Installation of Rainbow Transflex with practical experience in ICI Bridge Dockyard

2. RAINBOW TRANSFLEX INSTALLATION METHODOLOGY

3. Contents Introduction 1 Equipments used in project 2 Bridge Photographs (Portion A & B) 3-4 Installation Method of rainbow Transflex 5-14 Maintenance of Concrete & Rubber 15 Photographs of successful project 16-18 Accomplished Bridge (Experiment and Testing) 19-21 Premium Products 23-30 Services 32-36 Test Reports 38 Conclusion

5. EQUIPMENTS 2 Utilization of construction equipment: In our projects construction equipments have been used intermittently, utilization of output can be judged using the time and ratio of equipment use as an index. However, there in few projects which provided concrete data which on the demand and analyzed by us. As exercised out put ratio is seven of the ten schemes is reported that construction equipment was used sufficiently and appropriately. Equipments: 1. Floor Saw & Diamond Blade (cutting of the asphalt surfacing) 2. Compressor & Tools (Surfacing & scabbling) 3. Pan type mixer (mixing, screed & transition strip materials) 4. Heavy duty drill (drilling holes for anchors) 5. Small drill (fixing the anchors) 6. Selection of small hand tools 7. Minimum 8kva Generator 8. Labors All tools are depend on project

6. Bridge (Portion A) Photographs 3 The level of utilization of project roads and bridges can be judged using changes in the volume of traffic as an Manifest . This is best example of this kind of project which we have achieved recently and was judged as being sufficiently utilized as well as output is completed as planned.

7. Bridge (Portion B) Photographs 4

8. 1- Marking (Position of the place) Locate the expansion gap in the concrete deck and mark its centre line on barriers, prior to lying the surfacing. Working from the centre line and using a snap chalk line, mark the positions of the two outer edges of the recess. 5 2- Cutting of Asphalt After the alignment and marking of place with particular asphalt cutter has to cut marked destination (it is not final asphalt cutting), its only purpose of fixing for Rainbow Transflex .

9. 3- Removal of old joints (Iron Angle) After the cutting of marked asphalt, have to remove the old joints and repaired damaged concrete. 6 4- Making Surface for Concrete and Restoration of Check Edges After the making Surface of the cemented bed exercise, have to use specific chemicals for making surface to concrete joints, new concrete joints has to be more strengthen especially during the high capacity load and must be strong enough for heavy loaders .

10. 5- Making Bed for Level After the placement for bed of Rainbow Transflex, this procedure will be easy at the time of fixing. Its also composed for leveling as well as for other necessary procedures. 7 6- Curing of Bed Due to Strength of Cemented Bed, cemented bed need at least 7 days for its curing.

11. 7- Marking on Bed for Drilling After the successful completion of curing period, the next step is marking for studs; there are 14 studs in one Rainbow Transflex joint. Due to Heavy percussion drills has to use for this purpose, it can be less intensity of causing hurdles when positioning holes. It is, therefore suggested that small shallow pilot holes be drilled initially, with the unit or template still in place. Using the pilot holes as locators drill the holes out to the full diameter and required depth. 8 8- Drilling process for holes on bed Start drilling on bed, This procedure has to perform very vigilantly. All stud has to align and drill on same depth and dia.

12. 9- Cleaning Holes with use of Air Blower 9 This procedures also have essential part; all holes must maneuver clean with air pressure, must be remove all dust and sand. If this procedure is not performed well may be the next step produce some problems. 10- Stud fixing with Special Chemicals Major part of fixing in rainbow transflex. This procedure is taking and holding of rainbow transflex, we use all imported stud with special chemical for giving good quality of grip in joint and easy to change in other maintenance procedure.

