation other than about an axis
perpendicular to the plane of sliding. To accommodate rotation about an axis in the plane of
sliding additional arrangement shall be provided e.g. sliding assemblies may be combined
with other types of bearings like elastomeric bearings, metallic rocker bearings, Pot bearings
etc.
5.3.2.2 Pre-setting of top plate may be allowed, if necessary, while dimensioning it.
5.3.2.3 Sliding assemblies shall preferably have the stainless steel sliding sheet positioned
above the PTFE or UHMWPE, so that the sliding surfaces are kept clean.
5.3.2.4 Surfaces mating with PTFE or UHMWPE shall always be made of stainless steel.
The mating stainless steel surface shall always overlap the PTFE or UHMWPE even when
the extreme movement occurs.
5.3.2.5 Load distribution through the bearing components and the adjacent structures
shall be calculated considering the effective contact area after one vertical to one horizontal
(1V:1 H) of dispersion from confined PTFE / UHMWPE sheets. Effect of eccentricities shall be
applied as per Annexure B.
5.3.3 Particular recommendations for design of Pin Bearing
5.3.3.1 For Pin bearings the pin shall be designed to withstand the design horizontal force
considering the effect of coexisting design rotation. The diameter of pin shall in no case
be less than 150 mm. The inner diameter of the cylinder shall be in accordance with the
tolerance of fit specified in Clause 6.1.4.3.
5.3.3.2 The mating interface of pin and cylinder shall be designed to withstand the design
horizontal force and suitably detailed to facilitate rotational movement.
5.3.3.3 The effective curved contact width of the pin, we' shall be designed and detailed
as per Clause 5.3.1.4.2.
5.3.3.4 The minimum theoretical clearance between the top edge of cylinder and the
bottom edge of pin at design rotation shall not be less than 8, where, 8 =0.01 x di or 3 mm
whichever is greater, but not exceeding 10 mm (refer Clause 5.3.1.5).
5.3.3.6 The resultant of the coexisting moments produced due to design horizontal force
and that induced due to resistance to rotation, if any, shall not exceed the moment of resistance
of the group of anchors. The moment of resistance of the group of anchors shall preferably
be determined considering the position of the neutral axis by an appropriate method with the
35
basic assumption that plane section, normal to axis, remains plane after bending and the
limiting strains in ULS condition. For determining moment of resistance at concrete interface,
design properties of concrete shall be considered as per provisions of IRC: 112.
In absence of a proper evaluation of position of neutral axis, the same should be considered
along the centreline of the anchor(s) located at the edge of the group and parallel to the axis
about which the resultant moment acts. (Fig. 5.11).
Fig. 5.11 Distribution offorces on bolt/screw/stud group
5.3.3.7 Resistance of group of anchors in shear due to design horizontal force and
in tension due to the resultant moment shall be checked as per Clause 5.3.3.6 and
Annexure 0/ Annexure F as applicable. If the shear and tension are transferred through the
same anchors, the combined effect shall also be checked as per Annexure 0 / Annexure F
as applicable.
5.3.3.8 The thickness of the plates of the Pin bearing through which it is connected to the
I
:1
structure shall be determined considering the effect of maximum tensile force that may occur
i
II !
on any anchor due to resultant moment.
! I 5.3.3.9 The dimensions of the cylinder wall shall be determined using expressions given
!: in Clause 5.3.1.2.3 to 5.3.1.2.8.
5.3.3.10 Minimum thickness of cylinder base shall not be less than 2.5% of the inner
diameter of the cylinder. Minimum thickness of any steel component or part thereof shall in
no case be less than 16 mm.
5.3.4 Particular recommendations for design of Metallic Guide bearings

5.3.4.1 Metallic Guide bearings shall be provided to resist horizontal force along the
direction perpendicular to the direction along which it allows movement. Metallic Guide
36
bearings should not be used to accommodate rotation other than about an axis perpendicular
to the plane of sliding unless additional rotating device is introduced to accommodate rotation.
5.3.4.2 Sliding interface shall always consist of stainless steel sliding on sliding material
defined in Clause 5.2.4. The coefficient offriction at the sliding interface shall be in accordance
with Table 5.5. The mating stainless steel surface shall always overlap the sliding material
even when the extreme movement occurs.
5.3.4.3 Minimum thickness of any steel component or part thereof shall in no case be
less than 2.5% of the largest plan dimension (diameter or diagonal) or 16 mm, whichever is
higher.
5.3.4.4 The minimum theoretical vertical clearance between the sliding components at
design rotation shall not be less than 5 mm.
5.3.4.6 The resultant of the coexisting moments produced due to design horizontal force
and that induced due to resistance to rotation, if any, shall not exceed the moment of resistance
of the group of anchors. The moment of resistance of the group of anchors shall preferably
be determined considering the position of the neutral axis by an appropriate method with the
basic assumption that that plane section, normal to axis, remains plane after bending and the
limiting strains in ULS condition. For determining moment of resistance at concrete interface,
design properties of concrete shall be considered as per provisions of IRC: 112.
In absence of a proper evaluation of position of neutral axis, the same should be considered
along the centreline of the anchor(s) located at the edge of the group and parallel to the axis
about which the resultant moment acts.
5.3.4.7 Resistance of group of anchors in shear due to design horizontal force and
in tension due to the resultant moment shall be checked as per Clause 5.3.4.6 and
Annexure D / Annexure F as applicable. If the shear and tension are transferred through the
same anchors, the combined effect shall also be checked as per Annexure D / Annexure F
as applicable.
5.3.4.8 The thickness of the plates of the Guide bearing through which it is connected to
the structure shall be determined considering the effect of maximum tensile force that may
occur on any anchor due to resultant moment.
5.3.4.9 Components of the Metallic Guide bearing shall be checked for bending, shear
and combined resistance due to the effect of design horizontal force.
5.3.4.10 Cantilever vertical projection of metallic guide bearings shall be checked as per
Annexure C.
5.3.5 Design of guides for Pot bearings with Sliding assemblies
5.3.5.1 Sliding surfaces for guides of Pot bearings with sliding assemblies shall be
37
made of stainless steel sliding on either confined PTFE or UHMWPE or Composite Material
(CM1). The coefficient of friction at the sliding interface of guides shall be considered as per
Table 5.5.
5.3.5.2 For characteristics strength of sliding materials, refer Table 5.4
5.3.5.3 Cantilever vertical projection of guide of pot bearings shall be checked as per
Annexure C.
5.3.5.4 Guides shall either be in the form of one guide bar located centrally on the piston
of Pot bearing / fixed plate of sliding assembly or two guide bars attached sidewise to the
sliding plate.
5.3.5.5 Guides shall be monolithic or welded (refer Clause 6.2.1) to the component to
which it is connected. The thickness of the component to which the guide is connected shall
in no case be less than the thickness of the guide, measured along the direction of horizontal
force acting on the guide.
5.3.5.6 For central guides the thickness of the portion of sliding plate recessed to
accommodate guide shall not be less than 0.5 times the thickness of the sliding plate or 0.3
times the width of the recess or 12 mm, whichever is higher. (Fig. 5.12).
Thickness of the sliding plate

