CONSTRUCTION OF RAILWAY OVERBRIDGE CONSTRUCTION OF RAILWAY OVERBRIDGE AT DOMORIA PULL, JALANDHARAT DOMORIA PULL, JALANDHAR

BY ISHAN KAUSHALBY ISHAN KAUSHAL

ROLL NO. 1040252ROLL NO. 1040252

ROB AT DOMORIA PULL, JALANDHARROB AT DOMORIA PULL, JALANDHAR

Details of the ProjectDetails of the Project

ClientClient Municipal Corporation, JalandharMunicipal Corporation, Jalandhar Construction agencyConstruction agency M/S Gammon India Ltd.M/S Gammon India Ltd. Type of contractType of contract Item rateItem rate Total length of ROBTotal length of ROB 1.65 Km1.65 Km Cost of the projectCost of the project Rs 20 croresRs 20 crores Contract periodContract period 15 months15 months Starting dateStarting date 28-06-200428-06-2004

Due to some technical and financial constraints it is being delayed.Due to some technical and financial constraints it is being delayed.

Key Plan Of the ProjectKey Plan Of the Project

Company ProfileCompany Profile

Gammon India Limited is one of the leading construction Gammon India Limited is one of the leading construction companies in India today. companies in India today.

The company was established by late Mr. J. C. Gammon in The company was established by late Mr. J. C. Gammon in 1919 as a firm of Civil Engineers & Contractor. 1919 as a firm of Civil Engineers & Contractor.

From arch and bowstring girder bridges to balanced From arch and bowstring girder bridges to balanced cantilever, prestressed concrete and latest cable-stayed cantilever, prestressed concrete and latest cable-stayed bridges, Gammon's capabilities cover the entire spectrum of bridges, Gammon's capabilities cover the entire spectrum of technological advances in bridge engineering.technological advances in bridge engineering.

Besides designing and building bridges, Gammon has Besides designing and building bridges, Gammon has achieved perfection in the techniques of launching, achieved perfection in the techniques of launching, underwater concreting development of supporting equipment underwater concreting development of supporting equipment like pneumatic caissons, winches, cables, grouting like pneumatic caissons, winches, cables, grouting machinery etc., and building of enabling structures.machinery etc., and building of enabling structures.

When I joined….When I joined….

All the piling work was over.All the piling work was over.

All the pile caps were cast except the one at location DPG7.All the pile caps were cast except the one at location DPG7.

All the pier, pier caps, pedestals were cast except at the All the pier, pier caps, pedestals were cast except at the location DPG7.location DPG7.

Filling of the backfill in the ramp portions had been done.Filling of the backfill in the ramp portions had been done.

Training ScheduleTraining Schedule

11 June to 16 June11 June to 16 June Understood the Work Understood the Work Culture.Culture.

18 June to 21 June18 June to 21 June Started Collecting Data Started Collecting Data about the Projectabout the Project

21 June to 21 July21 June to 21 July Estimation Work And Estimation Work And Supervision of Site (Pile Supervision of Site (Pile

cap)cap)

23 July to 10 dec23 July to 10 dec Casting yard (Supervision Casting yard (Supervision Of pretensioned I-Girders)Of pretensioned I-Girders)

Some Important SpecificationsSome Important Specifications

Number of arms : Number of arms : 7(A,B,C,D,E,FO AND FI)7(A,B,C,D,E,FO AND FI) Total number of piles : Total number of piles : 248248 Type of piles : Type of piles : Bored cast in-situBored cast in-situ Diameter and depth of piles : Diameter and depth of piles : 1000 mm and 20 m resp.1000 mm and 20 m resp. Total number of piers : Total number of piers : 5151 Number of abutments : Number of abutments : 66 Type of superstructure : Type of superstructure : In-situ deck with pre-In-situ deck with pre-

tensioned I girders and tensioned I girders and RCC/post-tensioned box RCC/post-tensioned box girdersgirders

