Bridge construction project

Faridabad

Summer Training Period

20-05-2018 to 05-07-2018

PROJECT REPORT

Submitted By:
YOGESH SHARMA

(15113134)

Civil Engineering Department,

Indian Institute of Technology,

Roorkee
 Acknowledgement

Itake this opportunity to express my profound gratitude

and deep regards to Mr. Prakash Lal (A.E.N. PwD) for his
exemplary guidance, monitoring and constant
encouragement throughout in preparing of this report. The
blessing, help and guidance given by him time to time
shall carry me a long way in the journey of life on which I
am about to embark. This report provides me an
opportunity to put into knowledge.

I would also like to express my gratitude with a word of

thanks to Mr. Hitesh Khullar (Site Engineer), Mr. A.
Srinivas (Engineer-Safety) and all those who are directly
or involved with this report work.
 PROJECT TITLE:

Report on Construction of 4 lane segmental bridge

across river Yamuna in Faridabad.
Contents

1.Project description

2. Recommendations of Inland Waterways

Authority of India (IWAI)

3. Well Foundation
i. Cutting Edge
ii. Well Curb
iii. Well Steining

4. Precasting Techniques
i. Short line system
ii. Long line system

5. Laboratory

6. Summary
1.Project Description

 Project stretch falls in the States of Haryana and Uttar Pradesh which is
situated in the Northern part of India. Haryana is land-locked on all sides.

 The Govt. of Haryana was made the Nodal agency for preparation of DPR
and making Land available free from all encumbrances in consultation
with Government of Uttar Pradesh and to submit detailed estimate to the
Ministry for sanction.

 PWD, Govt. of Haryana appointed consultant in March 2015 for

preparation of DPR with completion period of three months.

 Govt. of Haryana coordinated with PWD, Govt. of Uttar Pradesh for NOC
and approval of alignment in their land.

 Government of Uttar Pradesh had given NOC for this ISC proposal on
03.10.2016.

 Government of Uttar Pradesh had provided their approval on the

alignment on 08.11.2016.

 Since Land for the entire project was not in possession, PWD, Haryana
requested MORTH on 02.12.2016 to split the above work in two phases :

Phase-I
Construction of Four Lane Major Bridge (630 m long) and River
Training /Guide Bund works (falling in Haryana State)

Phase-II
Widening, Strengthening and Construction of Two Lane road, Culverts,
Junction, Drain, Protection works, Covered Drain, Metal Crash Barriers, Stone
Pitching, Chute Drain, Retaining Wall, Launching Apron, Toe Wall, Bus Bay,
Truck Lay Byes and other miscellaneous items (falling in Haryana and UP
States)
2.Recommendations of Inland Waterways Authority of
India (IWAI) and Compliance by the State PWD

Recommendation
Minimum horizontal clearance of 50 metre between the piers.

Compliance
The State PWD, Haryana has proposed 57.50metre (=60m–2.5m) horizontal
clearances among piers in the GAD.

Recommendation
Vertical clearance of 6.00 metre above Navigational High Flood Level (NHFL)

Compliance
The State PWD, Haryana has proposed Vertical clearance of 6.272 metre
(=202.422m–196.150m) above Navigational High Flood Level (NHFL) in the
GAD.
3.WELL FOUNDATION

i.Cutting edge
Cutting edge is the lowermost part of the well.It is the part which cuts through
the earth.The mild steel cutting edge shall be made of structural steel
sections.
It should not weigh less than 40 kg per metre and should be properly
anchored to well curb.Sections are bent into shape by cold bending no
heating is done.

After locating the points cutting edge is placed at the specified points.

The cutting edge shall be fabricated with mild steel structural sections and
plated of specified grade as per approved drawings. Fabrication of cutting
edge is carried out at site . The cutting edges shall be fabricated in pieces /
segments. During the process of fabrication and handling / erection suitable
temporary supports are to provided / maintained to render rigidity and to keep
shape of the segments and / or parts thereof. Number of segments shall be
decided prior to start of fabrication depending on easement of handling and
transport. Checks are to be made on dimension and shape of the segments.

