CEP-Construction of Railwayoverbridge

8/13/2019 CEP-Construction of Railwayoverbridge

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CONSTRUCTION OF RAILWAY OVERBRIDGE

AT DOMORIA PULL, JALANDHAR

BY ISHAN KAUSHAL

ROLL NO. 1040252


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ROB AT DOMORIA PULL, JALANDHAR


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Details of the Project

Client Municipal Corporation, Jalandhar

Construction agency M/S Gammon India Ltd.

Type of contract Item rate

Total length of ROB 1.65 Km

Cost of the project Rs 20 crores

Contract period 15 months

Starting date 28-06-2004

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


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Key Plan Of the Project


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Company Profile

Gammon India Limited is one of the leading constructioncompanies in India today.

The company was established by late Mr. J. C. Gammon in1919 as a firm of Civil Engineers & Contractor.

From arch and bowstring girder bridges to balancedcantilever, prestressed concrete and latest cable-stayed

bridges, Gammon's capabilities cover the entire spectrum oftechnological advances in bridge engineering.

Besides designing and building bridges, Gammon has

achieved perfection in the techniques of launching,underwater concreting development of supporting equipmentlike pneumatic caissons, winches, cables, groutingmachinery etc., and building of enabling structures.


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When I joined.

All the piling work was over.

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

All the pier, pier caps, pedestals were cast except at the

location DPG7.

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


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Training Schedule

11 June to 16 June Understood the Work

Culture.

18 June to 21 June Started Collecting Data

about the Project

21 June to 21 July Estimation Work And

Supervision of Site (Pile

cap)23 July to 10 dec Casting yard (Supervision

Of pretensioned I-Girders)


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Some Important Specifications

Number of arms : 7(A,B,C,D,E,FO AND FI)

Total number of piles : 248 Type of piles : Bored cast in-situ

Diameter and depth of piles : 1000 mm and 20 m resp.

Total number of piers : 51

Number of abutments : 6 Type of superstructure : In-situ deck with pre-

tensioned I girders andRCC/post-tensioned boxgirders

Number of box girders spans : 10 Earth work involved : 10,000 m

Steel used : Fe 415 and Fe 500

High Tension strands (HT strands) : 15.2 mm diameter (7 ply)

Bearings : POT PTFE

Number of I girders : 144


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Equipments Used at Site

Needle type vibrator(60 mm dia) Concrete pump (56 m/hr)

Gantry girder( 60 ton) Transit mixer (7 m capacity)


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Slump Cone JCB

Batching Plant

PrestressingPump


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Pipeline Bucket (0.5 m capacity)

Hydra crane( 3 ton)


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PROJECT NO. 1

SUPERVISION OF SUBSTRUCTURE


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Foundation : Piles

Piles are long slender members that carry and transfer the

load of the structure to the ground located at some depth

below the ground and the earth surrounding the piles.

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

M35 grade of concrete was used at our site.

Average depth of the piles was 20 m.


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Estimation of Steel in Piles

Steel quantity

Dia of one pile = 1000 mm

Clear cover = 75 mm

Dia of the bar used for pile rings = 10 mm

Dia of pile ring, d = 1000- 2*75 = 850 mm

Circumference of pile ring = *d = *850 =2.669 mNo. of rings in the pile = 100

So total length of 10 mm bar = 100*2.669 = 266.9 m

Vertical bars

Diameter = 20 mm

Length of one single bar from top to bottom of the pile = 20.9 mNumber of the bars = 15

So total length = 15*20.9 = 313.5 m

Total weight of steel used in one pile = 10/162266.9 + 20/162*313.5

= 938.8 kg

For pile group having 4 piles total weight of steel = 4*938.8 = 3755.3 kg

For pile group having 6 piles total weight of steel = 6*938.8 = 5632.96 kg


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Pile Cap

Structural elements that tie a group of piles together.

Used to transmit forces from piers to the pile foundations.

At my site I studied the construction of the pile cap namedDPG7.

It was constructed to connect 9piles.

Concrete mix of M35was used in the pile cap.

Total of 93.2 mof concrete was used in this pile cap.

Height of the pile cap was 1.75 m.


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Plan of the pile cap DPG7


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Reinforcement Detailing of the Pile Cap


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Elevation of the Pile Cap


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Bar bending Schedule

Sr. no. Bar

mark

Bar

dia(mm)

Specifications Type

1 b1 25 150 c/c

2 b2 25 110 c/c

3 b3 16 110 c/c

4 b4 16 150 c/c

5 b5 12 sets of 7 stirrups @250 c/c

6 b6 16 2 sets of 6 bars


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Estimation of the Pile Cap DPG7

Shuttering quantity of pile cap

Dimensions of the pile cap are shown in the figure

Height of the pile cap = 1.75 m

Area of shuttering = 2*1.75*(3388+3388+847+847+2998+3000+790)

= 54.403 m

Concrete quantity

Volume of concrete to be used = ((7.693*7)-0.5929)*1.75

= 93.2 m


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Concrete Mix Proportion for Pile Cap

Different grades of concrete were used for the bridgeconstruction.

M35was used for the pile cap.