Number of box girders spans : Number of box girders spans : 1010 Earth work involved : Earth work involved : 10,000 m10,000 m³³ Steel used : Steel used : Fe 415 and Fe 500Fe 415 and Fe 500 High Tension strands (HT strands) : 15.2 mm diameter (7 ply)High Tension strands (HT strands) : 15.2 mm diameter (7 ply) Bearings : Bearings : POT PTFEPOT PTFE Number of I girders : Number of I girders : 144144

Equipments Used at SiteEquipments Used at Site

Needle type vibratorNeedle type vibrator (60 mm dia)(60 mm dia) Concrete pump (56 mConcrete pump (56 m³/hr)³/hr)

Gantry girderGantry girder ( 60 ton)( 60 ton) Transit mixer (7 mTransit mixer (7 m³ capacity)³ capacity)

Equipments Used at SiteEquipments Used at Site

Slump ConeSlump Cone JCBJCB

Batching PlantBatching Plant

Prestressing PumpPrestressing Pump

Equipments Used at SiteEquipments Used at Site

Pipeline Bucket (0.5 mPipeline Bucket (0.5 m³ capacity)³ capacity)

Hydra crane( 3 ton)Hydra crane( 3 ton)

PROJECT NO. 1PROJECT NO. 1

SUPERVISION OF SUBSTRUCTURESUPERVISION OF SUBSTRUCTURE

Foundation : PilesFoundation : Piles

Piles are long slender members that carry and transfer the Piles are long slender members that carry and transfer the load of the structure to the ground located at some depth load of the structure to the ground located at some depth below the ground and the earth surrounding the piles. below the ground and the earth surrounding the piles.

Bored cast in-situ friction RCC piles of diameter 1000 mm.Bored cast in-situ friction RCC piles of diameter 1000 mm.

M35 grade of concrete was used at our site.M35 grade of concrete was used at our site.

Average depth of the piles was 20 m.Average depth of the piles was 20 m.

Estimation of Steel in PilesEstimation of Steel in Piles

Steel quantitySteel quantityDia of one pile = 1000 mmDia of one pile = 1000 mmClear cover = 75 mmClear cover = 75 mmDia of the bar used for pile rings = 10 mmDia of the bar used for pile rings = 10 mmDia of pile ring, d = 1000- 2*75 = 850 mmDia of pile ring, d = 1000- 2*75 = 850 mmCircumference of pile ring = П*d = П*850 =2.669 m Circumference of pile ring = П*d = П*850 =2.669 m No. of rings in the pile = 100No. of rings in the pile = 100So total length of 10 mm bar = 100*2.669 = 266.9 m So total length of 10 mm bar = 100*2.669 = 266.9 m

Vertical barsVertical barsDiameter = 20 mmDiameter = 20 mmLength of one single bar from top to bottom of the pile = 20.9 mLength of one single bar from top to bottom of the pile = 20.9 mNumber of the bars = 15Number of the bars = 15So total length = 15*20.9 = 313.5 m So total length = 15*20.9 = 313.5 m Total weight of steel used in one pile = 10²/162266.9 + 20²/162*313.5Total weight of steel used in one pile = 10²/162266.9 + 20²/162*313.5 = 938.8 kg = 938.8 kg For pile group having 4 piles total weight of steel = 4*938.8 = 3755.3 kgFor pile group having 4 piles total weight of steel = 4*938.8 = 3755.3 kgFor pile group having 6 piles total weight of steel = 6*938.8 = 5632.96 kgFor pile group having 6 piles total weight of steel = 6*938.8 = 5632.96 kg

Pile CapPile Cap

Structural elements that tie a group of piles together.Structural elements that tie a group of piles together.

Used to transmit forces from piers to the pile foundations.Used to transmit forces from piers to the pile foundations.

At my site I studied the construction of the pile cap named At my site I studied the construction of the pile cap named DPG7DPG7..

