A girder is a type of concrete often used in bridge construction. Among the various forms of girders, the PCI girder, shaped like the letter "I," is notable.
You can generally purchase PCI girders from precast concrete suppliers. However, you can also produce them on-site at the project location. If you're unfamiliar with the term PCI girder, read this article for more information.
What Is a PCI Girder?
A PCI girder is an I-shaped girder and stands for Pre-stressed Concrete I girder. This type of girder is commonly used as a structural material in bridge construction. Bridges built using this girder are known as PCI girder bridges.
The Prestressed Concrete I Girder, as its name suggests, falls under the category of prestressed concrete. Pre-stressed concrete has higher durability and strength compared to regular concrete.
Typically, pre-stressed concrete contains tensioned steel cables, enhancing the concrete's strength and durability.
The strength and durability of the Pre-stressed Concrete I Girder make it an ideal choice as the primary structure of bridges. Additionally, this girder is easy to install, which helps smooth out the bridge construction process.
The Function of PCI Girder
The primary function of the PCI girder is to support the structure of a bridge or other similar construction.
It distributes the load to the underlying structure, which may include piers or abutments. This load distribution ensures the construction can evenly bear the weight, preventing load or force concentration points.
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Production Process of PCI Girder
As discussed earlier, you can produce PCI girders on-site or order them from precast concrete suppliers. The production involves several steps, which are outlined below:
1. Material and Design Preparation
The first step in producing a Pre-stressed Concrete I Girder is preparing material and design, also known as Beam Detail Drawing and Material Specification. At this stage, you'll choose the building materials for the PCI girder production, considering the quality and strength requirements of the girder.
Once you've chosen the materials, you'll then determine the dimensions and design of the PCI girder to meet the construction project's needs.
2. Site Preparation
The next step is site preparation or bed setting. Typically, PCI girders are produced in factories or specially designated areas. Once the location is set, a concrete or steel bed will be laid as a foundation.
After preparing the bed, you can assemble the mold for the Pre-stressed Concrete I Girder according to the previously created Beam Detail Drawing. The mold for the PCI girder usually consists of iron or steel materials.
3. Reinforcement Installation
Next is reinforcing the Pre-stressed Concrete I Girder, often called beam reinforcing. The purpose of adding steel reinforcement is to enhance the girder's strength to bear loads and reduce the potential for deformation or cracking.
4. Ducting Seat Placement
Placing the ducting seat is a crucial step in producing a PCI girder. The ducting seat is where the prestressed cables within the PCI girder are placed.
Proper ducting seat placement ensures that the PCI girder will have an optimal pre-stressing system, providing the girder with maximum strength and durability.
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5. End Plate and Steel Pin Installation
The next step is to install the end plate and steel pins according to the Pre-stressed Concrete I Girder design.
The end plate and steel pins connect the girder with structural elements such as columns, ensuring the structure's safety and stability.
6. Formwork Closing & Concreting
The next step in producing a Pre-stressed Concrete I Girder is formwork closing & concreting. During the formwork closing stage, you will lock and secure the girder mold to maintain the concrete's hardness.
Once the mold is locked and secured, you can proceed to the concreting process. Concreting involves pouring the concrete mixture into the prepared mold. After pouring the concrete, allow it to harden and form a strong girder.
7. Formwork Dismantle
Once the concrete inside the mold has hardened, you can proceed with the formwork dismantling. During this stage, you'll remove or disassemble the PCI girder mold, revealing the final girder.
8. Concrete Curing & Segment Stacking
The final step in producing a Pre-stressed Concrete I Girder is concrete curing & segment stacking. Concrete curing involves maintaining the moisture of the concrete to enhance its strength during the hardening process.
After curing, you can begin segment stacking, where you assemble the girder with other components, making it ready for use in the project.
These last two steps are crucial to ensuring the quality of the girder remains intact and meets the strength requirements of the construction project.
PT Motive Mulia, a part of PT Cemindo Gemilang Tbk, provides complete concrete solutions through the Merah Putih Beton brand. We offer integrated services for Ready-Mix Concrete, Precast Concrete, and Aggregates, designed to meet various application needs according to your demands.
Our precast concrete products are available in various grades and are ideal for different construction applications, including industrial, commercial, and infrastructure projects such as high-rise buildings, residential areas, highways, and PCI girders for bridges and heavy structures.
Contact us for more information or consultation about the best concrete solutions for your project. With Merah Putih Beton, build strong and durable constructions.
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