13. 11- Fixing Bolts (stud) in bed (concrete) Followed by filling with chemicals; fix studs and give healing time for studs to provide premium quality and strength on it. 10 12- Fixing of Rainbow Transflex Satisfaction of all previous procedure, start fixing of Rainbow Transflex and especially ensure about male female adjustment on joint to joint. Do not forget to make upper (external) surface of the unit has to aligned with wearing surface make equal to passageway from its wearing. Therefore, its very important to set the units to levels of wearing vigilantly and precisely.

14. 13- Firm With Bolts and Washer Subsequently fix special designed washer and screw with examined road level and aligned level during the design of joint rainbow transflex, ensure that the wearing surface is as consistent and smooth as possible from either sides of the joint. The surface should be properly laid. 11 14- Masking Tape As followed by step 13 ( firming with bolts and washer ). It is a process of using Mask tape for safety of studs, washers as well as for concrete and for dust. This step is useful for step 17 which is curing process.

15. 15- Cutting of final Asphalt After the satisfaction of fixing, alignment and adjustment of male female. The second step is cutting of asphalt for concrete. 12 16- Concrete on both sides of Masking tape Chipping, removing dust and cleaning each surface, use chemicals on old and new concrete to make auxiliary intensity/strength, and also use special chemical for concrete to make premium strength.

16. 17- Curing for concrete strength As followed by previous action, this process is for curing of concrete to make optimum dilution. Curing process is minimum seven (7) days. 13 18. Cleaning holes through high compressor Using high air compressor to cleaning the dust and expansion joints. This procedure will help and make easy for next phase.

17. 19- Filling Holes and Gaps This process is for filling holes with chemicals, make sure of examined gaps and other final finishing procedure. 14 Mixing Polysulphide Sealant for holes and gaps, for the long lasting of bolts, washer and studs.

18. Maintenance of Concrete & Rubber 15

19. Photographs of successful project 16

20. 17 Photographs (During Work)

21. Accomplished Bridge (Experiment and Testing) 18 Analyzed and tested with heavy Vehicles Crossing on joints Successful and well secured Experiment after concrete curing

22. Accomplished Bridge (Experiment and Testing) 19 Fluent passage of loaded trucks The maximum of 2,000 vehicles per day was achieved in Karachi Renovation project for ICI Bridge Keemari.

23. Accomplished Bridge (Experiment and Testing) 20

24. After successful accomplishment of the bridge maintenance, road has been spick and span appropriately before handover to the authority. 21

26. 28 National Products Various sizes of Bridge bearing pads Rubber and PVC water stops 23 Various Types of Rubber Fender

27. IMPORTED PRODUCTS AND STOCKIEST 24 Bridge Bearing Pads Pot Bearing Pads

28. IMPORTED ITEMS Various types of Expansion joints Rubber Fenders 25

29. Rubber Speed Humps Other Natural & Synthetic Rubber Products IMPORTED ITEMS Allied Machineries 26

30. Cat Eyes SOLAR SIGN BOARD IMPORTED ITEMS 27

31. Road Safety Barrel’s and Products: The Products include : Traffic Cones, Delineator Posts, Guide Posts, Water Filled Barrier Systems, Reflective Vests & Signal Batons and many more on request. IMPORTED ITEMS 28

33. Futuristic Development on Rainbow items: 30 Lifting Jacks for Change Bridge Bearing Pads Flat Hydraulic Jacks is special lifting system for super structure on bridges and it's helpful to replace old and Bulging Bridge Bearing Pads and very easy to repair Bridge Guarder, transom as well as for the other maintenance in inner structure of the Bridge and other heavy structure.