For bending the structural members, V — cuts may be made and after
bending such V —cuts am to be closed by welding. Joints in the length of
structural sections shall be made with fillet welds with a single cover plate or
as shown in the drawings.

Tools and Plants for Cutting Edge Fabrication:

 Rolling machine / Hydraulic Jacks for bending.
 Drilling machine.
 Electrical welding machine.
 Pug cutting machine.
 Hand grinding machine / Table mounted wheel grinder.

Fabrication of Cutting Edge:

Working Platform: The working platform is made up of plain steel plates
welded to each other over leveled concrete surface at the central fabrication
yard. The fabrication of the cutting edge involves the following steps.

Preparation of back angles:-

 layout of cutting edge is marked on working platform.
 Angle sections are cut of required length.
 A pair of angles shall be placed together back to back and shall be bent to
the required radius by hydraulic press on bending platform and same shall
he checked with curvature template and corrected if required

Preparation of MS plates:-
 The required width and length of the plate as per drawing shall be marked
and cut using pug cutting machine.
 Plate shall be bent to the required radius.
 The same shall be checked with curvature template and corrected if
required.

Preparation of Brackets:-
 Layout of Brackets is marked on working platform.
 Angle sections are cut of required length.
 The angles are welded as per the drawing, the same is to be checked on
the layout platform and corrected if required.

Assembly:-
 The MS plate shall be connected with angle by tack weld and checked for
the required radius. After final checking welding shall be done as
mentioned.
 Stiffeners shall be welded in required spacing.
 Bent plates shall be welded as per the drawing.

Prefabricated segments of the cutting edges shall be brought to site of work

and assembled at the well location. Segments of cutting edge shall be erected
on firm & levelled ground at the predetermined position. Temporary support as
required to facilitate assembly and keeping the entire assembly in true shape
shall be provided. Placement of the segments shall be made with the help of a
crane on wooden sleepers placed along the periphery of the cutting edge.
Placement of Cutting Edge:

 Accurate survey shall be carried out for fixing the well locations.
 Permanent reference pillars are to be provided at the four sides ie. along
and across centre line of bridge.
 Centre point of well is marked.
 Wooden sleepers are placed at a interval of I.50m along the
circumference of the cutting edge.
 Cutting Edge is placed over wooden sleepers using crane aligned and
joined with respect to centre lines. After alignment joints are to be welded.
 Level and alignment of cutting edge shall be checked finally using the
established horizontal controls. If required minor rigid bracing are provided
for maintaining proper level.

iii. Well curb

Curb is a structure having outer wall straight and inner wall at an angle
fabricated over the cutting edge.The curb should slightly be projected from the
steining to reduce the skin friction during sinking of well.It serves the purpose
of transferring load from steining to bottom plug.

Formwork and Rebar’s fixing

Inner formwork:

 Inner form panels are first cleaned and standard form releasing agent is
applied on the surface.
 To make the shutter joints leak proof masking tape at joints is used to
seal the joints.
 Inner formwork shall be erected and all the form panels shall be joined to
form the true shape as per the concrete profile, horizontal and diagonal
 supports erected. The erection of inner formwork shall be as per enabling
drawing. The formwork shall be handled by crane.

Fixing of Rebar:

 Rebars are cut and shaped as per the approved bar bending schedule.
 Adequate number of 75 mm cement concrete cover blocks shall be
placed to maintain cover along the periphery of formwork and also a the
bottom to maintain specified cover.

Fixing of Outer Formwork:

 Before fixing of outer formwork entire floor area shall be cleaned.
 Form panels shall be fixed as per drawing.
 To ensure the leak proof joints, masking adhesive tape shall be applied
over the shuttering joints.
 Access platform using landing mats are provided for inspection and
concrete purpose.

Concreting:
 Concrete shall be done by static concrete pump .
 Concrete shall be transported from the nearest batching plant through
transit mixers.