It was constructed to connect It was constructed to connect 99 piles. piles.

Concrete mix of Concrete mix of M35M35 was used in the pile cap. was used in the pile cap.

Total of Total of 93.293.2 m m³³ of concrete was used in this pile cap. of concrete was used in this pile cap.

Height of the pile cap was Height of the pile cap was 1.75 m1.75 m..

Plan of the pile cap DPG7Plan of the pile cap DPG7

Reinforcement Detailing of the Pile CapReinforcement Detailing of the Pile Cap

Elevation of the Pile CapElevation of the Pile Cap

Bar bending ScheduleBar bending Schedule

Sr. no.Sr. no. Bar Bar markmark

Bar Bar dia(mm)dia(mm)

SpecificationsSpecifications TypeType

11 b1b1 2525 150 c/c

22 b2b2 2525 110 c/c

33 b3b3 1616 110 c/c

44 b4b4 1616 150 c/c

55 b5b5 1212 sets of 7 stirrups @ 250 c/c

66 b6b6 1616 2 sets of 6 bars

Estimation of the Pile Cap DPG7Estimation of the Pile Cap DPG7

Shuttering quantity of pile capShuttering quantity of pile capDimensions of the pile cap are shown in the figureDimensions of the pile cap are shown in the figureHeight of the pile cap = 1.75 mHeight of the pile cap = 1.75 mArea of shuttering = 2*1.75*(3388+3388+847+847+2998+3000+790)Area of shuttering = 2*1.75*(3388+3388+847+847+2998+3000+790) = 54.403 m²= 54.403 m²

Concrete quantityConcrete quantityVolume of concrete to be used = ((7.693*7)-0.5929)*1.75Volume of concrete to be used = ((7.693*7)-0.5929)*1.75 = 93.2 m= 93.2 m³³

Concrete Mix Proportion for Pile CapConcrete Mix Proportion for Pile Cap

Different grades of concrete were used for the bridge Different grades of concrete were used for the bridge construction.construction.

M35M35 was used for the pile cap. was used for the pile cap. Steel used : Steel used : Fe 415Fe 415.. Cement used : Vikram cement (OPC 53 grade)Cement used : Vikram cement (OPC 53 grade) Aggregates used : 10 mm, 20 mm and sand.Aggregates used : 10 mm, 20 mm and sand. Admixture used : FORSOC CONPLAST SP 430.Admixture used : FORSOC CONPLAST SP 430.

Cement : Sand : Coarse Aggregate = 1 : 1.36 : 3.24Cement : Sand : Coarse Aggregate = 1 : 1.36 : 3.24

CementCement W/C W/C RatioRatio

Water Water Sand Sand 20 mm20 mm 10 mm10 mm Admixture Admixture

400 400 kg/mkg/m³³

0.370.37 148 148 kg/mkg/m³³

684 684 kg/mkg/m³³

592.5 592.5 kg/mkg/m³³

592.5 592.5 kg/mkg/m³³

0.40.4

11 0.370.37 1.361.36 1.941.94 1.31.3 0.0010.001

Pier CapPier Cap

Estimation of the pier capEstimation of the pier cap

All dimensions in mmAll dimensions in mm

Concrete quantityConcrete quantity

Ar1 = 9477600 mm² = 9.477 m²Ar1 = 9477600 mm² = 9.477 m²

Ar2 = 5.4882 m²Ar2 = 5.4882 m²

Total area = 9.477+5.4882 = 14.96 m²Total area = 9.477+5.4882 = 14.96 m²

Thickness of the pier cap = 3600 mmThickness of the pier cap = 3600 mm

So total volume of concrete to be used = 14.96*3.6 = 53.8 m³So total volume of concrete to be used = 14.96*3.6 = 53.8 m³

