Continental Engineering Corporation

METHODOLOGY FOR MINOR BRIDGES / UNDER PASSES

1.0 SCOPE
The Road consists of Minor Bridges and Under Passes at different locations.
In the Bye pass portion the entire length will be carried out in single operation
except 302+304 Underpass. Where as in existing road the structures will be
taken up first in New Carriage way portion. After diverting the traffic in New
Carriage way widening portion will be taken up. The foundation of the Minor
Bridges, VUP’s and PUP’s are open foundation. The Geotechnical
Investigation of Minor Bridges, VUP’s and PUP’s has been conducted. The
construction of structures will be carefully planned to take into consideration
of the existing traffic flow. In required structures traffic diversion plan will be
submitted and got approved from Engineer representative before starting the
work.
CONSTRUCTION METHODOLOGY:
2.0 SURVEY AND SETTING OUT WORKS:
Survey and Setting out works for Minor Bridges and Under Passes shall be as
per established grid lines /co-ordinates and bench marks and also as per
relevant construction drawings. All the Survey Instruments used shall be
calibrated periodically. Survey Check Reports and other relevant data will be
recorded relevant formats.
1. SITE CLEARANCE WORKS :
Site Clearance, Grubbing, Dismantling of Existing Structures and
disposal of unserviceable material at designated areas and stacking of
serviceable materials for use in Embankment Construction works etc
shall be carried out as per MOSRT&H and Technical Specification.

2. PLANT & EQUIPMENT:

1. Concrete Batching Plant

2. Transit Mixers
3. Concrete Pump
4. Water Pumps for dewatering
5. Vibrators with Needles
6. D.G. Set
7. Welding Set
 8. Trailer
9. Dumpers
10. Excavator
11. Concrete Bucket
12. Water Tankers

3. MATERIAL :

All the Grades of Concrete used in the particular stretch will be as per
approved Mix Designs.

4. EXCAVATION :

After the Site has been cleared according to Clause 201, the limits of
excavation shall be setout to lines, curves and slopes. Excavation shall be
set out true to lines, curves, slopes, grades and section as shown on the
drawing or as directed by the Engineer. Excavation shall be taken to the
width of lowest steps of footing / raft and the sides shall be left plumb
where the nature of soil allowing it, where the nature of soil or depth of
trench and season of the year donot permit vertical sides necessary shoring
or cut slopes to safer angle or both with due regards to the safety of
personnel and work shall be executed. The depth to which excavation is to
be carried out shall be as per approved drawings. Propping shall be
undertaken when any foundation or stressed zone from an adjoining
structure is with in line of one vertical to two horizontal from the bottom
of excavation, where water is met within excavation due to seepage
springs etc. adequate measure will be taken to pump out water to keep
foundation trench dry. If the hard rock found in any structure control
blasting will be done. The bottom foundation shall be leveled both
longitudinally, transversely and compacted by suitable methods. Over the
compacted base a leveling course of concrete of required thickness and
grade as specified in drawings shall be laid. Where as the structures at
299+135, 306+980, 302+300 excavation will be executed for Abutment
and Piers separately and the leveling course will be laid for Abutments,
Piers individually.

5. REINFORCEMENT :
Reinforcement Steel of grade Fe 415 (TMT Bars) conforming to IS 1786
shall be used. Bar Bending Schedules shall be prepared and got approved
before the actual cutting and bending work commenced. Specifications
furnished in section 1600 of MOSRT&H and Contract Technical
Specification on Reinforcement shall be followed.

6. FORM WORK:
Well-designed Specification and formwork shall be used for the
construction of Minor Bridges, Under passes as per IRC-87, MOSRT&H
Specification and Technical Specification Section 1500. The formwork
shall be constructed so as to remain sufficiently rigid during placing and
compaction of concrete and shall be such as to prevent loss of slurry from

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 the concrete. The forms shall not release until the concrete has achieved
strength of at least twice the stress to which concrete may be subjected at
the time of removal of form work. The removal of form work shall be
done as per MOSRT&H Clause 1508.