Curing:
 Curing shall be done by spraying water on surface covered with hessian
cloth.
 Curing can also be done by using approved curing compound.

De-shuttering and Gauge marking:

 Outer formwork shall be removed within 24 hours.
 Inner formwork shall be removed after 72 hours
 Gauge marking shall be done along both axes at four outer face location
of the well by using template.

Sinking of Well Curb:

 After removal of inner form panel gunny bags filled with sand shall be
placed in between wooden sleepers along the periphery at the bottom of
cutting edge.
 Grounding of the curb shall be done after removing the inner forms.
 The curb is sunk to the ground level by manual dredging in the dredge
hole. When the dredging is partially compete, the loose material is
removed from the dredge hole and is dumped outside the area of well
later, this dredged material shall be disposed to nearby area provided by
engineer.
 The sinking level is monitored at regular interval of 500mm.
 iv. Well Steining
It is the longest part of the well and transfers load from well cap to the well
curb at desired depth.Track of length is kept by marking well on 4 sides by
gauges.Steining is built in lifts of 2.15 m and each lift is aligned with previous
one.

Inner and outer formwork:

 Inner and outer formwork is made of 4mm MS Steel plates and rolled
steel sections fabricated for a lift of 2.5m.
 3.0 mm thick foam sheet adhesive tape at the location of joints are used
to seal the joints
 Form releasing agent shall be applied on the inner face of the panels coil
anchors/ nuts. which are to be embedded in concrete for erection of lift
are fixed at appropriate locations.
 The inner form panels are erected for the subsequent lilts.The rebar are
fixed in position followed by fixing of outer formwork. Over the inner
formwork, rigid horizontal supports shall be provide to keep the shutters
profile.

Rebar fixing:

 Rebar are cut and bent at the central rebar yard as per the approved bar
bending schedules.Rebars are fixed as per drawing and schedule.
 Adequate cement concrete cover blocks shall be provided along the
periphery of the formwork to maintain the cover of rebar.
Concreting and curing:

 Placement of concrete shall be done as described for the well curb.

 Shear key shall be provided at each construction joint. The concrete
surface shall be cleaned thoroughly and surface preparation is made to
receive the succeeding layer of concrete.

De-shuttering:
 The inner and outer form panels are removed after 12 hours of the
concrete finished time.

Steining Sinking:
Following the de-shuttering of steining lift, gauge marking is carried out at
both axes in line with well cut marking and reference height is marked on the
wall surface. The sinking operation would be started after 16 hrs of concreting
for steining.

SINKING OPERATION
Sinking of wells shall be carried out by dredge hole method by using the
following steps:
 The sinking operation involves lowering of the well by dredging in the
dredge hole.
 Plate grab shall be used in case of soft strata like sandy silt, soft clay,
dense sand. etc.
 In case of hard clay, stiff clay strata heavy-duty chisel shall be used.
followed by dredging using Tyne grab.
 Levels and alignment of well shall be checked regularly in intervals of 1hr
of sinking to observe the tilt and shift of the well at closer intervals if the
visual observation demands.
 Sinking operation shall be preferably carried out round the clock under
skilled supervision.
 Dredged materials shall be disposed off to locations designated by the
Engineer.
 The above cycle of well steining and sinking shall be repeated up to the
last lift of the well until well reaches to the founding level.
4.Precasting Techniques

i.Short line system

The basic premise of match casting is to cast the segments so their relative
erected position is identical to their relative casting position. This requires a
perfect fit between the ends of the segments and is accomplished by casting
each segment directly against the face of the preceding one using a debonder
to prevent bonding of the concrete. The segments are then erected in the
same sequence they were cast. The most common method for match casting
segments is called the "short line" method. Fig. 1 shows a schematic of a
short line match casting system.

With this system, the rate of segment production will approach one segment
per line of forms per day. A good average to use for a project is four segments
per line every 5 days. Fig. 2 shows the form arrangement for short line match
casting.