All dimensions in mmAll dimensions in mm

Shuttering quantityShuttering quantityA1 = 2*14.96 = 29.92 m²A1 = 2*14.96 = 29.92 m²A2 = 4203.4*3600 = 15.132 m²A2 = 4203.4*3600 = 15.132 m²A3 = 600*3600*2 = 4.32 m²A3 = 600*3600*2 = 4.32 m²A4 = 3018.87*3600 = 10.868 m²A4 = 3018.87*3600 = 10.868 m²A5 = 100*3600*2 = 0.72 m²A5 = 100*3600*2 = 0.72 m²Total surface area for shuttering = A1+A2+A3+A4+A5 = 60.96 m²Total surface area for shuttering = A1+A2+A3+A4+A5 = 60.96 m²

PROJECT NO. 2PROJECT NO. 2

SUPERVISION OF THE SUPERVISION OF THE SUPERSTRUCTURESUPERSTRUCTURE

Pretensioned I-GirderPretensioned I-Girder

Cross section of the I-girderCross section of the I-girder

Methodology for the construction of I-Girder: Methodology for the construction of I-Girder:

1.1. Preparing the shuttering:Preparing the shuttering:

Bearing plates Dowel barsBearing plates Dowel bars

Groove made for bearingsGroove made for bearings

Bearing plate

dowels

grease

Dowel bars

200 mm length

Outer dia 50 mm

Inner dia 22 mm

2.2. Lowering of the reinforcement cage:Lowering of the reinforcement cage: Gantry girder : 60 ton and 35 tonGantry girder : 60 ton and 35 ton

3.3. Cable threading:Cable threading:

Reinforcement cage

cables

Wedges and

barrels

4.4. Stressing:Stressing:

Least count of the pump : 5 kg/cmLeast count of the pump : 5 kg/cm².².

5.5. Closing of the side shuttersClosing of the side shutters

6.6. Concreting: Concreting:

Automatic batching plantAutomatic batching plant

Needle type vibrator : 60 mm diaNeedle type vibrator : 60 mm dia

Concrete pump : 56 mConcrete pump : 56 m³/hr³/hr

7.7. Deshuttering:Deshuttering:

After 24 hrsAfter 24 hrs

Concrete coming out of the pipe line

CementCement W/C W/C RatioRatio

Water Water Sand Sand 20 mm20 mm 10 mm10 mm Admixture Admixture

435 435 kg/mkg/m³³

0.300.30 130.5 130.5 kg/mkg/m³³

652 652 kg/mkg/m³³

741 741 kg/mkg/m³³

494 494 kg/mkg/m³³

0.8%0.8%

Deshuttered beam

8.8. DestressingDestressing

Using the grinder.Using the grinder.

9.9. Lifting of the girdersLifting of the girders

10.10. CuringCuring

For next 25 days at least.For next 25 days at least.Hessian

clothCables after

cutting at top

Cables after cutting at bottom

Prestressed ConcretePrestressed Concrete

Prestressed concrete is basically concrete in which internal stresses of aPrestressed concrete is basically concrete in which internal stresses of a

suitable magnitude and distribution are introduced so that the stressessuitable magnitude and distribution are introduced so that the stresses

resulting from external loads are counteracted to a desired degree. resulting from external loads are counteracted to a desired degree.

Concrete is strong in compression but weak in tension. The tensile strengthConcrete is strong in compression but weak in tension. The tensile strength

of concrete is about one-tenth of its compressive strength. Since concrete isof concrete is about one-tenth of its compressive strength. Since concrete is

weak in tension, an R.C.C beam at times develops minute cracks in concreteweak in tension, an R.C.C beam at times develops minute cracks in concrete

on tension side of the beam, even when the stress developed in tensile steelon tension side of the beam, even when the stress developed in tensile steel

is much less than its permissible value.is much less than its permissible value.

Prestressing has two types:-Prestressing has two types:-1.1. Pre-tensioning.Pre-tensioning.2.2. Post-tensioning.Post-tensioning.