Thickness of the recessed
portion of sliding plate
width of the recess

-------j-.--------1~
to accomodate guide
Fig. 5.12 Recess in Sliding Plate for Central Guide
5.3.5.7 For central guides the vertical clearance between the guide and the recessed
sliding plate shall not be less than 0.2 percent of the length of the recess or 3 mm, whichever
is higher.
I 5.3.6 Design of anchoring arrangement
5.3.6.1 Bearings should be designed and detailed to make it replaceable with minimum
lifting of the superstructure.
5.3.6.2 Design of fasteners:
5.3.6.2.1 Bolts of property class as required to satisfy the design requirement in

Annexure D shall be used for positive anchoring of the bearings with the adjoining structures.
The diameter, grade and number of the anchor bolts shall be so chosen such that it satisfy
the below expressions:
38
l
Resistance in Shear:
vxY,sd <- VRd

Where,
11k
VRd =-Y/l X NSdmin + VPd
'
VPd =n x Fv,Rd
Where,
Vxy,sd = Design horizontal force at ULS
VRd =Total resistance to force that including the anchorage strength and frictional resistance
VPd =Design value of anchorage resistance in Shear
NSd ,mm
. = Minimum vertical load on the bearing in ULS coexisting with V xy, Sd
J.ik = characteristic value of friction coefficient between bearing and adjacent structure
= 0.4 for steel on steel

= 0.6 for steel on concrete
y~ =Partial safety factor for friction
= 2 for steel on steel
n =Number of bolts
F v,Rd =Design shear resistance of single anchor as per Annexure D.
In case of dynamically loaded structures where extreme load fluctuations can occur e.g.
railway bridges or for structures in high seismic zones (Zones IV and V), contribution due to
friction shall not be taken into consideration while designing the anchorage i.e. J.ik=O
5.3.6.2.2 The edge distance for bolt/screw shall not be less than 1.5 times the diameter of
hole and the centre to centre distance shall not be less than 3 times the diameter of hole.
5.3.6.2.3 When fasteners (bolts / screws) are not fastened using compatible class of nut but
fastened inside tapped threaded holes in steel housing, the minimum fastening thread length
shall be as per Table 5.6
39
Table 5.6 Minimum Fastening Thread Length of Bolts I Screws Inside Plate
Material of steel Class of Bolts I Screws of Nominal Diameter of 'd'

housing
4.6 8.8 10.9
E250 1.0d 1.5d 1.8d
E350 0.8d 1.2d 1.5d
5.3.6.2.4 Slip critical/friction type joints may be designed as per IS: 4000
5.3.6.2.5 For temporary fasteners the above stipulations may be relaxed.
5.3.6.3 Design of shear studs
5.3.6.3. 1 Shear Stud Connectors - resistance in shear
Concrete Inserts when adopted in the form of Headed Shear Stud shall be minimum 16 mm
and maximum 25 mm in diameter. Also the nominal length of the stud shall be at least 3
times the stud diameter in any case. Headed Shear Studs should be welded as per Arc Stud
Welding Method in compliance with ISO 14555 and ISO 13918.
The design shear resistance of the headed studs embedded inside the concrete as well
design tension resistance, where applicable, shall meet or exceed the total shear for-ce as
per the expression below:
Vxy,sd -< VRd
Where,
Ilk
VRd =-
YJ1.
X NSdmin
'
+ VPRd
,
V
p,Rd = ns x PRd , where
VXY,Sd = Design horizontal force at ULS
V
Rd = Total resistance to force that including the anchorage strength and frictional
resistance
Vp,Rd = Design value of anchorage resistance in Shear
N~~ = Minimum vertical load on the bearing in ULS coexisting with V~ Sd
fJ k = characteristic value of friction coefficient between bearing and adjacent structure

Y/1 = Partial safety factor for friction
40
ns = Number of shear studs
PRd =Design shear resistance of single shear stud as per Annexure F.

In case of dynamically loaded structures where extreme load fluctuations can occur e.g.
railway bridges, structures in high seismic zones (Zones IV and V), contribution due to friction
shall not be taken into consideration while designing the anchorage i.e. IJk 0 =
Where headed stud connectors are subjected to direct tensile force in addition to shear, the
design tensile force per stud F ten should be calculated. If F ten :5 0.1 P Rd' the tensile force may
be neglected. Otherwise, special provision shall be made separately to cater for the tension
force on the anchorage.
5.3.6.3.2 Headed shear studs shall be spaced at a centre to centre distance of minimum 5
times the diameter of studs along direction of force and 2.5 times in other direction.
5.3.6.4 Design of anchor sleeves in concrete
5.3.6.4.1 The diameter of the anchor sleeves shall in no case be less than twice the nominal
diameter of bolts/screws (Fig. 5.13). Length of sleeve shall in no case be greater than five
times its diameter.
5.3.6.4.2 The resistance of concrete adjacent to the anchor sleeve, calculated as per the.
following expression, shall be greater than or equal to the design resistance in shear of single
bolt / screw calculated as per Annexure D.
. '.. ~: ~
.•.. '~
... '
:
... : " .' "">
l--'---~-,' ~. . "
I <J
~
• J'
II <J
I
I il <J
I
I
I
I <J
..
...
l '
__
I Ll :• .' -, .: • .-
L____il__ -=-_~_~ ~_~_~

~I 01I.....
Fig. 5.13 Typical Arrangement of Anchor Sleeves
F - fed
Rdu - D X L X ...f3
FRdu = resistance offered by concrete in ULS
41
lin
------------- --- - -- ------------------------
: I
f cd = Permissible direct compressive strength of concrete, calculated as:

f cd 0.67 x tck
=--~
1.5
5.3.6.5 Tension anchors, if needed, shall be designed as per ACI 318M or CENITS
1992-4-1.
6 MANUFACTURE
6.1 Manufacturing Tolerances
6.1.1 The overall dimensions of any assembled bearing or component thereof shall not
exceed the following tolerance limits given in Table 6.1
Table 6.1 Tolerance Limits
Plan dimension of assembled bearing -0 mm to +5 mm or 0.5 percent of plan

dimension (diameter or diagonal), whichever
is higher
Overall height of assembled bearing -0 mm to +5 mm or 3 percent of overall height,

whichever is higher
."
Parallelism of top surface of assembled 1 in 200
bearing w.r.t. the bottom surface as
datum
Height of confined elastomeric pressure -0 mm to +2.5 mm for di S 750 mm and -0 to

pad +di/300 for 750 mm < di < 1500 mm
Thickness of any machined steel -0 to +1 mm

component
Centre to centre of anchor bolt holes -1 mmto+1 mm
Stainless steel sliding surface
a) Flatness 0.0003L or 0.2 mm whichever is higher, where