7. CASTING OF RAFT FOUNDATION FOR ABUTMENTS,

PIERS:
PCC will be cured at least 3days before placing of reinforcement as per
approved bar bending schedule. The lap length of bar as per GFC &
Spacer will be provided as required. Placing and Fixing of
Reinforcement shall be inspected and approved by Engineer before
placing of Concrete. Shuttering plates of Standard size will be used for
outside shuttering vertical props and cross bracings of sufficient
strength shall be used to protect any bulkage of concrete. All the joints
will be properly sealed. Sealing tapes, foam, rubber willl be used in
order to prevent leakage of slurry. The concrete of required grade will
be poured and curing will be done for 14 days from date of casting.

8. CONSTRUCTION OF SUBSTRUCTURE ABUTMENT / PIER /

PIER CAP

Reinforcement, shuttering & concreting for substructure:

1. Clean the concrete surface and reinforcing bars by wire brush & tamping
and removing loose material.
2. Clean the shuttering plates and apply shuttering releasing agent on it
facing concrete surface.
3. Reinforcing bars are cut and bent at the stock yard as per bar bending
schedule approved by engineer and transported to site using suitable
means. Fixing of reinforcement is carried out for pier.
4. Fix the shuttering for 1st lift. To make the shutter joints leak proof suitable
foam sheets between shuttering joints and/or masking tape are used at
joints to seal the joints. Formwork shall be erected and all the form panels
shall be joined by bolts to form the true shape as per the concrete profile.
Sufficient supports will be provided for shuttering.
5. After checking & approval of engineer, concreting for 1 st lift is carried out.
Shear key shall be provided at each lift for vertical construction joint.
6. Repeat the above procedure for every lift up to last lift, as per level
mentioned in good for construction drawing.
7. Weep holes are provided in each lift, as mentioned good for construction
drawing (for abutments only).
8. Survey point for pier cap is marked on pier top after final lift of pier is
cast.
9. The cantilever portion of pier / abutment cap is beyond 1.5m length; H
Frame staging will be erected for supporting the cap shuttering. Other wise
brackets will be erected on pier / abutment for supporting of cap
shuttering.
10. Staging arrangement shall be got approval before execution.
11. Bottom shuttering will be fixed after necessary staging.
12. Reinforcing bars are cut and bent at the stock yard as per bar bending
schedule approved by engineer and transported to site using suitable

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 means. Fixing of reinforcement is carried out for pier cap (Including
verticals of pedestal).
13. Side shutters are fixed in position.
14. After checking and approval concreting of pier cap is done.
15. Pouring of concrete will be done by pump or crane and bucket.
Transportation of concrete will be done by transit mixer from batching
plant.
16. Side shutters will be removed after 16 hrs concrete. Cantilever portion
bottom shuttering will be removed when the concrete attains 85% strength.
17. Vertical face of concrete surface will be covered with Hessian cloth for
curing. Water will be sprayed over top and vertical surface.
18. Reinforcing bars are cut and bent at the stock yard as per bar bending
schedule approved by engineer and transported to site using suitable
means. Fixing of reinforcement is carried out for remaining pedestal
reinforcement.
19. Side shuttering will be erected.
20. After checking and approval concreting of pedestal is carried out.
21. Pedestal will be cast over pier / abutment caps as per the drawing.

9 METHOD OF CONSTRUCTION FOR SUPERSTRUCTURE:

 Solid Slab
 RCC T-Beam (with Deck Slab)
 Wearing Coat
 Crash Barrier
 Hand Rails (Steel)
 Footpath & Kerb
 Railing

10 Solid slab:

 Locations For Solid Slab

 Setting Out
 Fabrication Of Shuttering For Solid Slab
 Staging Arrangement
 Bottom & Side Shuttering
 Bearing Fixing
 Reinforcement Fixing
 Checking And Approval
 Concreting

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 12 Locations for solid slab:
Super Structure Details For Solid Slab
Type of
Type of Type of Super Type of Super
S.No. Location
Structure Foundation Structure Structure