Pre-tensioning:Pre-tensioning:In the pretensioning the tendons are first tensioned between rigid anchorIn the pretensioning the tendons are first tensioned between rigid anchorblocks cast on the ground or in a column or unit mould type tensioning bed,blocks cast on the ground or in a column or unit mould type tensioning bed,prior to the casting of concrete in the moulds. The tendons comprisingprior to the casting of concrete in the moulds. The tendons comprisingindividual wires or strands are stretched with constant or variableindividual wires or strands are stretched with constant or variableeccentricity with tendon anchorage at one end and jacks at the other end.eccentricity with tendon anchorage at one end and jacks at the other end.With the forms in place, the concrete is cast around the stressed tendon. With the forms in place, the concrete is cast around the stressed tendon.

Post-tensioning: Post-tensioning: In post tensioning the concrete units are first cast by incorporating ducts orIn post tensioning the concrete units are first cast by incorporating ducts orgrooves to house the tendons. When the concrete attains sufficient strength,grooves to house the tendons. When the concrete attains sufficient strength,the high tensile wires are tensioned by means of means of jack bearing onthe high tensile wires are tensioned by means of means of jack bearing onthe end face of the member and anchored by wedges or nutsthe end face of the member and anchored by wedges or nuts

Methodology for pre-tensioning of the I-girder:Methodology for pre-tensioning of the I-girder:

1.1. Laying of cablesLaying of cables

2.2. PVC pipes are used for debonding of the cables.PVC pipes are used for debonding of the cables.

3.3. Cables are locked using the wedges and barrels. These wedges and Cables are locked using the wedges and barrels. These wedges and barrels provide such arrangement that cable can come out of it, but barrels provide such arrangement that cable can come out of it, but can’t go back.can’t go back.

4.4. StressingStressing

Monostrand hydraulic

jack

Cables

Wedges and barrels

Prestressing pump

Stressing report: Stressing report:

GIRDER MARK P1-P2 (10 AND 11)GIRDER MARK P1-P2 (10 AND 11)

For strand NO. 1 TO 21For strand NO. 1 TO 21

ELONGATION (mm) MIN. = 292 MODIFIED= 307 MAX. = 322ELONGATION (mm) MIN. = 292 MODIFIED= 307 MAX. = 322

PRESSURE (kg/cm²) MIN. = 382PRESSURE (kg/cm²) MIN. = 382 MODIFIED= 402 MAX. = 422 MODIFIED= 402 MAX. = 422

For strand No. 22 and 23For strand No. 22 and 23

ELONGATION (mm) MIN. = 273ELONGATION (mm) MIN. = 273 MODIFIED= 287 MAX. = 301 MODIFIED= 287 MAX. = 301

PRESSURE (kg/cm²) MIN. = 382PRESSURE (kg/cm²) MIN. = 382 MODIFIED= 402 MAX. = 422 MODIFIED= 402 MAX. = 422

PRESSURE (kg/cm²)

0 50 100 150 200 250 300 350 402 Elg Reqd 100 reading Total Elg Zero correction Net Elg