L =length in direction of major movement
b) Surface finish Rz S 1 IJm as per ISO 4287
6.1.2 Flatness of backing plate in contact with sliding material shall be 0.0003 d or
0.2 mm, whichever is higher, here d is diameter or diagonal of the sliding material.
6.1.3 The shoulders of the recess of sliding material shall be sharp and square to restrict
the flow of sliding material. The radius at the root of recess shall not exceed 1 mm.
42
The depth of confining recess shall be as per Table 5.3.
In principle the sliding material shall fit the recess without clearance. Intermittent gap between
edge of sliding material and the recess shall not exceed the values given in Table 6.2
Table 6.2 Tolerance on Fit of Sliding Surface in the Recess
Dimension L (mm) Gap (mm)
75 - 500 0.5
501 - 1000 1.0
1001 - 1500 1.5
6.1.4 Tolerance of fit between different components of bearings shall be as follows:

6.1.4.1 The maximum diametrical clearance between the pot and piston shall not exceed
1 mm.
6.1.4.2 After filling up Elastomeric Pad inside the POT bearing the peripheral gap shall not
exceed 0.2 percent of the diameter of the pad or 1.0 mm whichever is higher.
6.1.4.3 For Pin bearings the diametrical clearance between the pin and cylinder shall be
+1.0 mm to +2.0 mm.
6.1.4.4 The tolerance of fit between sliding material of guide(s) and adjacent stainless
steel surface shall be +1 mm to +4 mm.
6.1.4.5 Surface Roughness
6.1.4.5.1 Surface Roughness Rz of the inner cylindrical surface of the pot in contact with the
elastomer shall not exceed 6.3 IJm.
6.1.4.5.2 Surface Roughness Rz of the plane surface of pot or piston in contact with the
elastomer shall not exceed 25 IJm.
6.2 Manufacturing Method
6.2.1 The main components of bearing shall be made as a single monolithic body.
However, in case welding is to be used for fabrication of main components, then the same
shall be allowed only if the manufacturer is having ISO 3834-2 certification along with EN
1090 or AISC certification.
6.2.2 For sliding components stainless steel sheet shall be attached to its backing plate
by continuous fillet welding along the edges in such a fashion so as to ensure flatness of
the stainless steel sheet throughout its service life and avoid entrapment of air and prevent
ingress of moisture at the interface. The backing plate shall extend beyond the edges of
the stainless steel sheet to accommodate the weld and the weld should not protrude above
43
II I
, I
IRC:83 (Part-III )-20 18
the stainless steel sheet. The heat affected zone (HAZ) of the stainless steel sheet shall be
protected with corrosion protection measure.
6.2.3 PTFEI UHMWPE shall be secured and confined in the recesses preferably by
shrinking fit method only for confinement. Glue may be used for vertical surfaces e.g. Guide
I Guide bearing. For large PTFE/UHMWPE sheets subdivided into parts, each individual part
shall be confined into separate recess.
6.2.4 For brass sealing ring type of internal seal, the configuration of the sealing system
shall be as per Table 6.3.
Rings with a minimum cross-section of 10 mm X 2 mm may have slits 7 mm deep' 0,5 mm

wide spaced at 5 mm around the inner diameter to facilitate forming. Rings with a smaller
cross-section shall not have slits.
Table 6.3 Allowable Solid Brass Sealing Ring Configurations
Diameter di mm Minimum cross section mm Slits Number of rings
:5 330 6 X 1,5 Not permitted 2
> 330 < 715 10 X 1.5 Not permitted 2
=715 <1500 10 X 1.5 Not permitted 3
< 1500 10 X 2 7 mm X 0,5 mm 3

5 mm spacing
6.2.5 For POM sealing chain type of internal seal, the sealing chain, made of individual
interlocking elements, shall be moulded as an integral part of the elastomeric pressure pad
during the vulcanisation process for proper functioning. Width and height of the individual
elements shall be:
a) elastomer diameter di:5 550 mm : 10 mm ± 0.5 mm;
b) elastomer diameter di> 550 mm: 15 mm ± 1.0 mm.
6.2.6 The carbon filled PTFE seal shall be completely recessed into the elastomeric
pad.
6.2.7 Stainless Steel seal shall be made from stainless steel strip formed into an equal
or unequal angle section inserted between the elastomeric pad and the pot wall. The leg
length and thickness of the section shall meet the following.
a) with notches:
where diameter di:5 700 mm - leg length 5 mm to 10 mm, thickness 1 mm minimum; where
diameter di > 700 mm mm leg length 15 mm to 17 mm, thickness 1,5 mm minimum; the
44
I
l
minimum overlap of the ring ends shall be 20 mm; where the thickness> 1 mm, the ends
shall be reduced in thickness at the overlap position.
b) without notches:
minimum leg length 3 mm; minimum thickness 1 mm; minimum overlap 5 mm; where the
thickness> 1 mm, the ends shall be reduced in thickness at the overlap position.
6.2.8 Any pre-setting of sliding element, if required, shall preferably be done in the
manufacturer's workshop before dispatch.
6.2.9 Bearings shall be provided with temporary transportation clamps to avoid

separation of parts during transportation and erection.
6.2.10 All welding shall be done by qualified welder on the basis of applicable WPS and
the same shall be preapproved by certified welding inspector subject to qualification tests.
All welding processes applied will be as per IS: 816 & IS 9595 with electrode or filler material
used as per IS: 814 or IS: 1278 or any other relevant applicable standards respectively. The
approved welder qualification record and relevant WPS & WPQR shall be made available
during inspection.
6.2.11 Headed Shear Studs should be welded as per Arc Stud Welding Method in
compliance with ISO 14555 and ISO 13918.
6.2.12 Movement indicators may be provided for bearing with sliding assembly to facilitate
routine inspection during service period.
6.2.13 All sharp edges, including edge of bolt holes (except housing recess of sliding
material) shall be made blunt by chamfering.
6.3 Finishing
6.3.1 Corrosion Protection
6.3.1.1 All non-working exposed surfaces, including 50 mm (min.) return on surfaces to

be in contact with concrete I steel shall be treated with full corrosion protection system as per
ISO 12944. Extremely severe zone as marked in Corrosion Map of India shall be considered
as C5M/C51 category, severe zone shall be considered as C4 category. All other zones of
Corrosion Map of India shall be considered as C3 category.
6.3.1.2 The surfaces mentioned above shall be suitably prepared by sand I grit blasting to
cleanliness standard of Sa 2% (minimum) as per ISO 8501-1. For thermal spraying of zinc,
surfaces cleanliness standard should be Sa 3.
6.3.1.3 Subsequent to surface preparation as stated above, all non-working exposed

