suhas p khedkar
TRANSCRIPT
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Hindustan Construction Co Ltd
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28 May 2012 Presetation to 3rd annual Bridges India Summit 2012 2
Erecting Long Span Briges to suit Indian Conditions and Requirements
Presentation by
Suhas P Khedkar
(AVP- Engineering,) Hindustan Construction Company
To 3rd Annual Bridges India Summit 2012
On 17th May 2012
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Table of Contents
Different Methods of erection of Superstructure
Cast in Situ Construction
Comparison of Conventional and Cantilever Construction Method
Innovative Construction of III rd Godavari Railway Bridge at Rajamahendri
Bandra Worli Sea Link – Superstructure Construction entirely by Precast segmental Construction.
Segment Casting and Erection of Appraoch Spans
Specaial Challenge during Construction- Relocation of LG
Construction of Cable stayed bridge
Conclusions
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Different Methods of Erection of Superstructure
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Different methods of Superstructure Erection
• Cast in situ construction
1. Conventional method for normal spans by use of staging
2. Using specialized technology for longer span bridges:
• e.g.. Use of centering girders,
• and bridge builders for cantilevering superstructures
• Construction using Precast elements
• Construction using precast girders of entire length,
• Construction using precast segments to be assembled during erection to form
girders of complete length
• Special techniques like Incremental launching method
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Different methods of Superstructure Erection
• Method of Erection of Superstructure is site specific. And also design specific.
• In fact design should suit the method of erection dictated by site conditions and other constraints
• Final Choice is to be made from cost considerations. Evaluation of a couple of alternatives is many times necessary for major projects to decide cost effectiveness.
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Cast in Situ Construction
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Cast in Situ Construction for Superstructure
• Conventional casting on staging
• Method suitable for normal spans
1. More suitable for normal span viaducts as staging can be supported on ground
2. Has been used for both I girders and Box Girders.
3. If number of spans are small , use of precast girders and launching system is not cost effective
4. For box girders conventional casting can not be avoided as launching system may not be feasible due to excessive weight of span.
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Cast in Situ Construction for Superstructure
• Conventional casting on staging of long span superstructure is generally not feasible beyond about 50 m span due to
– excessive weight,
– Large quantity of staging and
– increased cycle time and concrete pour size.
– Especially difficult for River Bridges as staging needs to be supported on temporary piles.
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Cast in Situ Construction for Superstructure
• Cast in Situ Cantilever Segmental Technique
.
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Cast in Situ Construction for Superstructure
• Cast in Situ Cantilever Segmental Technique
Method suitable for long span box girders. Advantages as follows:
1. Each stage of construction is self supporting after completion. The erection system or the bridge builder can be erected on the tip of units cast earlier.
2. Construction is done in segments of convenient length, so that formwork and bridge builder frames supporting the formwork can be optimally
designed.
3. Construction progresses from pier in both directions towards centre of span. This allows maintaining feed lines for concrete and access for men
and material from the pier location up to the working point.
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Conventional Casting Vs Cantilever Construction
Comparison of two methods:
• Yamuna bridge at Naini Allahabad – 60 m spans Cast in Situ on Conventional staging
Elaborate staging arrangement needed for the span at 20 m from water level
• Bridge over River Brahmaputra at Tezpur
• Compare the small Bridge Builder on the tip of the cantilever with the staging of Naini Bridge
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Conventional Casting Vs Cantilever Construction
Yamuna Bridge Staging – Elevation and Side View
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Conventional Casting Vs Cantilever Construction
Tezpur Bridge Bridge Builder – Elevation and Side View
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Cast in Situ Cantilever Construction for Long Span River Bridges
Tezpur Bridge over River Brahmaputra – Different spans in different stages of construction
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Cast in Situ Cantilever Construction for Long Span River Bridges
Ganga Bridge at Varanasi - Bridge Builder in Elevation and Side View
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Cast in Situ Cantilever Construction for Long Span River Bridges
Ganga Bridge at Varanasi – after Completion
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Innovative Construction for III Godavari Railway Bridge at Rajamahendri
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Innovative Construction for III Godavari Bridge Superstructure
III Godavari Railway Bridge
28 spans of 98 m each – 94 m C/C of bearings
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Innovative Construction for III Godavari Bridge Superstructure
• III Godavari Railway Bridge near Rajamahendri has been constructed using an innovative technique.
• The design itself was developed for the innovative erection technique, under typical constraints posed in the tender specifications.
