SPECIFICATION

&
QUALITY ASSURANCE PROCEDURE

FOR

SANFIELD
ELASTOMERIC BEARINGS

MANUFACTURER

SANFIELD INDIA LIMITED

BHOPAL
Prepared By : Reviewed By :
………………………….. …………………………..
………………………….. …………………………...

Approved By :
………………………
………………………

Page 1 of 34
 1
Quality Assurance Manual
1.0 Introduction

The purpose of a bridge bearing is to support the superstructure at a constant

elevation, to carry all forces from the superstructure into the substructure and to
allow necessary superstructure motions to take place. The Elastomeric Bearings
provides translation and / or rotation by internal deflection of the Elastomer layers
and the Steel laminates sandwiched in between the Elastomer Layers provides
capacity to resist Vertical and Horizontal Loads and Forces.

2.0 MATERIALS

2.1 Steel for Internal laminates, for top Sliding Assembly and for any other component
of the Elastomeric Bearings shall be Rolled Steel conforming to IS: 2062 Grade E250
or Equivalent. The mechanical and chemical properties of the Steel shall comply with
IS: 2062 Grade E250 or as Specified when tested for parameters specified in
Incoming Quality check Plan for Elastomeric Bearings.

2.2 Stainless steel for Sliding Interface and / or for Internal laminates (Optional) shall
conform to AISI 304.

2.3 The elastomer to be used for the Elastomeric Bearings shall be Chloroprene Rubber
complying with the properties as specified in IRC: 83 – 2015 (Part II). The
elastomer shall be tested for parameters specified in Incoming Quality check Plan
for Elastomeric Bearings. The elastomer of the Bearings shall generally have the
following properties:

Property Unit Limiting values

Hardness IRHD 60 + 5

Minimum tensile strength Mpa 14

Minimum elongation at break % 350

Maximum compression set % 35

Accelerated Ageing -

Raw Elastomer Content, min. % 60

Ash Content, max. % 5

 2

2.4 For Sliding Interface, wherever applicable, the raw material of PTFE shall be pure Poly
tetra fluoro ethylene. The mechanical properties of unfilled PTFE shall comply with
grade A of BS: 3784 and BS: 6564.

3.0 MANUFACTURING

Controlled procedure is adopted throughout the manufacturing process to ensure the

quality and conformance of the product with the parameters laid down by the relevant
codes and specifications. Non – Conformance Report is prepared in the specified format
“NON – CONFORMANCE REPORT“ Form No. Q/F/05 Rev. 04 for any deviations
observed throughout the manufacturing process and the error is suitably rectified and is
rerecorded for closing the NCR.

3.1 Raw Material Acceptance

All the raw materials required for the manufacturing of Elastomeric Bearings are
procured from Sanfield (India) Limited’s approved vendors. Further, the incoming
materials are checked for the parameters laid down in “INCOMING QUALITY CHECK
PLAN FOR ELASTOMERIC BEARINGS“ Form No. Q/S/04 Rev. 01. The dimensions of
the incoming materials are recorded in “INCOMING DIMENSION CHECK REPORT” Form
No. Q/F/01 Rev. 00. The raw materials fulfilling the requirements of the above
inspection plan are accepted and are used for the manufacturing process.

3.2 Process inspection

Controlled Quality check at each and every stage of manufacturing is carried out to
ensure the conformance of the product with the drawings or design requirements. Any
deviations, if observed in the manufactured or procured material at this stage are either
suitably rectified by reworking or leads to the rejection of the material. The
observations taken above are duly recorded in Standard Formats.

4.0 Markings

The each and every Elastomeric Bearing shall be provided with an Identification Sticker
having Bearing’s Serial Number, Size, Mfg. Month & Year etc.

5.0 Inspection / Testing

5.1 Inspection and testing of Elastomeric Bearings shall be as specified in Incoming Quality
check Plan for Elastomeric Bearings and consist of two types:

5.1.1 Inhouse Test The Bearings thus manufactured are subjected to rigorous In house
Testing prior to Acceptance Testing as per the relevant Specifications.
 3

5.1.2 Acceptance Bearings passing the In house Test requirements are then offered to
Test the Witnessing Authority for Acceptance Testing which is conforming
to IRC:83-2015 (Part II), Contract Specifications and Approved Testing
procedure.

6.0. Inspection Certificate

The details of the tests carried out both in house and in the presence of the Witnessing
authority are carefully recorded in the standard testing formats along with their
observations. These filled up formats are then compiled and are submitted to the
Witnessing Authority as Test reports.

7.0 Detail of Tests on Completed bearings.

7.1 Test on Specially Moulded Test Pieces

The specially moulded test pieces and dumbles produced from the same / identical
batch or compound and vulcanized under identical conditions are tested for the
following parameters to ensure their compliance with the limits specified in the
relevant specifications :-

i) Polymer Identification Tests.

ii) Hardness Tests.

iii) Tensile Strength Tests.

iv) Tests for Elongation at Break.

v) Compression Set Tests.

vi) Accelerated Ageing Tests.

vii) Ozone Resistance Tests.

viii) Tests for determination of Specific Gravity.

ix) Ash Content Tests etc.