Steel used : Fe 415.

Cement used : Vikram cement (OPC 53 grade)

Aggregates used : 10 mm, 20 mm and sand.

Admixture used : FORSOC CONPLAST SP 430.

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

Cement W/C

Ratio

Water Sand 20 mm 10 mm Admixture

400

kg/m

0.37 148

kg/m

684

kg/m

592.5

kg/m

592.5

kg/m

0.4

1 0.37 1.36 1.94 1.3 0.001


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Pier Cap


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Estimation of the pier cap

All dimensions in mm

Concrete quantity

Ar1 = 9477600 mm = 9.477 m

Ar2 = 5.4882 m

Total area = 9.477+5.4882 = 14.96 m

Thickness of the pier cap = 3600 mm

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


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All dimensions in mm

Shuttering quantity

A1 = 2*14.96 = 29.92 m

A2 = 4203.4*3600 = 15.132 mA3 = 600*3600*2 = 4.32 m

A4 = 3018.87*3600 = 10.868 m

A5 = 100*3600*2 = 0.72 m

Total surface area for shuttering = A1+A2+A3+A4+A5 = 60.96 m


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PROJECT NO. 2

SUPERVISION OF THE

SUPERSTRUCTURE


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Pretensioned I-Girder


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Cross section of the I-girder


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Methodology for the construction of I-Girder:

1. Preparing the shuttering:

Bearing plates Dowel bars

Groove made for bearings

Bearing

plate

dowels

grease

Dowel bars200 mm length

Outer dia 50 mm

Inner dia 22 mm


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2. Lowering of the reinforcement cage:

Gantry girder : 60 ton and 35 ton

3. Cable threading:

Reinforcement

cage

cables

Wedges

and

barrels


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4. Stressing:

Least count of the pump : 5 kg/cm.

5. Closing of the side shutters

6. Concreting:

Automatic batching plant

Needle type vibrator : 60 mm dia

Concrete pump : 56 m/hr

7. Deshuttering:

After 24 hrs

Concrete coming out of

the pipe line

Cement W/C

Ratio

Water Sand 20 mm 10 mm Admixture

435

kg/m

0.30 130.5

kg/m

652

kg/m

741

kg/m

494

kg/m

0.8%

Deshuttered beam


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8. Destressing

Using the grinder.

9. Lifting of the girders10. Curing

For next 25 days at least.Hessian

clothCables

after

cutting at

top

Cables after

cutting at bottom


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Prestressed Concrete

Prestressed concrete is basically concrete in which internal stresses of a

suitable magnitude and distribution are introduced so that the stresses

resulting from external loads are counteracted to a desired degree.

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

of 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 concrete

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

is much less than its permissible value.


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Prestressing has two types:-

1. Pre-tensioning.

2. Post-tensioning.

Pre-tensioning:

In the pretensioning the tendons are first tensioned between rigid anchor

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 comprising

individual wires or strands are stretched with constant or variable

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.

Post-tensioning:

In post tensioning the concrete units are first cast by incorporating ducts orgrooves to house the tendons. When the concrete attains sufficient strength,

the high tensile wires are tensioned by means of means of jack bearing on

the end face of the member and anchored by wedges or nuts


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Methodology for pre-tensioning of the I-girder:

1. Laying of cables2. PVC pipes are used for debonding of the cables.

3. Cables are locked using the wedges and barrels. These wedges and

barrels provide such arrangement that cable can come out of it, but

cant go back.

4. Stressing

Monostrand

hydraulic

jack

Cables

Wedges and

barrels

Prestressing pump


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Stressing report:

GIRDER MARK P1-P2 (10 AND 11)For strand NO. 1 TO 21

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

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

For strand No. 22 and 23ELONGATION (mm) MIN. = 273 MODIFIED= 287 MAX. = 301

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


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PRESSURE

(kg/cm)

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


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Box Girder

I-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, box

girders are used.


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Cross-section of the box girder near the support


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Methodology for the construction of post-tensioned box girder:

1. Constructing the temporary foundation for the temporary structure forsupporting the box girder shuttering.

2. Erecting the trestles.

3. Placing the shuttering.

4. Placing the reinforcement.

5. Passing the cables through sheathing pipes.

6. Concreting.

7. Curing.

8. Constructing the deck slab.

9. Post-tensioning.10. Grouting.

11. Removing the trestles.


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Safety Requirements

1. Training the workers.

2. Providing the first aid.

3. List of nearby hospitals.

4. Safety manual.5. Banners.

6. Using the safety equipments.

7. Providing the vehicle.


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Problems Faced at Site

1. Sometime the strength of the girders didnt come on time.

Remedy:

First off all, aggregates were washed before using them. It would

increase the rate of bond formation between the aggregates and

cement.

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

of strength.

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

problem.Remedy:

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


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Problems Faced at Site

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

Remedy:

Proper and regular maintenance helped to reduce this problem.

4. While shifting the I-girders, traffic was a problem.Remedy:

the girders were shifted at night to avoid this problem.

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

Remedy:

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

curing was also done.


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TH NKS


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CEP-Construction of Railwayoverbridge