1 294+575 Minor Bridge Open Foundation Deck Slab Not Applicable

2 296+440 Under Pass Open Foundation Deck Slab Not Applicable
3 299+135 Minor Bridge Open Foundation Deck Slab Elastomeric Bearing
4 300+240 Minor Bridge Open Foundation Deck Slab Not Applicable
5 300+850 Minor Bridge Open Foundation Deck Slab Not Applicable
6 302+076.478 Under Pass Open Foundation Deck Slab Not Applicable
7 305+950 Minor Bridge Open Foundation Deck Slab Not Applicable
8 306+093.930 Under Pass Open Foundation Deck Slab Not Applicable
9 306+980 Minor Bridge Open Foundation Deck Slab Elastomeric Bearing
10 311+401.891 Minor Bridge Open Foundation Deck Slab Not Applicable
11 311+486.250 Minor Bridge Open Foundation Deck Slab Not Applicable
12 313+846 Minor Bridge Open Foundation Deck Slab Not Applicable
13 314+402 Under Pass Open Foundation Deck Slab Not Applicable
14 318+594.900 Minor Bridge Open Foundation Deck Slab Not Applicable
15 321+327 Minor Bridge Open Foundation Deck Slab Not Applicable
16 325+065.150 Minor Bridge Open Foundation Deck Slab Not Applicable
17 326+145.400 Minor Bridge Open Foundation Deck Slab Not Applicable
18 327+575 Minor Bridge Open Foundation Deck Slab Not Applicable

13 Setting out:

Survey points will be marked over the pier cap on either direction of the
alignment by total station from control points. A benchmark shall also be
established on pier cap top. The benchmark shall be checked regularly with
respect to the permanent benchmark established at the bridge site.

14 Fabrication of shuttering for solid slab:

Standard shutters will be procured or required size shutters will be

fabricated at centralized fabrication yard.

15 Staging arrangement:

Staging arrangement for all bridges will be H Frame staging over sleepers.
SBC of soil below the sleeper will be examined and incase SBC is less than
required, soil will be strengthened or replaced with the suitable granular
materials according to requirement of the load bearing capacity of ground.

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16 Bottom and side shuttering:

 Clean the shuttering plates and apply shuttering releasing agent on it

facing concrete surface.
 After completion of staging, bottom & side shutters are erected in line
and level as per the drawing.
 The stopper shutters will be fixed after fixing the reinforcement.
 To make the shutter joints leak proof suitable foam sheets / masking
tape will be used. Suitable shuttering releasing agent will be applied
on the surface, facing concrete.

17 Bearing fixing:

The Bearings will be fixed as per drawing.

 Surface of pedestal is prepared for fixing the bearings.
 Mark the centerline on the top surface of pedestal.
 Elastomeric bearing is fixed in position.
 Check the line and level of bearing after fixing.
 Bearings will be fixed when the soffit shuttering is in progress. After
fixing the bearings balance gap of soffit shutters will be filled with
wooden planks.
 Source of approval will be taken before ordering the materials and
testing of materials will be followed as mentioned in IRC: 83 (Part- I
&II).

18 Reinforcement fixing:

Reinforcing bars are cut and shaped at the stock yard as per the approved bar
bending schedule and transported to site using suitable means. Fixing of
reinforcement is carried out.

Reinforcement is provided as mentioned in drawings & approved bar bending

schedule. Chairs and supporting rods shall be provided with required spacing
to maintain the profile of bars. To maintain the clear cover, concrete cover
blocks will be provide at required spacing.

19 Checking and approval:

Approval for survey work, shuttering and reinforcement will be taken stage by
stage whenever the activities are completed.

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20 Concreting:

 Concreting shall be done by crane and bucket or pump as per the

availability.
 Concrete will be transported from the batching plant through transit
mixers.
 Concrete shall be placed in a single continuous pour in such a sequence,
which will avoid formation of cold joints.
 Keep the provision for expansion joint fixing.

21 RCC T-BEAM (With deck slab):

 Locations For RCC T-Beam (with Deck Slab)

 Setting Out
 Fabrication Of Shuttering & Reinforcement for RCC T Beam (with
Deck Slab)
 Staging Arrangement
 Bearing Fixing
 Shuttering And Reinforcement
 Checking And Approval
 Concreting

22 Locations of RCC T – Beam (with deck slab):

Super Structure Details For RCC T-Beam

Type of Type of Type of Super
S.No. Location Type of Bearing
Structure foundation Structure
T – Beam
Vehicular
1 302+304.058 Open Girder with Elastomeric Bearing
Under Pass
Deck Slab

23 Setting out:

Survey points will be marked over the pier cap on either direction of the
alignment by total station from control points.

A benchmark shall also be established on top of pier cap. The benchmark shall
be checked regularly with respect to the permanent benchmark established at
the bridge site.