7.2 Test on Finished Bearings

Bearings passing the In house Test requirements are then offered to the Witnessing
Authority for Acceptance Testing. Consideration for Sampling, Testing Frequency and
Tests to be conducted on Finished Bearings etc. shall be made on a lot Basis in
accordance with the relevant contract specifications and approved Testing Procedure.
Following Acceptance tests are performed on the Bearings under acceptance: -
 4

7.2.1 All Bearings of the lot shall be visually checked for surface finish or any other
discernible superficial Defects.

7.2.2 All Bearings of the lot shall be checked for overall dimensions and tolerances to
ensure their compliance with the limits specified in the relevant specifications.

7.2.3 All Bearings of the lot shall be subjected to Short Duration Compressive Stiffness
Tests.

7.2.4 Maximum 10 % and minimum of 1 Bearing per lot shall be subjected to Long Duration
Compressive Stiffness Tests.

7.2.5 Two Bearings selected at random from the Lot shall be subjected to Tests for
determination of Elastic Modulus (for Large Lots only).

7.2.6 The above tested pair of Bearings shall be subjected to Tests for determination of
Shear Modulus (for Large Lots).

7.2.7 One Bearing out of the above tested two Bearings shall be bevelled cut in two pieces
and subjected to the Tests for determination of Adhesion Strength (for Large Lots
only).

7.2.8 The other remaining Bearing out of the above tested two Bearings shall be subjected
to Tests for determination of Ultimate Compressive Strength (for Large Lots only).

The Bearings over which the destructive tests are performed shall be excluded from
the lot accepted. However for the small lots, test for determination of Shear Modulus
is permitted over the randomly selected two bearings out of the Acceptance Lot.

8.0 Final Examination

After Tests are completed, the tested bearings are removed from the test machine and
are examined for any signs of distress, warping, scoring or other permanent defects,
which may affect the serviceability or durability of the bearing.

8.1 Marking

The completely manufactured Elastomeric Bearings shall have suitable markings by

indelible ink or in the form of Stickers to give complete information about the
following:

 Name of Manufacturer  Production Batch No.

 Date of Manufacture  Acceptance Lot No.
 Elastomer Grade Used  Date of Testing
 Bearing Dimensions  Bridge Name & Location
 5

9.0 Packing and Transportation

The bearings thus approved by the Witnessing Authority after complete Testing and
Quality Check are then properly packed with heavy-duty polythene sheets. These
Bearings are then Transported to the site.

10. Installation, Maintenance, Testing and Replacement of Elastomeric

Bearings

For Installation, Maintenance, Testing and Replacement of Elastomeric Bearings,

please refer to Shop Drawings and enclosed manuals.

11. Annexures

11.1 Incoming Quality Check Plan for Elastomeric Bearings – Sheet 1 of 4 to Sheet 4 of 4

11.2 Incoming Dimension Check Report

11.3 Non – Conformance Report Form

11.4 General Inspection and Physical Dimension Check

11.5 Format for Axial Load Test

11.6 Test Format for Determination of Shear Modulus

11.7 Test Format for Determination of Elastic Modulus

11.8 Test Format for Determination of Adhesion Strength

11.9 Test Format for Determination of Ultimate Compressive Strength

11.10 Methodology for Installation of Elastomeric Bearings

11.11 Guidelines for Maintenance of Elastomeric Bearings

11.12 Testing Procedure for Elastomeric Bearings

11.13 Figure showing Test Set-Up for Shear Modulus Tests in Elastomeric Bearings

11.14 Figure showing Test Set-Up for Elastic Modulus Tests in Elastomeric Bearings

11.15 Figure showing Test Set-Up for Adhesion Strength Tests in Elastomeric Bearings
 INCOMING QUALITY CHECK PLAN FOR ELASTOMERIC BEARINGS
Form No. Q/S/04
Rev. No. 01

Component
Test to be Relevant Testing Acceptance Testing
S# to be Procured from Remarks
Conducted Specifications frequency Criteria Agency
tested
1. Steel M/s Essar Steel * Physical Tests: IS: 2062 Grade One Sample Manufacturer’s Test Manufacturers
Plates for Ltd. / SAIL / E250 or Equivalent per Batch certificates shall be Laboratory
Laminates TISCO / furnished.
Rashtriya Ispat 1. UltimateTensile
Nigam / Local Strength
Distributors or (U.T.S.)
Agents 2. Yield Stress
3. % Elongation
* Chemical Tests: Manufacturer’s Test Manufacturers
certificates shall be Laboratory
C, Mn, Si, S and P furnished.