35. Bridge Maintenance: Bridge maintenance is undertaken to extend the life of the structure and to ensure that it functions as designed, thus ensuring public safety. This Operational Statement applies only to: deck sweeping and washing to remove traction material (e.g., sand and salt residue), cleaning of all bridge components (substructure, superstructure and deck), the removal and application of protective coatings, deck wearing surface replacement, the removal of debris to protect piers and abutments, and structural repairs involving no instream work. Aims of maintenance plan: • Maintain safe passage for bridge way users. • Protect the asset value of the bridges. • Ensure consistent standards of maintenance across relative to road usage. • Ensure expeditious movement of traffic by complying with the Traffic Management Act. • Facilitate technical and financial monitoring in order to establish trends in Bridge condition. • Provide a framework for reviewing policies and standards and for developing strategies. • Implement the principles outlined in the Code of Practice for Maintenance Management. SERVICES: 32

36. Critical to successful concrete repair is proper surface preparation of the area being repaired. This includes complete removal of concrete around and below the reinforcing steel and preparation of the substrate. Combined, these techniques ensure maximum bond between the new repair material and the existing substrate, resulting in effective, long-lasting repairs. An effective repair strategy must draw from a variety of repair materials, each having an installation technique that best suits both the material and the strategy. At Structural Preservation Systems, we have the expertise to utilize specialized techniques applicable to surface repair material installation. CONCRETE REPAIR: Concrete repair replaces defective, damaged, or deteriorated concrete; restores structural function; protects the surface or underlying concrete from aggressive environments; and restores any lost performance requirements. Concrete repair problems are diverse in nature. Each condition requires a clear understanding of what is expected of the repair including appearance, protection needs, and load carrying requirements. Services: 33

37. Expansion Joint Fixing Whether you're fixing of expansion joint material, the application method for repair is always the same. Expansion joints are an integral part of concrete structures. They are built into deck systems to control the stresses of volume changes in concrete. Depending on the type of construction (cast-in-place, precast, etc.), joints are installed to isolate ramps, buildings, and large expanses of deck surface. They may also be needed to provide free rotation of deflecting members. Most joints open and close according to daily and seasonal fluctuations in deck surface temperatures. Joints provide a natural place for water, salts, and debris to collect. They also present a hazard to pedestrians who may trip over them. To prevent these problems, joint seals can be installed. Seals must be designed for the intended movement of the joint, as well as for water tightness, wheel action (traffic, equipment), pedestrian safety, and reparability. SERVICES: 34

38. ROAD CONSTRUCTION SERVICES: We construct broadly encompasses the issues relevant to the process of road construction and maintenance, including the design, contracting, implementation, supervision, and maintenance of roads and related structures, such as bridges and interchanges. 35

39. Reflective Paints The light emitting paint is nonconventional source of energy. The light emission is guaranteed lifelong. These paint may be termed as illumination source with least installation cost, no operating cost & maintenance free. It is absolutely safe, nonradioactive & nontoxic. Road Safety Paints: SERVICES: Other than Paints, Inks, Vinyls & Color Transfers we also undertake job work of road marking, lane marking & zone marking for indoor & outdoor areas. We also offer signage & hoardings as per customer's specification. We have our infrastructure with digital cutters, fabrication & paint shop. Light Emitting Paint for Road We offer light emitting paint for road. There is great scope for this paint in infrastructure projects like road, highways, express highways, bridges, tunnels, etc. Quiet high number of accidents takes place due to poor lighting. The present hot melt plastics & fluorescent paints used for lane marking and road marking are visible only when light fall on it in a particular angle. Whereas light emitting paints offer great visibility in the dark. It avoids many of mishaps and accidents. Also the the fluorescent paint looses its luster within short period. On the contrary light emitting paints offers illumination for long period. The lane marking strips, zebra crossings, direction indicator arrows, STOP signs at signal are being painted with light emitting paints. The anti crash barriers installed at sides of the highways are painted with black & white strips of light emitting paints, adding safety in the dark too. Various curves & obstacle at ghat sections & hilly terrains can be easily indicated in dark with light emitting paints. All these infrastructure projects spend huge expenditure on street lighting for installation, maintenance & operating cost. Light emitting paints is maintenance free solution with no operating cost & minimum expense on installation. Street lights operated by photoelectric switches often malfunction in urban areas causing collision of vehicles against dividers, side railing, pillars & post. 36

40. TEST REPORTS 22

41. TEST REPORTS