• The foundations and substructure was designed to suit standard railway span of 94.0 m using steel girders.
• The tender for superstructure invited alternatives with prestressed concrete (PSC) superstructure.
• Challenge to design a PSC superstructure within the design capacity of the substructure and foundations, which were designed and constructed for the lighter loads of the steel superstructure.
• A bow string girder design was proposed by HCC.
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Innovative Construction for III Godavari Bridge Superstructure
Salient Features:
1. Structural System – Bow String Girder in Prestressed Concrete
2. Span of Girder: 94.0 m
3. Arches in Reinforced concrete Constructed using Cast in situ segmental technique
4. Suspenders in High tensile Steel – BBR Dyna hangars
5. Tie Girder in Prestressed Concrete – Box shaped
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Innovative Construction for III Godavari Bridge Superstructure
Innovative Features:
1. Top down Construction – Arch was constructed first
2. Tie girder constructed using formwork supported on suspenders
3. Arch was constructed using cast in situ cantilevering segmental technique in 7 stages
4. Arches from the two piers progressed to meet at the midspan, connected by a closure pour
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Innovative Construction for III Godavari Bridge Superstructure
Stages of Construction of Arch:
1. Erect central tower
2. Cast starting stubs
3. Erect formwork for typical segment supported by stay cables
4. Cast first segment
5. Repeat stages 3 and 4 for balance 6 segments
6. Erect formwork for closure pour on the last segment at crown
7. Cast closure pour
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Innovative Construction for III Godavari Bridge Superstructure
Stage 1 Cast starting stubs Stage 2 Erect Formwork for first
segment on starting stubs
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Innovative Construction for III Godavari Bridge Superstructure
Itermediate Stage: Formwork supported on completed arch ready to receive for concrete for the next segment
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Innovative Construction for III Godavari Bridge Superstructure
Itermediate Stage: Formwork supported on completed arch ready to receive for concrete for the next segment
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Innovative Construction for III Godavari Bridge Superstructure
Closure Pour: Formwork supported on the last segment of 1/2 arch
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Innovative Construction for III Godavari Bridge Superstructure
Arches for various spans completed
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Innovative Construction for III Godavari Bridge Superstructure
Construction of Tie Girder
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Innovative Construction for III Godavari Bridge Superstructure
Completed Bridge
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Bandra Worli Sea Link Project Superstructure Construction entirely by Precast Segmental Technique, for both Cable Stayed and Approach Spans.
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Bandra Worli Sea Link Project – special Features • First Sea Link in India and with
Precast Segmental construction
• The entire sea link, including the cable stayed bridges has been constructed using precast segments for the superstructure.
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Bandra Worli Sea Link Project – special Features Many Firsts in our country
• First Cable Stayed Bridge across sea: India’s first open sea and longest cable stayed bridge.
• First Cable Stayed Bridge with a Single Central Pylon.
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Bandra Worli Sea Link Project – special Features Many Firsts in our country
• The entire sea link, including the cable stayed bridges has been constructed using precast segments for the superstructure. Total 2342 segments have been cast and used.
• The precast segments used for this sea link are one of the widest and heaviest in our country; - 18.1 m & 20 m in width , weight 120 to 140 MT
•Needing a very large casting yard with short line casting cells, large capacity gantries, matching capacity multi axle trailer for segment transportation, and specially designed gantries for segment erection.
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Special Features of the Project
Engagement of Asian Hercules, one of the largest floating shear leg crane in the world for shifting 1260 MT launching truss from Bandra end to Worli end of the main cable stay bridge
Up to 25-m high piers in open sea, giving ample headroom to marine traffic
Use of Politron Disc bearings for the first time in India
Piling through rocks exceeding 120 Mpa crushing strength
Use of Automatic Climbing Formwork for Pylon Construction
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Bandra Worli Sea Link Salient Design Features • Precast Segmental superstrucure except KAGK Link Bridge • Aesthetically pleasing deck profile, with uniform depth for all
bridges - Bandra approach , Bandra Cable Stayed, Worli Cable Stayed, Worli Approach.