24 Fabrication of shuttering and reinforcement for RCC T-beam (with deck

slab):

Standard shutters will be procured or required size shutters will be

fabricated at fabrication yard. Reinforcement will be fabricated at yard
and it will be transported to site by tractor or trailer.

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25 Staging arrangement:

Staging arrangement for all bridges will be H Frame staging over sleepers.
SBC of soil below the sleeper will be examined and incase SBC is less than
required, soil will be strengthened or replaced with the suitable granular
materials according to requirement of the load bearing capacity of ground.

26 Bearing fixing:

 Surface of pedestal is prepared for fixing the bearings.

 Mark the centerline on the top surface of pedestal.
 Elastomeric bearing is fixed in position.
 Check the line and level of bearing after fixing.
 Bearings will be fixed when the soffit shuttering is in progress. After
fixing the bearings balance gap of soffit shutters will be filled with
wooden planks.
 Source of approval will be taken before ordering the materials and
testing of materials will be followed as mentioned in IRC: 83 (Part- I
&II)

27 Shuttering and reinforcement:

 After completion of staging, girder soffit shuttering will be fixed over

cross beams in line and level.
 All the three girders and cross diaphragm reinforcement will be fixed.
 Fix the deck shuttering along with girder and cross diaphragm side
shutters in line and level.
 Deck shutters will be supported from cross beams of staging.
 Fix the deck reinforcement.
 Fix the deck side shutters.
 To make the shutter joints leak proof suitable foam sheets / masking
tape will be used. Suitable shuttering releasing agent will be applied
on the surface, facing concrete.

28 Checking and approval:

Approval for survey work, shuttering and reinforcement will be taken stage by
stage whenever the activities are completed.

29 Concreting:

 Concreting shall be done by crane and bucket or pump as per the

availability.
 Concrete will be transported from the batching plant through
transit mixers.
 Concrete shall be placed in a single continuous pour.
 Remove the side shutters of deck and girders after 7 days.
 Remove girder soffit shutters when the concrete attains full strength.
 Keep the provision for expansion joint fixing.

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30 EXPANSION JOINT:
 Tested and approved expansion joints will be used for construction.
 The expansion joints will be provided over the full width of
superstructure including kerb and foothpath.
 Fabricated pieces of expansion joint will be erected at site in position,
and extension of pieces will be done by welding.
 Initially erection of expansion joints will be done in presence of
manufacturer’s representative.
 Second stage of concrete will be done after final checking of expansion
joint.

31 Wearing coat:
Wearing coat shall be 65mm thick comprising of 2 layers of 40mm thick
Bituminous concrete and one layer of 25mm thick mastic asphalt will be layed
after kerb / crash barrier construction.

32 Crash barrier:
 Crash barrier is to be cast as per the drawing.
 Main reinforcement will be embedded in.
 Balance reinforcement steel and shuttering will be fixed as per drawing.
 After approval of engineer concreting shall be carried out.
 Fixtures for hand rails will be provided before concreting.

33 Footpath and kerb:

 Foot Path is to be cast as per the drawing.
 Main reinforcement will be embedded in deck slab concrete.
 Balance reinforcement steel and shuttering will be fixed as per drawing.
 After approval of engineer concreting work is to be carried out.

34 Hand rails (GI):

 Handrails are to be fixed as per the drawing.

35 Railing (RCC):

 Precast the horizontal beams of railing.

 Vertical reinforcement (for post) will be embedded in deck slab.
 Fix the stirrups of column, shuttering and place the precast beams in
position before casting the column.
 Cast the vertical column
 Railing will be cast for a length from one expansion joint to another
expansion gap.

QUALITY CONTROL :

All the Quality Control Tests will conducted as per Section: 900 of
MOSRT&H and Technical Specification

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SAFETY:

Work site will be barricaded by putting wooden ballies having reflective tape spots
over it and will be tied with the warning tape for night vision also. It will be ensured
that no unauthorized person should enter in the working area.
Generally the one side of two lane wide will be constructed first in all respects. The
existing or second side of construction will be taken up only after diverting the traffic
on newly constructed side.
During construction, the road width for two lane traffic movement will be maintained
open at all times.
All persons shall use appropriate personnel protective equipments as required.

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