IMP :- In addition to the parameters specified above the Items shall be physically verified and visually and dimensionally inspected
 INCOMING QUALITY CHECK PLAN FOR ELASTOMERIC BEARINGS
Form No. Q/S/04
Rev. No. 01

Component
Procured Test to be Relevant Testing Acceptance Testing
S# to be Remarks
from Conducted Specifications frequency Criteria Agency
tested
2. Elastomer M/s Jyoti Hardness IRC: 83 (Part II) - Samples from 60  5 IRHD Jyoti Rubber
(Neoprene) Rubber 2015 Production Engineers Lab.
Engineers, Minimum Tensile Batches 14 MPa Jyoti Rubber
Bhopal Strength Engineers Lab.
Minimum 350 % Jyoti Rubber
Elongation at Break Engineers Lab.
Maximum 35 % Jyoti Rubber
Compression Set Engineers Lab.
Accelerated Ageing Jyoti Rubber
Engineers Lab.
Maximum change +5% Jyoti Rubber
in Hardness Engineers Lab.
Maximum change - 15 % Jyoti Rubber
in Tensile Strength Engineers Lab.
Maximum change - 30% Jyoti Rubber
in Elongation Engineers Lab.
Ash content 5 % Max. Jyoti Rubber
Engineers Lab.
Polymer Neoprene Jyoti Rubber
Identification Engineers Lab.
Ozone Resistance No cracks shall be Bayer / IRMRA /
Observed at the Attuned Polymer
end of the Test Lab.

IMP :- In addition to the parameters specified above the Items shall be physically verified and visually and dimensionally inspected
 INCOMING QUALITY CHECK PLAN FOR ELASTOMERIC BEARINGS
Form No. Q/S/04
Rev. No. 01

Component
Test to be Relevant Acceptance Testing
S# to be Testing frequency Remarks
Conducted Specifications Criteria Agency
tested
3. Elastomeric Visual Inspection IRC: 83 (Part All Bearings No Visual Defect shall be Observed In House
Bearings II) - 2015
Dimensional Inspection All Bearings Bearings shall satisfy the Limits and In House
and Check for Tolerances specified in Table 5 of
Tolerances IRC: 83 (Part II) – 2015

Short Duration All Bearings Bearings shall not show any sign of In House
Compressive Stiffness defect or cracking and the
Tests / Axial Load Test deflection of the bearings shall be
within limits.
Long Duration Maximum 10 % Bearings shall not show any sign of In House
Compressive Stiffness and minimum of defect or cracking both during and
Tests. 1 Bearing per lot after the Tests.

Shear Modulus (for Two Bearings per 0.9 MPa + 20 % In House

Large Lots) Lot

Elastic Modulus (for Two Bearings per 1 + 20 % In House

Large Lots Only) Lot (0.2 + 0.0005)
S2
Adhesion Strength (for Two Pieces from No evidence of peeling or In House
Large Lots Only) a Test Bearing separation shall be noticed both
per Lot during and after the Tests
Ultimate Compressive One Test Bearing The Vertical compressive stress at In House
Strength (for Large Lots / Piece per Lot failure shall not be less than 60
Only) MPa

IMP :- In addition to the parameters specified above the Items shall be physically verified and visually and dimensionally inspected
 INCOMING DIMENSION CHECK REPORT Form No. : Q / F / 01
Rev. : 00.
Sheet : 1 of 2

Report No.: ……………...……………….……….Date: …………………….

P. O. / W. O. No. : …...…………………………. Date: …………………….

In House M/c / Vendor Code: ……………… MRN No.or Challan No. / Date: ……………/…..…………..

Material Description / Process Details: .…….……………………………………………………………..

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Customer / Project Details: …………...……………………………………………………………………..

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S. No. Item Quantity Product ID No. Remarks

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COMMENTS : Q. C. SEAL

( ACCEPTED /
REJECTED )
TEST CERTIFICATE NO.:

Q. C. Inspector

FILED IN FILE NO. : ……………………….. Q. C. Engr./GM (Tech)

NOTE ; FOR DIMENSIONAL REPORT SEE AT THE BACK SIDE

Page 10 of 34
 INCOMING DIMENSION CHECK REPORT Form No. : Q / F / 01
Rev. : 00.
Sheet : 2 of 2

DIMENSIONAL REPORT

Report No. : ………………………. Date : …………………. Sheet : ……….. of …………

S. No. / Item : …………………….………….....……………... Relevant Drawing No.: ………………………………………..

Revision No.: …………… Qty. Offered : .….………… Qty. Checked : ……...……

Dimension Theoritical ID No. Observed Dimensions

Description Dimension C / Mj / Mn
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S. No. / Item : …………………….………….....……………... Relevant Drawing No.: ………………………………………..

Revision No.: …………… Qty. Offered : .….………… Qty. Checked : ……...……

Dimension Theoritical ID No. Observed Dimensions

Description Dimension C / Mj / Mn
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S. No. / Item : …………………….………….....……………... Relevant Drawing No.: ………………………………………..

Revision No.: …………… Qty. Offered : .….………… Qty. Checked : ……...……

Dimension Theoritical ID No. Observed Dimensions

Description Dimension C / Mj / Mn
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Checked By : Signature …………………….. Name ………………………………………………………… Date ……………………..