• Unique Design of Bandra Cable Stayed - 250 m spans on either side , supported on a Central Pylon,
A1
P19
P19
A1 P17
16x50 = 800m
600mBANDRA CABLE STAY
4X50=200m(SPAN-BY-SPAN)
350mWORLI CABLE STAY
28X50 = 1400mPRECAST SEGMENTAL (SPAN-BY-SPAN)
P6 P12
500mPRECAST SEGMENTAL
(BALANCED CANTILEVER) 150mPRECAST SEGMENTAL
(FORWARD CANTILEVER)
PRECAST SEGMENTAL
BANDRA CABLE STAY600m
WORLI CABLE STAY350m
NORTH 800m
NORTH APPROACH BRIDGE SOUTH APPROACH BRIDGE
BANDRA
WORLI
APPROACH ROAD
546m
APPROACHBRIDGE
& TOLL PLAZABANDRA
WORLI
200mSOUTH APPROACH BRIDGE
1400m
LIN
K BR
IDG
E81
1m
(SPAN-BY-SPAN)
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Bandra Worli Sea Link Project Segment Casting and Erection
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Casting Yard and Erection Gantry at BWSLP The project needed a very large casting yard, and two specially designed LGs, which needed to to be supplemented by one more LG from Worli end in the last season.
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Advantages of Precast Superstructure Vs Cast in Situ
• Construction of Superstructure in parallel with Foundation construction.
• When Foundations are being constructed at various site locations, superstructure elements can be precast in a separate casting facility.
• Advantages of factory production, with ease in quality control, and dimensional accuracy, due to easy acces, and dedictaed equipment, and survey stations.
• Good quality control due to planned facilities like proper curing arrangement, dedicated supervision.
• The above are relatively much difficult at actual site locations due to difficult access, great heights and different locations.
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Principles of Precast Segmental Construction
• Span is divided into a number of segments of full deck width
• The segments are match cast to attain the final geometry as of the erected span.
• Match casting and geometric control are of great importance as the bridge is virtually built in the casting yard. Any error in match casting will be difficult to correct during erection, as the span will not fit on the piers.
• Precision Survey in casting yard to attain desired geometry
• Precast Segmental Construction offers use of industrialized, repetitive construction procedures, which contribute to improved quality control as well as reduction in construction time .
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Importance of Precision in Precast Segmental Construction
• Span is divided into a number of segments which are match cast to attain the final geometry as of the erected span.
• The bridge is virtually built in the casting yard. Any error in match casting will be difficult to correct during erection, as the span will not fit on the piers.
• The bridge has both vertical gradient, and Horizontal curvature.
• The bridge deck therefore follows a space curve.
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Precast Segmental Construction for Bandra Worli Sea Link Project, Mumbai – CEMCON 2007
February, 23 - 2007 Page 42
SEGMENT : MATCH CASTING
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Planning and Management for Casting Yard
(LONGITUDINAL DIRECTION)TYPICAL CROSS SECTION AT SEGMENT STORAGE AREA
(TRANSVERSE DIRECTION)TYPICAL CROSS SECTION AT CASTING CELL AND STORAGE AREA
(STORAGE BAY 1) (STORAGE BAY 2)
(REBAR JIGS)
CASTING YARD & STACKING YARD CROSS-SECTION
(CASTING CELL)
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Precasting Yard at BWSLP- Capacity to stack 400 segments. And 9 casting cells.
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Prefab Reinforcement Cage handling
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Match casting at Precasting Yard
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Precast Segment Pour Sequence
3.17 CUM
1.26 CUM
1.26 CUM
2.52 CUM2.19 CUM2.69 CUM4.28 CUM
1.66 CUM
1.66 CUM
7 89
2.52 CUM 2.19 CUM 2.69 CUM
2
3
45
3.17 CUM
1.26 CUM
1.26 CUM 1.66 CUM
1.66 CUM6
CONCRETE PLACING SEQUENCETOTAL CONCRETE QUANTITY = 44.30 CUM
12a
3a
4a 5a
6a
7a8a 9a10
5.33 CUM
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Segment Handling at Precast Yard
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Segment Transportation on Special Trailer
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Main Truss
Front Leg
Suspension Frames
Rear Leg
Rear Pylon
Front Pylon
Center Leg
Connection Beam
Rear Trolley
Front Trolley
Launching Girder at BWSLP
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Segment Transportation in Sea on Barge
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Main Challenge During Construction of Approach Span: Relocation of LG from Bandra Approach spans beyond Bandra Cable Stayed bridge: Shifting by 500 m in the sea.
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Text (Font Arial 16, Color Black, Line Spacing 30 points).
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Text (Font Arial 16, Color Black, Line Spacing 30 points).
Text (Font Arial 16, Color Black, Line Spacing 30 points).
Need for Relocation
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Text (Font Arial 16, Color Black, Line Spacing 30 points).
Text (Font Arial 16, Color Black, Line Spacing 30 points).