Strand no. 1 20 40 75 115 160 190 235 265 300 307 75 225 85 310

2 20 50 75 120 160 190 240 270 310 307 75 225 85 310

3 15 50 85 120 160 195 235 270 315 307 85 230 75 305

4 20 48 80 120 155 190 220 270 310 307 80 230 75 305

5 10 25 65 105 145 180 225 260 300 307 65 235 80 315

6 20 45 80 120 160 200 245 225 320 307 80 240 80 320

7 20 80 120 160 200 235 280 320 360 307 120 240 80 320

8 20 70 100 140 175 225 265 310 360 307 100 260 65 325

9 20 65 105 145 180 225 260 305 350 307 105 245 75 320

10 32 70 115 150 185 230 280 320 365 307 115 250 70 320

11 25 75 110 155 195 230 275 310 345 307 110 235 85 320

12 25 50 90 125 165 200 245 285 320 307 90 230 75 305

13 20 55 75 130 155 200 245 280 315 307 75 240 80 320

14 20 40 75 115 150 190 230 265 305 307 75 230 75 305

15 25 55 100 135 175 210 250 285 330 307 100 230 75 305

16 10 50 90 130 175 200 240 280 315 307 90 225 85 310

17 25 65 100 140 180 215 255 295 330 307 100 230 80 310

18 20 80 120 155 200 240 280 320 355 307 120 235 80 315

19 35 80 115 155 190 235 275 310 350 307 115 235 75 310

20 25 75 115 150 190 230 270 310 350 307 115 235 75 310

21 25 65 105 145 185 225 265 300 335 307 105 230 80 310

22 25 50 82 120 150 185 220 255 305 287 85 220 68 288

23 25 40 75 105 140 175 210 245 295 287 75 220 65 285

Box GirderBox Girder

I-girders can be used only for the spans smaller than 20-25 m or which areI-girders can be used only for the spans smaller than 20-25 m or which are

not curved. For curved spans and spans which are greater than 20-25 m, boxnot curved. For curved spans and spans which are greater than 20-25 m, box

girders are used. girders are used.

Cross-section of the box girder near the supportCross-section of the box girder near the support

Methodology for the construction of post-tensioned box girder: Methodology for the construction of post-tensioned box girder:

1.1. Constructing the temporary foundation for the temporary structure for Constructing the temporary foundation for the temporary structure for supporting the box girder shuttering.supporting the box girder shuttering.

2.2. Erecting the trestles.Erecting the trestles.

3.3. Placing the shuttering.Placing the shuttering.

4.4. Placing the reinforcement.Placing the reinforcement.

5.5. Passing the cables through sheathing pipes.Passing the cables through sheathing pipes.

6.6. Concreting. Concreting.

7.7. Curing.Curing.

8.8. Constructing the deck slab.Constructing the deck slab.

9.9. Post-tensioning.Post-tensioning.

10.10. Grouting.Grouting.

11.11. Removing the trestles.Removing the trestles.

Safety RequirementsSafety Requirements

1.1. Training the workers.Training the workers.

2.2. Providing the first aid.Providing the first aid.

3.3. List of nearby hospitals.List of nearby hospitals.

4.4. Safety manual.Safety manual.

5.5. Banners.Banners.

6.6. Using the safety equipments.Using the safety equipments.

7.7. Providing the vehicle.Providing the vehicle.

Problems Faced at SiteProblems Faced at Site

1.1. Sometime the strength of the girders didn’t come on time.Sometime the strength of the girders didn’t come on time.

RemedyRemedy: :

First off all, aggregates were washed before using them. It would First off all, aggregates were washed before using them. It would increase the rate of bond formation between the aggregates and increase the rate of bond formation between the aggregates and cement.cement.

also if use a higher grade of cement, I will help in early achievement also if use a higher grade of cement, I will help in early achievement of strength.of strength.

2.2. While transporting the concrete by transit mixers, traffic created a big While transporting the concrete by transit mixers, traffic created a big problem.problem.

RemedyRemedy: :

Three transit mixers were used at time to reduce the time gap.Three transit mixers were used at time to reduce the time gap.

Problems Faced at SiteProblems Faced at Site

3.3. Power failure and batching plant failure delayed the processes.Power failure and batching plant failure delayed the processes.

RemedyRemedy::

Proper and regular maintenance helped to reduce this problem.Proper and regular maintenance helped to reduce this problem.

4.4. While shifting the I-girders, traffic was a problem.While shifting the I-girders, traffic was a problem.

RemedyRemedy::

the girders were shifted at night to avoid this problem. the girders were shifted at night to avoid this problem.

5.5. In summer days, water for curing dried too early.In summer days, water for curing dried too early.

Remedy:Remedy:

Hessian cloth was used to retain water for longer period. Continuous Hessian cloth was used to retain water for longer period. Continuous curing was also done. curing was also done.

THANKSTHANKS