Notations : 1) C = Critical ; 2) Mj = Major ; 3) Mn = Minor ; 4) N/A = Not Applicable

Page 11 of 34
 NON – CONFORMANCE REPORT
Ref No.: Dated: Form No. Q/F/05
Rev.04
Item Description:

Quantity:
P.O.No./ W.O.No.: Drawing/Specs.:
Customer:

S.No. Nature of Rejection Quantity

S.No. Reasons for Non – Conformance Quantity

(Quality Incharge)
Accept as it is Rework Reject

Corrective / Preventive Action Suggested:-

GM (Works) / Design Incharge

Prepared By & Date:- Received By & Date:-

Corrective / Preventive Action Taken:-

GM (Works) / Manufacturing Incharge

Re-offered By & Date:- Re-checked by Quality:-
Closed By & Date

Page 12 of 34
 GENERAL INSPECTION & PHYSICAL DIMENSION CHECK
Report No. Dated: Form No.Q/F/14 Rev. 02

Project:

Bearing Size: Date of Inspection:

S. No. Bearing ID Overall Length (lo) Overall Width (bo) Total Brg. Thickness (ho)
mm mm mm
Dim as per drg. +6/-0 6/-0 5% / - 0%
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Remarks

1 Any visual defects in surface finish or shape or any other descernible superficial defects
observed in any of the Bearings. Yes / No

2 All the Bearings were checked for parallelism & tolerances as specified in Table 2 of IRC : 83
(Part-II) and were found satisfactory. Yes / No

Tested by: Witnessed by:

For SANFIELD (INDIA) LTD. For

----------------------------------------------
General Manager (Works) ----------------------------------------------

Page 13 of 34
 AXIAL LOAD TEST
Report No. Dated Form No.Q/F/16 Rev 00
Project :

Date of testing :

Vertical Ram Area : cm2

Sr.No. BEARING - BEARING SIZE EFFECTIVE PLAN STESS VERTI. PRESSURE TIME (min)
ID AREA(mm2) (Mpa) GUAGE Rd. (kg/cm 2
)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Remarks

1 Misalignment of reinforcing plates Yes / No

2 Poor bond at laminate / steel interface Yes / No
3 Variation in hi or he. Yes / No
4 Low stiffness Yes / No
Visual defects were /were not observed.

Tested by : Witnessed by :

For SANFIELD (INDIA) LIMITED. For

______________
______________
Genral Manager (Works)

Page 14 of 34
 TEST FOR DETERMINATION OF SHEAR MODULUS
Form No. : Q / F / 17 Rev. : 02
Project :-

Lot Size :-

Bearing Id ( Sr. No.) :- Date of testing :

Size of the Bearing :- x x mm

2
Effective plan Area of the Bearing :- mm

Vertical Ram Area :- 2827.43 cm2

Horizontal Ram Area :- 785.71 cm2

Total Height of Elastomer in the Bearing ( h ) :- mm

Normal Test Load (N test) (corresponding to Avg. Compressive Stress of 5 Mpa) :- Newtons

Pressure Gauge Reading (to give Compressive Stress of 5 Mpa over the Bearing) :- kg / cm 2

Horizontal Deflection
Range
(  h ) in mm
Strain ( h / h ) 0.2 0.4 0.6 0.8 1.0 0.8
Horizontal Press. Gauge
Reading ( kg / cm 2 )
Horizontal Load
( Newtons )
Stress over Bearing
( MPa )

m = Stress at 1.0 Strain - Stress at 0.2 Strain = - = MPa

2 2

tan  = Final Strain - Initial Strain = 1.0 - 0.2 = 0.8

Shear Stress, G = m = = MPa

tan 0.8

Permissible value of Shear Modulus :-

1 MPa + 20% i. e. 0.7 MPa to 1.15 MPa

Result :- a) No abnormal behavior, deformation and / or destruction of the Bearing and its component
observed both during and after the Testing.

b) As the Observed value of Shear Modulus is within the Permissible Limits as specified in
IRC : 83 ( Part - II ) . Hence Satisfactory.

Tested by : Witnessed by :

For SANFIELD (INDIA) LIMITED. For

______________
______________
General Manager (Works) ______________
 GRAPH OF SHEAR MODULUS FOR ELASTOMERIC BEARINGS

Project :-

Lot Size :-

Bearing Id ( Sr. No.) :- Date of testing :

Size of the Bearing :- x x mm

Deflection Strain Stress Stress Over Individual Bearing

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

Shear Modulus

1.00

0.90

0.80

0.70

0.60
Stress ( MPa )

0.50

0.40

0.30

0.20

0.10

0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 2.00 4.00 6.00 8.00 10.00 12.00
Strain

Page 16 of 34
 TEST FOR DETERMINATION OF ELASTIC MODULUS
Form No. : Q / F / 18 Rev. : 02

Project :-

Lot Size :-

Bearing Id ( Sr. No.) :- Date of testing :

Size of the Bearing :- x x mm

Effective plan Area of the Bearing :- mm2

Vertical Ram Area :- 2827.43 cm2

Total Height of Elastomer in the Bearing ( h ) :- mm

Normal Test Load (Ntest) (corresponding to Avg. Compressive Stress of 10 Mpa) :- Newtons

Normal Test Load (Ntest) (corresponding to Avg. Compressive Stress of 20 Mpa) :- Newtons

Sr.No. Stress on Vert. Pre. Deflection (mm)

bearing Gauge Rd
A B C D Avg.
(Mpa) ( kg/cm 2 )

1 0

2 2

3 5

4 10

5 15

6 20

σm = 20 - 10 = 10.00 MPa , δh = = mm

Ea = σm = 10.00 = 10.00 = MPa

δh / 2 h

Shape Factor of bearing ' S ' * :-

For calculating Permissible value of Elastic Modulus :- 1 / [ ( 0.2 / S ^ 2 )+ 0.0005 ] MPa + 20 %

= MPa + 20 %
Permissible value of Elastic Modulus :-

Maximum Value :- MPa

Minimum Value :- MPa

Result :- a) No abnormal behavior, deformation and / or destruction of the Bearing and its component
observed both during and after the Testing.

b) As the Observed value of Elastic Modulus is within the Permissible Limits as specified in
IRC : 83 ( Part - II ) . Hence Satisfactory.