Relocation of Launching Trusses using 1600 MT capacity Barge Mounted Crane – Asian Hercules
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Relocation of Launching Trusses using 1600 MT capacity Barge Mounted Crane – Asian Hercules
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Relocation of Launching Trusses using 1600 MT capacity Barge Mounted Crane – Asian Hercules
Entire LG weighing 1260 MT , of length 105 m was physically lifted and shifted from P17-P18 to P20-P21
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Construction of Cable Stayed bridge
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Need for detailed Construction Stage Analysis
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Results of stage-by-stage Analysis
Stage-by-Stage Analysis
Tower Construction Deck Erection
Precamber Values Fibre Stresses
Strutting Requirements and Force Levels Casting Curve, Erection Curve and Control Lines
Stay Cable Forces for Installation, Tensioning and fine tuning Forces
Stage Deformations
Temporary PT
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28 May 2012 Presetation to 3rd annual Bridges India Summit 2012 61
Casting Curve
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28 May 2012 Presetation to 3rd annual Bridges India Summit 2012 62
Stage by Stage Deck Camber Curves Deck Camber Curves for Bandra Bridge Stage by Stage
-100-90-80-70-60-50-40-30-20-10
0102030405060708090
100110120130140150160170180190200210220230240250260270280290300310320330340350360370380390400410420430440450
-300
-275
-250
-225
-200
-175
-150
-125
-100 -7
5
-50
-25 0 25 50 75 100
125
150
175
200
225
250
275
300
Chainage x [m]
Ele
vatio
n y
[mm
]
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28 May 2012 Presetation to 3rd annual Bridges India Summit 2012 63
66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 3 2 1 0 1 2 3 6 7 8 9 10 11 12 13
Segment Node No. 5090 Segment Node No. 5113
1
76
543
2
424140393837363534333231
3029
282726252423
2221
2019
1817
161514
131211
109
S8
S9
S10
S11
S12
S13
S14
S15
S16
S17
S18
S19
S20
S21
S22
S23
S24
S25
S26
S27
S28
S29
S30
S31
S32
S33 S33
S7
Stage Deflections
-80
-30
20
70
120
170
220
270
320
370
420
-300 -294 -288 -282 -276 -270 -264 -258 -252 -246 -240 -234 -228 -222 -216 -210 -204 -198 -192 -186 -180 -174 -168 -162 -156 -150 -144 -138 -132 -126 -120 -114 -108 -102 -96 -90 -84 -78 -72 -66 -60 -54 -48 -42 -36 -30 -24 -18 -12 -6 0 6 12 18 24 30 36 42
Deformation at previous stage Deformation after completion of this stage : LC1190 Deformation at handover for traff ic movement (Design Camber) @ T=0 : LC1298
Lift Non-stay Segment
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28 May 2012 Presetation to 3rd annual Bridges India Summit 2012 64
66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 3 2 1 0 1 2 3 6 7 8 9 10 11 12 13
Segment Node No. 5090 Segment Node No. 5113
1
76
543
2
424140393837363534333231
3029
282726252423
2221
2019
1817
161514
131211
109
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
S17
S18
S19
S20
S21
S22
S23
S24
S25
S26
S27
S28
S29
S30
S31
S32
S33 S33
Stage Deflections
-80
-30
20
70
120
170
220
270
320
370
420
-300 -294 -288 -282 -276 -270 -264 -258 -252 -246 -240 -234 -228 -222 -216 -210 -204 -198 -192 -186 -180 -174 -168 -162 -156 -150 -144 -138 -132 -126 -120 -114 -108 -102 -96 -90 -84 -78 -72 -66 -60 -54 -48 -42 -36 -30 -24 -18 -12 -6 0 6 12 18 24 30 36 42
Deformation at previous stage Deformation after completion of this stage : LC1191 Deformation at handover for traff ic movement (Design Camber) @ T=0 : LC1298
Stress Previous Cable to Ft
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28 May 2012 Presetation to 3rd annual Bridges India Summit 2012 65
67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 3 2 1 0 1 2 3 6 7 8 9 10 11 12 13
Segment Node No. 5090 Segment Node No. 5113
1
76
543
2
424140393837363534333231
3029
282726252423
2221
2019
1817
161514
131211
109
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
S17
S18
S19
S20
S21
S22
S23
S24
S25
S26
S27
S28
S29
S30
S31
S32
S33 S33
Stage Deflections Lift Stay Segment
-80
-30
20
70
120
170
220
270
320
370
420
-300 -294 -288 -282 -276 -270 -264 -258 -252 -246 -240 -234 -228 -222 -216 -210 -204 -198 -192 -186 -180 -174 -168 -162 -156 -150 -144 -138 -132 -126 -120 -114 -108 -102 -96 -90 -84 -78 -72 -66 -60 -54 -48 -42 -36 -30 -24 -18 -12 -6 0 6 12 18 24 30 36 42
Deformation at previous stage Deformation after completion of this stage : LC1192 Deformation at handover for traff ic movement (Design Camber) @ T=0 : LC1298
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28 May 2012 Presetation to 3rd annual Bridges India Summit 2012 66
Stage Deflections Install Cable and stress to Fi
67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 3 2 1 0 1 2 3 6 7 8 9 10 11 12 13
Segment Node No. 5090 Segment Node No. 5113
1
76
543
2
424140393837363534333231
3029
282726252423
2221
2019
1817
161514
131211
109
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
S17
S18
S19
S20
S21
S22
S23
S24
S25
S26
S27
S28
S29
S30
S31
S32
S33 S33
-80
-30
20
70
120
170
220
270
320
370
420
-300 -294 -288 -282 -276 -270 -264 -258 -252 -246 -240 -234 -228 -222 -216 -210 -204 -198 -192 -186 -180 -174 -168 -162 -156 -150 -144 -138 -132 -126 -120 -114 -108 -102 -96 -90 -84 -78 -72 -66 -60 -54 -48 -42 -36 -30 -24 -18 -12 -6 0 6 12 18 24 30 36 42