 The length of the side forms is equal to the length of the segment being
cast plus 1 or 2 in. (25 or 51 mm) to seal around the match cast joint.
 The side forms have the capability of being folded back away from the
segment to permit removal of the segment. This is done either with screw
jacks or hydraulic rams.
 The collapsible inside formwork which forms the void of the box girder
rolls on rails to allow removal of the form, enabling the segment to be
lifted vertically.
 The first operation is to determine the relative position as the segments
actually were cast. This is done by shooting elevations and center line
with an accurate survey instrument. These shots are called "early morning
shots." .
 All of the geometry of the bridge (horizontal or vertical curves and super
elevation or transitions) is cast in by adjusting the old segment. The forms
are never adjusted for geometry.
 A prefabricated reinforcing bar cage is then set in the new segment
position. Once the side forms are closed and the inside form is rolled
forward, the casting machine is ready for casting the segment.

Fig. 3

Fig. 3 shows a casting machine for a long line match cast system.

Fig. 4 is a schematic of the geometry control layout for a short line casting
method.
The survey instrument is usually a theodolite capable of measuring accurately
to 1/32 of an inch (nearly 1 mm). The permanent target is generally a concrete
pile driven into the ground and insulated to prevent bending due to the sun
shining on one side. Elevations are shot using a survey rod. The data
measured are elevation differences.
 Fig. Gantry girder

The segment survey control point positions are shown in Fig. 5.

Each segment has six control points—four over the two webs and two on the
center line. .

The designer of the bridge will provide information to develop a theoretical

casting curve. The theoretical casting curve is a curve along which the
segments should be cast so the final desired alignment will be achieved after
all deformations. The computation of these deformations is quite intricate
since most are time dependent and interdependent. Among the causes of
deformations are self weight of the structure, camber due to prestress,
prestress losses, creep and shrinkage of the concrete and temperature
variations.

Fig. 6 shows a crest vertical curve as a final desired alignment.The erected

cantilever would deflect upward an amount A due to the prestressing as
represented by the erected cantilever curve in Fig. 6. Therefore, it is obvious
the segments must be cast with -a downward deflection of A so when the
camber occurs the proper alignment will be achieved. A curve depicting this
downward deflection is the theoretical casting curve. In reality, when all the
deformations are considered, the theoretical casting curve usually bends
upward rather than downward.
Fig. 7 (top) shows the theoretical casting curve developed previously. Since
segments cannot be cast curved, the curve is approximated by casting
segments on the chords. This is the procedure followed whether the curve is
horizontal or vertical. Therefore, chords equal to the length of the segments
are laid out on the theoretical casting curve so a tangent to the curve can be
drawn at the points of intersection of the chords. Angles B, and B 2 can then
be measured from the local tangent defining the desired relative position of
the segments as they are match cast and erected. This must then be related
to the position of the casting machine.

Two assumptions relative to the casting machines must be made the first can
be controlled, the second cannot.
 The first assumption is that the steel bulkhead at the opposite end of the
new segment from the cast-against segment is established and
maintained absolutely vertical with the top being completely horizontal. In
addition, the bottom soffit is established and remains absolutely
horizontal.

 The second assumption is that the segment being cast is perfect. While
this second assumption is not too important to this explanation, it is very
significant when performing actual geometry control procedures.

To transfer the segment relationship from Fig. 7 (top) to the casting machine,
one has to examine the direction of casting and erection. In this case
Segment 1 is cast and erected before Segment 2. Therefore, on the casting
machine Segment 1 is in the old position and Segment 2 is in the new
segment position as shown by Fig. 7 (bottom). Remembering the steel
bulkhead located on the left side of Fig. 7 (bottom) is always vertical and the
soffit is always horizontal, one must adjust the attitude of Segment 1 to
duplicate the segment relationship found in Fig. 7 (top). This is done simply by
rotating Segment 1 by an angle equal to the summation of B, and B2.
The purpose of the early morning shots is to determine the magnitude and
direction of movement or casting error.
 These data are plotted directly on the theoretical casting curve as shown
by Point B on Fig. 8 (top).