Tested by : Witnessed by :

For SANFIELD (INDIA) LIMITED. For

______________
General Manager (Works) ______________

* Shape Factor ( S ) = = =

Page 17 of 34
 GRAPH OF ELASTIC MODULUS FOR ELASTOMERIC BEARINGS

Project :-

Lot Size :-

Bearing Id ( Sr. No.) :- Date of testing :

Size of the Bearing :- x x mm

Stress Deflection Strain

- - -

- - -

- - -

- - -

- - -

- - -

Graph for Elastic Modulus

1.00

0.90

0.80

0.70
Stress ( MPa )

0.60

0.50

0.40

0.30

0.20

0.10

0.00 - - - - -
0.000 2.000 4.000 6.000 8.000 10.000 12.000
Strain

Page 18 of 34
 TEST FOR DETERMINATION OF ADHESION STRENGTH

Form No. : Q / F / 19 Rev. : 02

Project :-

Lot Size :-

Bearing Id ( Sr. No.) :- Date of testing :

Size of the Bearing :- x x mm

Effective plan Area of the Bearing :- mm 2

Size of the Test Pieces :- x x mm

( Two test Pieces of above size cut from a Test bearing of I. D. No. )

Effective plan Area of the test Piece :- mm 2 ( x )

Vertical Ram Area :- 2827.43 cm 2

Horizontal Ram Area :- 785.71 cm 2

Normal Test Load (Ntest) (corresponding to Avg. Compressive Stress of 4 Mpa) :- Newtons

Horizontal Test Load (Htest) (corresponding to Avg. Shear Stress of 3 Mpa) :- Newtons

Vertical Pressure Gauge Reading (corresponding to Avg. Compressive Stress kg / cm2

of 4 Mpa over the Bearing) :-

Horizontal Pressure Gauge Reading (corresponding to Avg. Shear Stress kg / cm2

of 3 Mpa over the Bearing) :-

Time of Loading :- Time of Unloading :- Duration of Load :-

Result :- a) No abnormal behavior, deformation and / or destruction of the Bearing and its component
observed both during and after the Testing.

b) As no Stripping Off / debonding of the Elastomer Layers and Steel Laminates is observed
both during and after the Test. Hence Satisfactory.

Tested by : Witnessed by :

For SANFIELD (INDIA) LIMITED. For

______________
General Manager (Works) ______________

Page 19 of 34
 TEST FOR DETERMINATION OF ULTIMATE COMPRESSIVE STRENGTH

Form No. : Q / F / 20 Rev. : 02

Project :-

Lot Size :-

Bearing Id ( Sr. No.) :- Date of testing :

Size of the Bearing :- x x mm

Effective plan Area of the Bearing :- mm 2

Vertical Ram Area :- 7853.98 cm 2

Normal Test Load (Ntest) (corresponding to Avg. Compressive Stress of 20 Mpa) :- Newtons

Axial Compressive Stress on Bearing ( Vertical Pressure Gauge Reading

S. No. Remarks
Mpa ) ( kg / cm 2 )

Time of Loading :- Time of Unloading :- Duration of Load :-

Result :- a) The Bearing was loaded till the failure of the Steel Plate / till the Squeeze out of
the Elastomer / when the average Compressive Stress exceeded 60 Mpa.

b) As, no abnormal behavior, deformation and / or destruction of the Bearing and its
component observed both during and after the Testing.

Tested by : Witnessed by :

For SANFIELD (INDIA) LIMITED. For

______________
General Manager (Works) ______________

Page 20 of 34
INSTALLATION METHODOLOGY FOR ELASTOMERIC BEARING

01. The Levels and the dimensions of the Pedestals shall be checked for
compliance to the Requirements of the Bearing.
02. The position of the bearings shall be accurately marked. The areas
where the bearings will be seated shall be accurately levelled.

03. The concrete surface shall be free from any loose material and cleaned
of any grease, oil, paint etc. It shall be dried at the time of fixing of the
bearing. The surface shall be sandblasted, cleaned of all laitance and
levelled true.
04. A Recess of typ. 5 mm deep and 10 mm plus the bearing dimension
shall be made on to the Pedestal for the Bearing Seating.

05. After the surface preparation, thin layer of Epoxy shall be applied to
the interface of the Bearing and the adjacent Concrete Structure
(both Top and Bottom).
06. Bearings shall then be placed between the true horizontal surfaces and
at true plan position of their control lines marked on receiving surfaces.

07. The Superstructure shall then be slowly lowered down on to the

Bearings alowing the Bearing to bear the load of the Superstructure.

08. The surrounding area shall then be cleaned off all deposits, loose
materials and tools and tackles etc. shall be removed from the job site.