Deformation at previous stage Deformation after completion of this stage : LC1194 Deformation at handover for traff ic movement (Design Camber) @ T=0 : LC1298
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28 May 2012 Presetation to 3rd annual Bridges India Summit 2012 67
Erection Monitoring
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P19 tower Pilecap
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Tower Leg Construction in Progress
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Isometric View of Piertable
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Piertable Truss Erection
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Pier table Truss Erection
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Lifting Frame Operations
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Lifting Frame Operations
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Segment Transportation on Barge
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Piertable Segment Lifting with Lifting Frame
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Pier Table Segment Alignment
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Segment Supported on Pier Table Truss
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Pier Table Segments Alignment in Progress
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Diaphragm Concreting
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Isometric view of Middle Tower Legs
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Construction of Middle Tower with ACS
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Construction of Middle Tower with ACS
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Construction of Middle Tower with ACS
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Construction of Middle Tower with ACS
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Construction of Middle Tower with ACS
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Construction of Middle Tower with ACS
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Construction of Middle Tower with ACS
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Construction of Middle Tower with ACS
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Construction of Middle Tower with ACS
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Construction of Middle Tower with ACS
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P19 Middle tower leg in Progress
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P19 Middle tower leg in Progress
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P19 Middle tower leg in Progress
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Strutting at Junction Top
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Strutting at Junction Top
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Assembly of tower head formwork prototype
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Alignment of Anchorage Boxes at 100m above MSL
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Construction of Tower Head
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Erection of Deck
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Erection of Deck
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Erection of Parallel Wire Stay Cables
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Erection of Parallel Wire Stay Cables
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Erection of Parallel Wire Stay Cables
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Erection of Precast Segmental Deck
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Erection of Precast Segmental Deck
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Erection of Precast Segmental Deck – Deck Closure
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Erection of Precast Segmental Deck
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Erection of Precast Segmental Deck
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Erection of Precast Segmental Deck
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Completed View of Bandra CSB
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28 May 2012 Presetation to 3rd annual Bridges India Summit 2012 112
Conclusions
• Indian Engineers are Well Experienced in Construction of loang Span Bridges, and Erection of Bridge Decks, using various methods
• Choice of the method is Site Specific and Design Specific • Bridge Design should Suit Erection Method
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I acknowledge with Thanks opportunity given to me for presentation of a very important and interesting topic. I thank the organizers, and the audience.
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Disclaimer
This presentation contains certain forward looking statements concerning future business prospects and profitability of HCC, which are subject to a
number of risks and uncertainties and actual results could materially differ from those in such forward looking statements, important developments
that could affect the company's operations include a downtrend in the infrastructure sector, significant changes in political and economic
environment in India, tax laws, labor relations, litigation etc. The company does not undertake to make any announcement in case any of these
forward looking statements become materially incorrect in future or update any forward looking statements made from time to time by or on behalf
of the company.