 To get back to the theoretical casting curve when casting Segment 2,

assumed to be perfect, a correction must be included in the attitude of
Segment 1 as it is placed in the old or cast against position.As shown by
Fig. 8 (top and bottom) the proper angle of rotation of the segment is B,
plus B2 plus correction C.

The curve generated by plotting all the early morning shot data is a curve
which wiggles on either side of the theoretical casting curve. This curve is
known as the "as-cast curve." If the as-cast curve starts deviating away from
the theoretical casting curve,the engineer can take corrective steps before the
situation gets out of hand. The as-cast curve is also valuable information for
the field engineer because it shows the actual relationship between the
segments as they were cast. This relationship must be duplicated again when
the segments are erected.

All of the casting geometry control be set up graphically and drawn to the
largest possible scale.. Also, a separate set of curves should be used for each
line of control points even though two of them may be theoretically
symmetrical. Frequently, the early morning data will not be symmetrical.

Of course, mathematical equations can be set up to calculate settings for all

the points since all have a straight line geometrical relationship. However,
these equations should only be used as an independent check of the
graphics. It is much more difficult to determine tendencies and directions by
examining sets of numbers than by examining graphical plots.
The short line system does offer some advantages:
 the space required for set up is minimal resulting in a centralized
operation.
 Any geometry desired can be obtained by twisting the position of the
cast-against segment.

The primary disadvantage of the method is the accuracy at which the cast-
against segment must be set. Also, the casting machine must be flexible
enough to conform to the twisted cast-against segment but rigid enough to
adequately support the loads. This is particularly so when casting segments
for a super elevation transition.

ii.Long line system

Fig. Side forms with permanent soffit. Fig. Long line match casting system.

An alternative to the previously discussed short line system is the long line
system. The system is similar except that a continuous soffit the length of a
cantilever is built. Figs. 9 and 10 show such an example. All the segments are
cast in their correct relative position with the side forms moving down the line
as each segment is cast. Geometry control is established by adjusting the
side forms and soffit. Variable depth structures may be cast by varying the
elevation of the soffit, i.e., curves are cast by curving the soffit.
A long line is easy to set up and to maintain control of the segments as they
are cast. Also, the strength of the concrete is not as critical since the
segments do not have to be moved immediately.

When considering a long line system several things must be taken into
account. First of all, substantial space is required. The minimum length of
soffit required is generally a little more than one-half the longest span of the
structure. The foundation must be strong and relatively settlement free
because the segment weight to be supported can be 5 tons per lineal foot or
more. Any curing and handling equipment must be mobile since the side
forms travel along the soffit. The contractor must set up a monitoring system
and adjust the soffits periodically to correct for any settlement.

5.Laboratory

Compression Testing Machine(CTM):

 Concrete compression test is done to know the concrete compressive
strength. It is one of two well-known concrete tests.
 For this purpose, either concrete cube or cylinder specimens are tested in
the laboratory.

 3 concrete specimens are generally made and cured for 28 days at site
and then sent to laboratory .
Impact Value:

Slump Test:
The slump test measures the consistency of fresh concrete before it sets. It is
performed to check the workability of freshly made concrete, and therefore the
ease with which concrete flows. It can also be used as an indicator of an
improperly mixed batch. The test is popular due to the simplicity of apparatus
used and simple procedure. The slump test is used to ensure uniformity for
different loads of concrete under field conditions .
Digital Oven:

Concrete Cube Mould:

6.SUMMARY:
The compete project had several components like construction of well
foundation, casting of bride segments ,launching of superstructure etc.

Construction of well foundation , in the duration of the training, was in the

stage of sinking of the well .Coming till this stage included several steps like
making of the cutting edge, casting of well curb and sinking of well steining.
Gaining the first hand experience of this work going on showed the practical
aspects of the processes that we had only read in books.

The other work that was going on during the training period was of casting of
segments for the superstructure. Understanding this work required the study
of various methods used in segment casting which also broadened the
knowledge on various processes used in bridge construction .