09. When bearings are installed prior to the concreting of the Superstructure,
the forms around the bearings shall be soft enough for easy removal.
Forms shall also fit the bearing snugly and prevent any leakage of
mortar grout. Any mortar contaminating the bearings during concreting
shall be removed before the concrete has set.

10. Care shall be taken in handling & during installation to avoid any
mechanical damage, contamination with oil, grease and dirt, undue
exposure to sunlight and weather that may affect the Bearing Performance.

Page 21 of 34
 1
GUIDELINES FOR THE MAINTENANCE OF
ELASTOMERIC BEARINGS

The Guidelines given in this section are for inspection and maintenance of
Elastomeric Bearings during service period. Bearings are designed and
manufactured to make them virtually maintenance free so that the undesirable
effects caused by extreme atmosphere or aggressive environmental condition /
unforeseen events can be eliminated to a great extent. However, the surrounding
area of the bearings shall always be kept clean and dry to avoid damage to the
Bearings.

Provisions for suitable easy access to the bearing shall be made in the
construction drawings for the purpose of inspection and maintenance. Provision
shall be made for jacking up the superstructure so as to allow replacement of the
bearings, if required at any time in future.
Inspection of Bearing at site is required to be carried out from time to time to
ascertain the performance of the Bearings. Periodic nominal maintenance of
bearing shall be carried out in order to ensure better performance and longer life
of the Bearings. The Bearings are generally required to be inspected at an interval
of approx. one year for the first five years and at an interval of two years
thereafter or as agreed between the client and the contractor. However, the
bearings shall also be examined carefully after unusual occurrences, like heavy
traffic, earthquakes, cyclones and battering from debris in high floods.

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.

Elements of Inspection

The following are recommended inspection elements and actions which are
considered necessary to monitor and upkeep the bearings:

(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.

Page 22 of 34
 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.
(3) Evidence of locked in Condition: If the Bearing is found to be in locked -
in / jammed condition not able to take rotation and / or translation because
of Concrete or Slurry Deposit, necessary rectification measures shall be taken
immediately.

(4) Evidence of Cracking: If cracking or abnormal buldging in any part of the

bearing is detected, the measures to identify the root cause of the problem
shall be taken immediately with necessary replacement and proper actions
should be taken to avoid recurrence of the problem. The possible causes
shall be as follows:

• Excessive Loading on to the Bearing.

• Non – uniform Loading.
• Non-horizontal placing of the Bearing.
• Mishandling at the time of Installation, etc.
(5) Condition of the adjacent Bridge Structure: The adjacent bridge
structure to the Bearings is also required to be inspected for any damage
and necessary actions to repair the same, should be taken immediately.

Results and Actions

The results of every inspection has to be recorded in the inspection report and
shall be deeply discussed with the project Consultants and the Bearing
Manufacturer and classified in different categories depending upon the action
required to be taken like:
(1) Re - inspection and / or monitoring is required

(2) Further measurements / long-term monitoring or design analysis needed

(e.g. considering extreme temperatures / exposures, variation of loads, etc.).

(3) Minor repair works e.g. cleaning, repainting of adjacent Structure, etc.

(4) Replacement / Realignment of entire Bearing.

In case of defects where the cause of necessary actions cannot be determined by
the inspecting person or the Bridge Engineer responsible, the bearing
manufacturer shall be consulted.

Page 23 of 34
 TESTING PROCEDURE FOR ELASTOMERIC BEARING
1 of 8

Scope of Work: -
The main function of a bridge Bearing is to provide a connection to control the
interaction of loading and movement between superstructure and substructure. An
elastomeric Bearing provides the Translation and / or rotation by internal deflection of
the Elastomer whereas the load bearing capacity comes from the reinforcement in the
form of steel laminates sandwiched in between the Elastomer Layers.
Test Set-Up: -
The test set-up consists of 1000 MT and 4000 MT capacity test presses used for
compressive loading having 300 MT and 1000 MT capacity hydraulic jacks for
horizontal loading respectively. The pre-calibrated dial gauges are used for measuring
the displacement. Suitable load bearing plates, wedge plates, distribution Plates etc., are
used as and when required.
Acceptance Testing and Inspection: -
Test on Specially Moulded Test Pieces: -
The specially moulded test pieces and dumbles produced from the same / identical
batch or compound and vulcanized under identical conditions are tested for the
following parameters to ensure their compliance with the limits specified in the relevant
specifications: -
i) Polymer Identification Tests.
ii) Hardness Tests.
iii) Tensile Strength Tests.
iv) Tests for Elongation at Break.
v) Compression Set Tests.
vi) Accelerated Ageing Tests.
vii) Ozone Resistance Tests.
viii) Tests for determination of Specific Gravity.
ix) Ash Content Tests etc.
In addition to the above tests, the completely manufactured and finished Bearings are
also subjected to rigorous in house Testing prior to Acceptance Testing as per the
relevant Specifications.