surfaces shall be given suitable protective coat by painting or by thermal spraying of zinc.
Thermally sprayed surface should be covered with at least one coat of barrier coating. The
protective coating shall be designed as per ISO 12944-5 for high durability with life more
45
~. [ :'
f.'11.!
"
'Ii' i:I·I!
I, than 15 years. Total dry film thickness for any corrosivity category shall not be less than the
I:
'I' minimum DFT value specified in Table 6.4.
il
Table 6.4 Minimum OFT as per Corrosivity Category
Corrosivity Category Min. OFT
C5M/C51 320l..lm
C4 240l..lm
C3 160l..lm
6.3.1.4 Application of protective coating shall comprise with sacrificial primer coating and
barrier coating followed by a finish coat comprised of material mainly used for UV protection
against degradation of paint system.
Most commonly used coating specification is as given below:
- Zinc rich epoxy primer or thermally sprayed zinc or zinc rich ethyl silicate primer
as sacrificial primer coat
- Epoxy MIO I Epoxy or equivalent as intermediate coat
- Polyurethane I Epoxy as finish coat
6.3.1.5 Bearing components to be in contact with concrete structure beyond return zone
of full corrosion protection shall be given a nominal sacrificial coat as mentioned in Clause
6.3.1.4 before despatch to prevent corrosion during transportation and storage at site. The
protective coating shall not affect the bond between the bearing component and the concrete.
6.3.1.6 Bearing component in contact with steel structure or any steel to steel contact
surface of the bearing shall be provided with a coat of Zinc Rich Ethyl Silicate primer beyond
return zone of full corrosion protection system.
6.3.1.7 Surface of backing plates in contact with sliding material shall be provided with a
nominal sacrificial coat before fixing of sliding material.
tl I. 6.3.1.8 For corrosivity category C4 and above, all fasteners shall be either hot dip
!'\,1 galvanized to minimum 40 I..Im or applied with equivalent Dacromet coating. For all other
;1
~
corrosivity category electrogalvanized coating of 15 I..Im may be adopted.
l
6.3.2 Appropriate silicon grease shall be applied at the sliding material - stainless steel
interface of bearing.
46
6.3.3 Appropriate silicon grease shall be applied to lubricate the pressure pad which
must not affect the material of confined elastomer.
7 ACCEPTANCE SPECIFICATION
7.1 General
7.1.1 Bearings shall be manufactured to high standards both in terms of material quality
and workmanship. The manufacturer shall have requisite load test and NOT facilities required
for process and acceptance control tests installed at his plant. The test facilities and their
operation shall be open for inspection. For confirmatory tests on raw materials, tests shall be
conducted at in-house facility of the manufacturer or at NABL accredited laboratory.
7.1.2 As a prerequisite, the bearing manufacturer shall be certified in accordance with

ISO 9001. In addition, the following requirements shall be fulfilled by the manufacturer.
7.1.2.1 Fabricated construction of component is allowed only if the manufacturer is

having ISO 3834-2 certification along with EN 1090 or AISC certification, all welders should
be qualified and duly certified in accordance with ISO 9606 or IS: 7318 or AWS 01.5. The
manufacturer should have on-board qualified welding inspector holding CWI / CSWIP / IWE
/ IWT qualification.
7.1.2.2 NOT Level II experts for visual test, liquid penetration test and ultrasonic test
should be available onboard with the manufacturer.
7.1.2.3 On-board availability of NACE Certified Coating Inspector (Level 1) and certified
spray metalizer are also preferred.
7.1.3 All tests on raw materials and finished bearings shall be carried out as per
procedures described in this section. All the test reports duly certified by the inspector shall
be furnished by the manufacturer at the time of despatch of the bearing.
7.1.4 Acceptance testing shall commence with the prior submittal of testing program
in form of Inspection and Test Plan (ITP) prepared by the manufacturer and approved by
concerned authority, to the inspector.
7.2 Inspection Procedure
7.2.1 Inspection and testing of the bearings shall require the following two types of tests:
7.2. 1. 1 Type test
Type test, which includes inspection and testing as per Clauses 7.4.2 & 7.4.3 shall be carried
out on at least one bearings of each type and load capacity selected at random. The inspector
may also carry out random tests as per Clause 7.4.1 as per approved Inspection and Test
Plan on raw material samples drawn by the manufacturer for such tests. In such cases the
inspector may be present for identification and marking of the sample when it is drawn.
47
7.2. 1.2 Routine test

Routine test, which includes inspection and testing as per Clauses 7.4.1, 7.4.2 & 7.4.3 shall
be carried out by the manufacturer for the bearings of each lot under acceptance.
7.2.2 The various inspection and tests may be classified into the following categories:
- Raw materials inspection.

- Inspection and testing of finished bearings.
- Process inspection.
7.3 Quality Control Report

A detailed quality control report of routine test shall be furnished by the manufacturer to the
inspector, for each lot of bearing offered for inspection.
7.4 Detail of tests

7.4.1 Tests on raw materials
7.4.1.1 Mill Test Certificates (MTC) shall be furnished by the manufacturer. In absence
of MTC, test on raw materials as per relevant material standards shall be carried out by the
manufacturer and Test Report shall be furnished.
7.4.1.2 The manufacturer should be able to establish the traceability of all major raw
material (Annexure G) with procurement and consumption record and Mill Test Certificate/
material test report.
7.4.1.3 Mill Test Certificates (MTC) or material test report carried out by manufacturer
shall at least include the materials and control parameters described in Annexure G
7.4.2 Process Inspection:

7.4.2. 1 All bearing components shall be checked for dimension control as per manufacturing
tolerances specified in Clause 6.1.
7.4.2.2 Tolerance of fit and surface roughness shall be controlled as per Clause 6.1.
7.4.2.3 Major metallic components as specified in Annexure G, shall be ultrasonically

tested for soundness as per Level: 3 of IS: 9565 prior to use in bearings.
7.4.2.4 All structural welds shall be visually checked for weld size and location as per
drawing as well as controlled as per the following tests:
- Visual test (all structural welds)
- Liquid penetration test as per IS: 822 (all structural welds)
- All full penetration butt welds shall be controlled through ultrasonic testing as per IS 4260
/ AWS D1.5 / ASME Section VIII
I,
48
.1
l
7.4.2.5 Corrosion protection: Corrosion protection measures shall be controlled in

accordance with the requirement specified in Clause 6.3.
7.4.3 Inspection of finished bearings
7.4.3.1 All bearings of the lot shall be visually inspected for absence of any defects in
surface finish, shape or any other discernible superficial defects.
7.4.3.2 All bearings shall be checked for overall dimensions as per manufacturing
tolerances specified in Clause 6.1.
7.4.3.3 At least one or a pair of bearings (depending on the requirement) of each type and
different vertical load capacity selected at random shall be load tested as described below:
7.4.3.3.1 Proof Load test: Bearings shall be load tested for a test load equal to 1.5 times
the specified design vertical load in SLS condition. Load shall be applied gradually and the
test load shall be held for 30 minutes. The load shall then be removed and the bearing shall
be dismantled and visually examined as given in Clause 7.4.3.4.
7.4.3.3.2 Friction test: For bearings with sliding component, friction test shall be performed
to determine static coefficient of friction of properly lubricated sliding interface at constant
vertical load equal to the design vertical load in SLS condition. Test assembly may comprise
of a pair of bearing or a bearing and dummy sliding interface made of similar material. The
horizontal load shall be applied till sliding occurs. Coefficient offriction (~) shall be determined
as the ratio of Horizontal Load at which sliding occurs divided by 2 times the applied Vertical-
Load (two times the vertical load in denominator represents two sliding interface due to use
of a pair of bearing or a bearing with dummy sliding interface). The value of coefficient of
friction shall not exceed the value specified in Clause 5.2.4.6.
7.4.3.3.3 Rotation test: Rotation test shall be performed on Pot bearing with properly
lubricated elastomeric pressure pad under a constant vertical load equal to design load in
SLS condition and for rotation value of 0.02 radian or design rotation, whichever is higher.
Rotation may be applied using tapered plate having slope of test rotation value.
7.4.3.4 The test bearing(s) shall be visually examined both during and after the test.
Any resultant visual defects such as physical destruction, cold flow of sliding material with
reduction of projected height beyond 0.5 mm, damage of internal seal and/or extrusion of the
confined elastomeric pressure pad for Pot bearing, defects / cracks at metal-to-metal contact
surfaces etc. shall cause rejection.
7.4.3.5 Proof Load test, Friction Test and Rotation Test are normally not applicable for
Pin and Metallic Guide Bearings. In case of any special requirement of load test for Pin or
Metallic Guide Bearing, the test specification, requisite test facility and fixing arrangement
of the bearing in test rig shall be pre-discussed and agreed upon with the manufacturer and
included in the approved ITP.
49
7.4.4 In case of any evidence of process of acceptance control testing being deemed
unsatisfactory by the inspector, complete bearing or particular component(s) of the entire lot
may be rejected depending on the cause of rejection i.e. if the raw material testing result of
any material is unsatisfactory the component(s) involving that material shall be rejected for
the entire lot but if a finished bearing fails in load test the complete bearing shall be rejected
and all the bearings of that type and load capacity shall be load tested before acceptance.
If the result of process inspection is unsatisfactory, proper rectification measures should be
adopted and the acceptance test(s) shall be repeated.
8 CERTIFICATION & MARKING
8.1 Certification and marking should be done as follows:
8.1.1 Bearings should be transported to bridge site after final acceptance by the inspector/
inspection agency appointed by the concerned authority and shall be accompanied by an
authenticated copy of the certificate to that effect.
8.1.2 It is desirable to list the required bearing characteristics in a consistent and

comprehensive manner in an information card duly certified by the manufacturer and append
the same with the inspection certificate.
8.1.3 All bearings shall have suitable index markings made of indelible ink or flexible
paint, which if practicable shall be visible after installation, identifying the following information:
• Name of manufacturer
• Month and year of manufacture
• Bearing designation
• Type of bearing
• Load and movement capacity
• Centreline markings to facilitate installation
• Direction of major and minor movement, if any
• Pre-set, if any
i!I,: 9 INSTALLATION
,
"11
III 9.1 General

I
1
I
9.1.1 Bearings should be installed with care to ensure their correct functioning in
accordance with the design for the whole structure. Bearings shall be so located as to avoid
accumulation of dirt and debris likely to interfere with their performance and the structure so
detailed that water is prevented from reaching the bearings. Proper installation of bearing is of
utmost importance to ensure proper functioning of bearing and its durability. Poor installation
may not only damage a high quality bearing but also may cause damage, instability and
collapse of structures.
50
9.1.2 In order that moving surfaces are not contaminated, bearings should not normally
be dismantled after leaving the manufacture's workshop but if for any reason they are, then
this should only be done under expert supervision and the manufacturer's assistance should
be sought.
9.1.3 Transfer of superstructure weight on to bearings should not be allowed until