Page 24 of 34
 TESTING PROCEDURE FOR ELASTOMERIC BEARING
2 of 8

Acceptance Test: -
Test on Finished Bearings: -
Bearings passing the In house Test requirements are then offered to the Witnessing
Authority for Acceptance Testing. Consideration for Sampling, Testing Frequency and
Tests to be conducted on Finished Bearings etc. shall be made on a lot Basis in
accordance with the relevant contract specifications. Following Acceptance tests are
performed on the Bearings under acceptance: -
i) All Bearings of the lot shall be visually checked for surface finish or any other
discernible superficial Defects.
ii) All Bearings of the lot shall be checked for overall dimensions and tolerances to
ensure their compliance with the limits specified in the relevant specifications.
iii) All Bearings of the lot shall be subjected to Short Duration Compressive
Stiffness Tests.
iv) Maximum 10 % and minimum of 1 Bearing per lot shall be subjected to Long
Duration Compressive Stiffness Tests.
v) Two Bearings selected at random from the Lot shall be subjected to Tests for
determination of Elastic Modulus (for Large Lots only).
vi) The above tested pair of Bearings shall be subjected to Tests for determination of
Shear Modulus (for Large Lots).
vii) One Bearing out of the above tested two Bearings shall be beveled cut in two
pieces and subjected to the Tests for determination of Adhesion Strength (for
Large Lots only).
viii) The other remaining Bearing out of the above tested two Bearings shall be
subjected to Tests for determination of Ultimate Compressive Strength (for Large
Lots only).
The consideration for the above tests shall be done on a lot Basis only.
Sampling and Lot Size: -
Large Lot: -
A Lot comprising of 24 or more Nos. of Bearings shall be considered as Large Lot for
which two extra bearings shall be manufactured for the purpose of conducting the
Destructive Tests specified above. The above two Bearings shall be randomly selected
from the lot offered for acceptance and shall be excluded from the lot supplied.

Page 25 of 34
 TESTING PROCEDURE FOR ELASTOMERIC BEARING
3 of 8

Small Lot: -
A Lot size comprising of less than 24 Nos. of Bearings shall be defined as a Small Lot.
As the destructive tests are not applicable for Small Lots, no extra Bearings are required
to be manufactured for these Lots. However, if instructed by the Engineer – in – charge,
the Tests for determination of Shear Modulus may be conducted on two randomly
selected Bearings from the Lot under acceptance. These Bearings shall however be a
part of the Lot accepted.
Procedures for conducting the Acceptance Tests on Finished Bearings: -
i) Short Duration Compressive Stiffness Tests: -
The Bearing shall be placed centrally into the Test Press with suitable load Bearing
Plates on Top and Bottom. The Bearing shall then be subjected to an axial
compressive load corresponding to a stress value of 15 MPa over the Bearing. The
load is applied gradually in steps and held constant for a minimum period of 5
minutes while the visual examination is made for the following: -

• Misalignment of Reinforcing Plates.

• Poor bond at Laminate / Elastomer Interface.

• Variation in Internal / Outer Elastomer Layers.

• Low Stiffness.
Values of deflection between stress range of 5 MPa and 15 MPa shall be measured
and recorded for all Bearings with sufficient accuracy. Variation in stiffness of any
individual bearing from the mean of the measured values for all such bearings of
the lot, if exceeding than 20% shall be a cause for rejection.
ii) Long Duration Compressive Stiffness Tests: -
The randomly selected Bearing shall be placed centrally into the Test Press with
suitable load Bearing Plates on Top and Bottom. The bearing shall then be loaded
in Compression to 1.5 times its maximum serviceability design load for a
minimum period of 15 hours. The bearing shall be visually examined both during
and just before the unloading, after the tests duration, for any sign of surface
cracking, laminates imparallelism or poor bonding at the Elastomer / Steel
interface which shall be a cause for rejection.

Page 26 of 34
 TESTING PROCEDURE FOR ELASTOMERIC BEARING
4 of 8

iii) Test for Determination of Elastic Modulus: -

Scope :
The test shall determine the value of apparent Elastic Modulus `Ea’ under
specified short-term axial loading.
Test Piece :
Two Test Bearings.
Test Assembly :
As shown in Fig. (a).
Conditioning Loading :
Bearings shall be preloaded up to N test. The load shall be retained for 10 minutes
and unloaded upto σ m = 2 MPa before test loading.

Rate of Loading :
The axial load N is increased gradually upto the maximum test loading N test which
shall correspond to σ m = 20 MPa.

Measurement :
Load and deflection measurements shall be made in approximately equal load
intervals not less than 5. Deflection shall be measured at four edges and mean
value shall be taken into the calculation.
Evaluation :
A compressive stress strain curve shall be plotted and the value of apparent Elastic
Modulus `E a’ shall be determined as below :
E a = ∆ σm / ∆ , ä in MPa
Where,
σm = N / A and (N = Applied Vertical Load giving Comp. Stress)
ä = δ h / 2 h, (δ h = Vertical Compressive Deflection in the Bearings,
mean of values measured at four ends)

Page 27 of 34
 TESTING PROCEDURE FOR ELASTOMERIC BEARING
5 of 8

The range `∆’ for the purpose of doing the above calculation shall be taken as the
difference of values between 20 MPa stress and 10 MPa Stress.
Result :

Test result shall be deemed satisfactory if `Ea’ determined is within ± 20 % of

1/(0.2/S 2 + 0.0005) and provided there is no evidence of any defect or damage
disclosed by close visual inspection during the test.
iv) Tests for Determination of Shear Modulus: -
Scope :
The test shall determine the value of shear modulus `G’ under specified short term
loading.
Test Piece :
Two Test Bearings.
Test Assembly :
As shown in Fig. (b).
Conditioning Load :
Bearings shall be preloaded with maximum horizontal load H test (with N test held
constant) and unloaded before test loading.
Rate of Loading :

N test corresponding to σ m = 5 MPa shall be held constant during the test and the
horizontal loading H shall be gradually increased.
The horizontal loading H shall be increased upto a maximum Htest which
corresponds to a horizontal deflection equal to the thickness of elastomer into the
Bearing ‘h’.
Measurement :
Load and deflection measurements shall be made at approximately equal intervals
not less than 5.
Evaluation :
A shear stress strain curve shall be plotted and the value of shear modulus ‘G‘ shall
be determined as below :-

Page 28 of 34
 TESTING PROCEDURE FOR ELASTOMERIC BEARING
6 of 8

G=∆ τm / ∆ tan ϒ, in MPa

Where,
tan ϒ = δ h / h, (δh = Horizontal Deflection in the Bearings)

τm = H / A and (H = Horizontal Force required to cause the

corresponding deflection, δ h)
The range `∆’ for the purpose of doing the above calculation shall be taken as the
difference of values between 1.0 strain and 0.2 strain.
Result :

The test result shall be deemed satisfactory, if `G’ determined is within ± 20 % of 1

MPa and provided there is no evidence of instability, defect or damage discovered
by close inspection during the test.
v) Test for Determination of Adhesion / Stripping Strength: -
Scope :
The test shall determine whether requisite adhesion exists between the elastomer
and steel laminate.
Test Piece :
Two identical test pieces shall be cut from the test bearings. The plan dimensions
of each test piece shall not be less than 100 mm x 200 mm. Two opposing ends of
each test piece shall be beveled to an angle of 45o.
Test Assembly :
As shown in Fig. (c).
Maximum test Loading :

Ntest corresponding to Compressive Stress σm = 4 MPa is to be held constant

during the test.
The Horizontal Loading H shall be increased gradually up to a maximum Shear
Stress τ = 3 MPa.

Page 29 of 34
 TESTING PROCEDURE FOR ELASTOMERIC BEARING
7 of 8

Evaluation :
Both the Vertical and Horizontal Loads shall be held constant for a minimum
period of 5 Minutes and the test pieces are examined for evidence of cracking or
peeling both in the strained and unstrained state.
Acceptance Criteria :
If neither test piece shows evidence of peeling or separation at or near the interface
between rubber and reinforcement layers, the bearing shall be deemed to have
satisfactory adhesion.
vi) Test for Determination of Ultimate Compressive Strength: -
Scope :
The test is to determine the Ultimate Strength of the Laminated Elastomeric Bearing
under the action of Compressive Load.

Test Piece :
One complete Bearing or a small section (not less than 100 x 200 mm) cut from the
test bearing.
Test Assembly :
The test assembly may be identical to that of the Elastic Modulus Tests having
only one Bearing or a section of a Bearing in between the Load Plates.
Rate of Loading :
The Bearing shall be loaded gradually upto the maximum test load and the rate of
loading shall not exceed 10 MPa per minute.
Evaluation :
The test pieces are to be loaded either till the failure of the steel laminate or till the
irreversible squeezing out of elastomer whichever is earlier.
Result :

The result of the test shall be deemed satisfactory, if the compressive stress σm at
failure is not less than 60 MPa.

Page 30 of 34
 TESTING PROCEDURE FOR ELASTOMERIC BEARING
8 of 8

Inspection Certificate: -
The details of the tests carried out both in house and in the presence of the
Witnessing authority are carefully recorded in the standard testing formats along
with their observations. These filled up formats are then compiled and are
submitted to the Witnessing Authority as Test reports.

Page 31 of 34
 N test ( σm = 5 MPa )

RIGID
CONCRETE
SLAB
(FIXED)

RIGID
DEFLECTED UPTO CONCRETE
'h' (h = THK. OF SLAB
ELASTOMER IN ATTACHED
ONE BEARING) TO
HORIZONTAL
RAM

RIGID
CONCRETE
SLAB
(FIXED)

FIGURE - B

TEST SETUP FOR DETERMINATION OF

SHEAR MODULUS

Page 32 of 34
 N test ( σm = 20 MPa )

TOP PLATEN

BEARING - A

INTERMEDIATE
PLATEN

BEARING - B

BOTTOM PLATEN

FIGURE - A

TEST SETUP FOR DETERMINATION OF

ELASTIC MODULUS

Page 33 of 34
 N test ( σm = 4 MPa )

MOUNTING
PLATE

MOUNTING LOADING PLATES LOADING

RECESSED OR PROFILED TO PLATE
PREVENT SLIPPAGE
'H' TO BE
GRADUALLY
INCREASED TO
H test
( m = 3 MPa )
τ

FIGURE - C

TEST SETUP FOR DETERMINATION OF

ADHESION STRENGTH

Page 34 of 34