sufficient strength has developed in the bedding material to resist the applied load. Temporary
clamping devices should be removed at an appropriate time before the bearings are required
to accommodate movement. Consideration should be given to any treatment required to
holes exposed on the removal of temporary transit clamps. Where reuse of these fixing holes
may be required, the material selected to fill them should not only give protection against
deterioration but also should be easily removable without damaging the threads.
9.1.4 Suitable temporary supporting arrangements under bearing base plates should
be made to accommodate thermal movement and elastic deformation of the incomplete
superstructure, if necessary. Such temporary supports, if provided, should be compressible
under design loading or removed once the bedding material has reached the required
strength. Any voids left as a consequence of their removal should be made good using the
same type of bedding material. Steel folding wedges and rubber pads are suitable for such
temporary supports under bearing base plates.
9.1.5 A bearing will only work properly if the connected parts of the structure are rigid
enough. This is usually achievable for massive concrete structure with properly done bedding-
(Clause 9.2). But in case of steel superstructure an increased level of stiffness with adequate
stiffeners to avoid local bending / buckling of bottom girder seating above the bearing is
absolutely necessary.
9.1.6 Correct location and orientation of the bearing with respect to the structures is
of immense importance Mixing up in location or orientation may cause severe structural
instability during construction and service.
9.1.7 Stability of structure or structural component (girder) over bearing shall be ensured
at every stage of construction. Adequate external support/arrangement may be necessary
to ensure stability of superstructures or its part at every stage of construction and till overall
stability of the structure is achieved.
9.2 Bedding
9.2.1 Bearing shall not be placed directly on matured concrete surface without use of
appropriate bedding material.
9.2.2 The choice of bedding materials is influenced by the method of installation of the
bearings, the size of the gap to be filled, the strength required and the required setting time.
When selecting the bedding material, consideration should therefore be given to various
factors like type of bearing, size of bearing, loading on bearing, construction sequence and
timing, early loading, friction requirements, access around the bearing, thickness of material
51
!:
required, design and condition of surface in the bearing area, shrinkage of the bedding
material etc. as appropriate.
9.2.3 The thickness of the bedding material should be made as less as possible
maintaining the requirement of workability and strength.
9.2.4 It is essential that the composition and workability of the bedding material be
specified with the above factors in mind. In some cases it may be necessary to carry out
trials to ascertain the most suitable material. Commonly used materials are non-shrink, free
flow, cementitious or chemical resin mortar and grout.
9.2.5 To ensure even loading on bearings and the supporting structures, it is essential
that any bedding material whether above and below the bearing, extend over the whole area
of the bearing. Improper application of bedding material, below and above the bearing, i.e.
voids, gaps, impurity etc. may attribute to failure of the bearing irrespective of the quality of
the product.
9.2.6 Bearings shall be bedded over their whole area. After installation there shall be no
voids or hard spots. The bedding material shall be capable of transmitting the applied load to
the structure without damage. Surfaces to receive bedding mortar shall be suitably prepared
to a state compatible with the mortar chosen. The top surface of any extension of the bedding
beyond the bearing shall have a downward slope away from the bearing.
9.3 Fixing of Bearing
9.3.1 To cater for vibration and accidental impact, some anchorage should be provided.
Anchorage should be accurately set into recesses cast into the structure using templates and
the remaining voids in the recesses should be filled with material capable of withstanding the
loads involved.
9.3.2 Bearings that are to be installed on temporary supports should be firmly fixed to
the substructure by anchorage or other means to prevent disturbance during subsequent
operations. Finally voids beneath the bearings should be completely filled with bedding
material using the appropriate method.
9.3.3 Bearings may be fixed directly to metal bedding plates that may be cast in or
bedded on top of the supporting structure or bottom of superstructure to the correct level
and location. It is not advisable to fix foundation anchorages to both substructure and the
superstructure simultaneously. This is for the reason of construction tolerances on the span
length. Generally recess are provided in the substructure for the anchorages.
9.3.4 If the structure is of steel, the bearings may be bolted orwelded directly to it. Proper
care shall be taken to ensure that there are no mismatch in the bolt holes of the structure and
the bearing. In case of welding care should between to assess and avoid damage of bearing
or its components due to heat or distortion.
52
9.3.5 Threaded fasteners shall be tightened uniformly to avoid overstressing of any part
of the bearing.
9.3.6 Where bearings are installed prior to forming an in-situ concrete deck, formwork
around bearings should be carefully sealed to prevent grout / slurry leakage. However,
it is essential that the bearings and particularly the working surfaces be protected during
concreting operations. Sliding plates should be fully supported and care taken to prevent
tilting, displacement or distortion of the bearings under weight of wet concrete. Any mortar
contaminating the bearings should be completely removed before it sets.
9.3.7 For bearings supporting precast concrete elements a thin layer of synthetic resin
mortar should be used between bearings and precast concrete beams. Bearings shall be
bolted to anchor plates or metal bedding plates embedded in precast elements.
9.3.8 For bearing supporting steel elements a machined sole plate shall be used to
ensure proper contact.
9.4 Installation Tolerance
9.4.1 The tolerances given in Clause 9.4.2 shall be observed unless otherwise specified.
9.4.2 Bearings shall be located so that their centrelines are within +/- 3 mm of their
correct position. The level of a bearing or the mean levels of more than one bearing at any
support shall be within a tolerance of +/- 0.0001 times the sum of the adjacent spans of
a continuous girder but not exceeding +/- 5 mm. Bearings shall be placed in a horizontal -
plane within a tolerance of 1 in 200 in any direction unless otherwise specified, even under
superstructure in gradient.
10 MAINTENANCE
10.1 This section stipulates the requirements for inspection and maintenance of Pot,
Sliding, Pin and Metallic Guide bearings during service period.
10.1.1 Bearings should be designed and manufactured to make it maintenance free

so that it can eliminate undesirable effects caused by extreme atmosphere or aggressive
environmental condition / unforeseen events. However, the surrounding area of the bearings
shall always be kept clean and dry to avoid damage to the bearings.
10.1.2 Suitable easy access to the bearing shall be provided for inspection and
maintenance. It is advisable to provide adequate maneuvering space all around the bearing.
Provision shall be made for jacking up the superstructure so as to allow repair/ replacement
of the bearings.
10.1.3 Inspection of bearing at site is required from time to time to ascertain the
performance of the bearings. Periodic nominal maintenance of bearing shall be carried out in
order to ensure beUer performance and longer life of the bearings. The bearings are required
to be inspected at an interval of one year for the first five years and at an interval of two years
53
thereafter. However the bearings shall also be examined carefully after unusual occurrences
like heavy traffic, earthquakes, cyclones and battering from debris in high floods.
10.1.4 The inspection shall be preceded by careful cleaning of the bearings as well as its
surrounding space, depending on the actual conditions around the bearings e.g. deposit of
salt, debris, dust or other foreign material.
10.2 Elements of inspection

10.2.1 Measurement of movement
During inspection at site, measurements are required to be taken and documented to

compute its movement and rotation values in relation to their design values to ascertain
whether the performance of the bearings are satisfactory. To ascertain maximum movement,
measurement should be taken once during peak winter (early morning) and once during
peak summer (afternoon) and corresponding atmospheric temperature should be recorded.
The recorded value of movement shall be compared with the design values.
10.2.2 Measurement of dimensions
Overall dimensions of the bearings are required to be measured and compared with the
actual dimensions to ascertain any excessive stress or strain on the bearing.
10.2.3 Evidence of locked in condition
If any movable or rotating part of a bearing is found to be in locked-in / jammed condition,

necessary rectification measures shall be taken immediately.
10.2.4 Evidence of corrosion
If corrosion of any part of exterior exposed steel surface of the bearing is detected the
following measures may be taken. In addition, the root cause of defect should be searched
and proper actions should be taken to avoid recurrence of the problem.
- Detect affected part
- Wire brush the affected portion to clean of its rust.
- Apply protective coating as per manufacturer's specifications.
10.2.5 Condition of the adjacent bridge structure
The adjacent structure of the bearings are also required to be inspected for any damage and
necessary actions to repair the same, should be taken immediately.
10.3 Results and actions

The results of every inspection has to be recorded in the inspection report and shall be
classified in each case into the following types of action:
54
X No action.
XX Further measurements / long-term monitoring or design analysis needed (e.g.
considering extreme temperatures / exposures, variation of loads etc.). Actions to be outlined
in a report.
XXX Minor repair works e.g. cleaning, repainting etc.
XXXX Repair or replacement of entire bearings or parts of the bearings. Actions to be
outlined in a report.
In case of defects where the cause of necessary actions cannot be determined by the
inspecting person or the responsible bridge engineer, the bearing manufacturer shall be
consulted.
55
j
:1
1
ANNEXUREA
A.1 Typical Load Data Format:
1 Structure Reference
2 Bearing Identification mark
Type of Bearing
3 Number Off
4 Seating Material Upper Surface

and characteristic
strength Lower Surface
Vertical max
permanent
Serviceability
Limit state min
(SLS)
Transverse
. -
5 Design Load (KN) Longitudinal
Vertical max
min
Ultimate Limit
state (ULS)
Transverse
Longitudinal
Irreversible Transverse
Longitudinal
SLS
Reversible Transverse
Longitudinal
6 Displacement (mm)
Irreversible Transverse
Longitudinal
ULS
Longitudinal
56
7 Rotation (Radians) SLS Irreversible Transverse
Longitudinal
Longitudinal
8 Maximum bearing Upper Surface Transverse

dimensions (mm), if
restricted Longitudinal
Lower Su rface Transverse
Longitudinal
Overall height
9 Maximum acceptable reaction to rotation under Transverse

serviceability limit state (kN x m), if restricted
Longitudinal
10 Type of fixing required Upper face
Lower face
11 Corrosivity category (Refer Clause 6.3)
12 Special requirements (if any)
57
ANNEXURE B
B.1 Reduced Area for Eccentric Loading
Ar = Aco (1 - O.75rrf ) for circular loaded area
= Aco - 2e x a for rectangular loaded area

Ar =reduced area
Aco =loaded area for no eccentricity
L =diameter of circular loaded area
a = dimension of loaded area across eccentricity
b =dimension of loaded area along eccentricity
e = eccentricity and the above formula is only valid if the one of following criteria is met:
L
e ::;"8 (for circular loaded area)
b
e ~ "6 (for rectangular loaded area)
L b
NOTE 1: If e >"8 (for circular loaded area) or "6 (for rectangular area), separation of part is
expected and in such cases special measure, if applicable, may be taken to avoid separation.
---
e
- e Ar
0,5 b 0.5 b
---------------~---------I
Fig. B. 1 Reduced Contact Area for Rectangular and Circular Loaded Surfaces
58
ANNEXURE C
C.1 Design Resistance for Guides:
Table C. 1: Types of Guides
a) !. . . . . . . . ! Guides monolithic to plate No weld design

tba 1-- ~I
vSdf-,~
1
J I ..
b) Guides connected by full The design resistance of

penetration butt weld a full penetration butt weld
should be taken as equal
to the design resistance
of the weaker of the parts
connected
c) Guides connected by partial VSd
Vw = - - -
penetration butt weld 2 x L,eff
VSd x ha
Tw = -;---"-"---------;-
{(ku - 2, Zw) x L,ef[}
d1 )
-11
~!
v~-rT1
:s: VSd
V W = -:----=---
2 x L,eff
-~-l- Guides connected by fillet weld

VSd x ha
Tw=---
ku x L,eff
---------------------
v~~l
d2)
J L
Vw = Shear force per unit length of weld
Tw = Tension force per unit length of weld
C.1 ,1 Shear resistance:
VSd = Horizontal force
59
---------------------------
Where,
ku = Thickness of the guide

L,eff = Effective Length of guide
= L + 2 x ha or length of the guide, whichever is greater
L = Length of side sliding material

fy = Yield strength of guide

C.1.2 Bending resistance in combination with shear resistance:
MSd:S:; M Rd, where
MSd = bending moment = VSd X ha

M Rd =Reduced bending resistance
_ k~xL'effx f~
Ym
ha =Height of application of horizontal force on guide
f'y =(1- p) f y
p =0, if VSd:S:; 0.5VRd
_(2 XVSd
- --,::r;;t - 1
)2.If V Sd > 0.5VRd
fy =Yield strength of guide

ym = 1.1 for cast steel
=1.0 for rolled steel

C.1.3 Design of welds for guides:
F w,Ed :s:; F w,Rd ,where,
F w,Ed is the design value of the weld force per unit length = -Jv,3 + T~
Vw = shear force per unit length of weld obtained from Table C.1
Tw = tension force per unit length of weld obtained from Table C.1
F w,Rd = design weld resistance per unit length from Annexure E.
60
ANNEXURE 0
0.1 Design Resistance for Individual Fasteners:
Failure Mode Bolts
Shear resistance per shear plane CX:vx tUb X A

F = -C..-"":"'::'::"_
v,Rd Ym2
FV,Rd = shear resistance per bolt per shear
plane
A gross cross section of the bolt if shear
plane passes through unthreaded portion
A=As i.e" tensile stress area of the bolt if
shear plane passes through the threaded
portion
fUb = Ultimate Tensile Strength of bolt
Where the shear plane passes through the
threaded portion of the bolt:
- for classes 4,6 and 8,8: av = 0,6
- for class 10,9: a v = 0,5
Where the shear plane passes through the
unthreaded portion of the bolt: av = 0,6 for
any class of bolt
Bearing resistance 1.25 x tu x d x t

Fb,Rd = Ym2 ' where,
f is the ultimate tensile strength of weaker
U
material
d is the nominal diameter of bolt
t is the thickness of bearing area
Tension resistance tUb Wh
FtRd -- k2 X X As
,ere
, Ym2
fUb =Ultimate Tensile Strength of bolt
k2 = 0.63 for countersunk bolt,
Otherwise, k2 = 0.9
61
Combined shear and tension FVSd F t Sd

-'-+
FV,Rd
'
1.4 X Ft,Rd :5 1.0, were,
h
Fv,Sd is the design shear force per bolt per

shear plane
Ft,Sd is the design tensile force per bolt
Ym2= 1.25
The bearing resistance Fb.Rd for bolts
- In oversized holes is 0.8 times the bearing resistance for bolts in normal holes.
- In slotted holes, where the longitudinal axis of the slotted hole is perpendicular to the
direction of the force transfer, is 0.6 times the bearing resistance for bolts in round, normal
holes.
For countersunk bolt:
- The bearing resistance Fb Rdshould be based on a plate thickness 'f equal to the thickness
of the connected plate minus half the depth of the countersinking.
62
ANNEXURE E
E.1 Design Resistance for Fillet Weld
The design resistance of a fillet weld may be assumed to be adequate if, at every point along
its length, the resultant of all the forces per unit length transmitted by the weld satisfy the
following criterion:
FW,Ed::; Fw,Rd, where:
FW,Ed is the design value of the weld force per unit length; In case of orthogonal forces applied
on the weld, it should be derived by vectorial addition of two orthogonal forces applied on the
weld.
Fw,Rd is the design weld resistance per unit length.
Independent of the orientation of the weld throat plane to the applied force, the design
resistance per unit length F w,Rd should be determined from:
F w, Rd = fvw, d X a, where:
fvw,d is the design shear strength of the weld
a is the throat thickness = weld leg size

,fi
The design shear strength fVw,dof the weld should be determined from:
fu
fu is the ultimate tensile strength of the weaker part joined
f3 w = 0.8 for E250 grade steel or equivalent

= 0.9 for E350 grade steel or equivalent
Ym2= 1.25
E.2 Design Resistance for Partial Penetration Butt Weld
The design resistance of a partial penetration butt weld may be determined using the method
for a fillet weld given in B.1
E.3 Design Resistance for Full Penetration Butt Weld
The design resistance of a full penetration butt weld should be taken as equal to the design
resistance of the weaker of the parts connected, provided that the weld is made with a
suitable consumable which will produce all-weld tensile specimens having both a minimum
yield strength and a minimum tensile strength not less than those specified for the parent
metal.
63
ANNEXURE F
F.1 Design Resistance for Individual Headed Shear Stud:

The shear resistance of a single headed shear stud shall be derived from the lesser value
when calculated from the following expressions:
2
P Rd = (o.s/u x 0.25nd ), where Yv = 1.25
Yv
2
h - 1 25
= 0.29 a xd .J0.S/
Yv
ckXEcm
1 were Y - .
v
P Rd = Design resistance of single headed stud in shear
ju =Specified min. ultimate tensile strength of the stud material but in no case shall exceed
500 MPa
ex = 0.2 ( dh s+c1) for 3 ::; dhsc ::; 4

hsc
=1 for -
d
>1
d = stud diameter
hsc = length of stud including head

Ecm = short term static modulus of elasticity of concrete as per IRC: 112
fCk = characteristics compressive strength of 28 day's concrete cube
64
ANNEXURE G
G.1 Nominal Control Requirements for Raw Materials:
Table G.1: Nominal control requirements for raw materials
Raw Material Nominal Control Parameters Frequency
Mild / Rolled Chemical Test: For each plate/ heat number

steel (Clause - C, Mn, Si, S, P
4.1.1 )
Mechanical Test: For each plate/ heat number

- Ultimate Tensile Strength
- Yield Stress
- % Elongation
- Charpy Impact Test at -20°C
(for use of bearing in sub-zero
condition)
Ultrasonic Test for Soundness Applicable for all plates of
(as per level 3 of IS: 9565) thickness> 63mm
Cast Steel Chemical Test: For each heat number

(Clause 4.1.2) - C, Mn, Si, S, P
Mechanical Test: For each heat number
- Yield Stress
- % Elongation
Charpy Impact Test at -20°C
(for use of bearing in sub-zero
condition)
Ultrasonic Test for Soundness 100% (each steel casting)
(as per level 3 of IS: 9565)
Forged Steel Chemical Test For each heat number

(Clause 4.1.3) - C, Mn, Si, S, P
Mechanical Test: For each heat number

- Yield Stress
- % Elongation
Ultrasonic Test for Soundness 100% (each steel forging)
(as per level 3 of IS: 9565)
65
Raw Material Nominal Control Parameters Frequency
Stainless Steel Chemical Test For each heat number / per lot of
(Clause 4.1.4) - C, Mn, Ni, Cr, Si, S, Mo & P procurement of each thickness
Mechanical Test: For each heat number / per lot of
- Hardness (EN 10088-1) procurement of each thickness
Unfilled PTFE Mechanical Test: Each production batch

(Table 4.1) - Mass density
- Tensile strength
- Elongation at break
- Ball hardness
UHMWPE UHMWPE Valid approval

document from international
approving bodies like ETA, FHWAor
similar acceptance by other leading
international Specifications in the
name of Bearing Manufacturer
Elastomeric Mechanical Test:

Pad (Table 4.3) - Tensile strength Each production batch
- Elongation
- Hardness
- Tear resistance Once for the entire supply order
- Compression Set
- Accelerated Ageing
- Ozone Ozone test may be conducted on

the compound by the manufacturer
at least once in each quarter
Fasteners Chemical Properties Each size per procurement lot

(Clause 4.8)
Mechanical Properties Each size per procurement lot
Shear Stud Chemical Test Each size per procurement lot

(Clause 4.9) - C, Mn, Si, S, P
~
Mechanical Test Each size per procurement lot
~I,
- UTS .'
- Yield' Stress
- % Elongation
66

Standard Specifications AND Code of Practice FOR Road Bridges

Uploaded by

Copyright:

Available Formats

Standard Specifications AND Code of Practice FOR Road Bridges

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Standard Specifications AND Code of Practice FOR Road Bridges

Uploaded by

Copyright:

Available Formats

IRC:83 (Part-III)-2018

INDIAN ROADS CONGRESS

Price Rs. 600/-

First Published March,2002

(All Rights Reserved. No part of this publication shall be reproduced,

Printed by India Offset Press, Delhi- 110064

S. No. Description Page No.

Personnel of Bridges Specifications and Standards Gommittee .......................................... i-ii

3 Symbols and notations ............................................................................................. 10

7 Acceptance specification ........................................................................................... 47

8 Gertification & marking ................................................................................................ 50

PERSONNEL OF THE BRIDGES SPECIFICATIONS

26 Pandey, R.K. Member (Project), National Highway Authority of India (NHAI),

STANDARD SPECIFICATIONS AND CODE OF

(i) Shri A.K. Banerjee, Convener;

(ii) Shri H.C. Arora;

(iii) Shri Alok Bhowmick;

(iv) Col. Ashok Bhasin;

(v) Dr. S.S. Gaharwar.

Secretary General, IRC

2.1 Pot Bearing

A bearing consisting of a metal piston supported by a disc of unreinforced elastomer that is

2.1.1 Fixed Pot Bearing:

2.1.2 Sliding Pot Bearing:

Free to rotate about any axis in the horizontal plane

Sliding Top Plate

Fig. 2.2 Sliding Pot Bearing

2.1.3 Guided Pot Bearing:

Sliding restrained along this direction

Free to rotate about any axis in the horizontal plane

Sliding Top Plate With

a) With Side Guide

Stainless Steel Plate

;;R-----+------ Internal Seal

b) With Central Guide

Fig. 2.3 Guided Pot Bearing

2.2 Sliding Assembly

2.2.1 Free Sliding Assembly

Stainless Steel Plate

Fig. 2.4 Free PTFE Sliding Assembly

2.2.2 Guided Sliding Assembly:

a) With Side Guide

Sliding Top Plate

-1=====~=~~~~-------:---- Stainless Steel Plate

b) With Central Guide

Fig. 2.5 Guided PTFE Sliding Assembly

2.3 Pin Bearing

- - - - - Anchors (See Fig. 2.8)

--------- External Seal \

2.4 Metallic Guide Bearing

Plane of FreE) Rotation

'- - - _______---'_====~I---- - Bottom T

Fig. 2.7 Metallic Guide Bearing

2.7 Confined elastomeric pressure pad

2.8 Sliding component

2.9 Accumulated slide path

2.11 Internal seal

2.12 External seal

2.14 Anchoring arrangement