Mega Bridges Using Precast Technology SKD

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Hindustan Construction Co Ltd


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Construction of

Mega Bridges using Precast

Segmental Methodology

Mr S.K.DharmadhikariGroup Technical OfficerHCC Group of Companies

December 14, 2012


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Mega Bridges

Current Scenario


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Mega Bridges by nature have significant

Design & Construction Challenges

December 14, 20124 Precast Segmental Construction in Mega Bridges


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December 14, 2012 Precast Segmental Construction in Mega Bridges7




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Requirements of Mega Bridge Projects

Constructability Faster Construction Ease & flexibility inConstruction Cutting Edge Technologies Value Engineering Specialised skills & resources

AestheticsMost Mega Bridges are Signature structuresThe Bridges dominate the local landscapeThe layout to be in harmony with Environment Innovative Design

DurabilityHigh Construction Investments.High Quality & High precision Low maintenance costShould be strong & durable during its life

time.SecurityHigh value projects - potential terrortargetsDesign to mitigate the security risks



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Precast Segmental construction provides solutions

to these challenges and exceeds Project Requirements



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Precast Segmental Bridges are highly durable

structures for a number of reasons

Superstructure is Post-tensioned in both the Transverse and Longitudinal directions, placing

the bridge deck in compression at all times

This eliminates the possibility of cracking of the bridge deck and intrusion of corrosive agentsthat would damage the mild steel reinforcement and the post-tensioning in the deck

These factors combined with low-maintenance detailing of the bearings and expansion joints

enable the structure to easily achieve its design life with minimal maintenance by the owner

When building over water, efficiency is achieved through the simplification of operation.

Allows off-site casting that removes complicated casting procedures and unpredictableweather from the critical path.

Once the segments are cast, they can easily be barged to the erection site, lifted onto theerection truss using a barge-mounted crane, and assembled



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This is the most suitable method for Long Span

Bridges across River / Sea / Creeks

ReducesIntermediatePiers & thusObstructions

to flow

Avoidsystem of

staging fromriver bed

level

Faster &economical

technique asit saves

time.



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Construction Planning has to be Meticulous and needs

lot of Care

Delicate process and needs fine balance.

Careful and Systematic Approach needed for

Segment Casting as any Imbalance can causesevere damages

Proper Sequencing of Key ConstructionOperations should be clearly established.



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HCC A brief profile


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Business Lines

Hydro

Dams & Barrages

Tunnels

Powerhouses

Shafts & Penstocks

Water Solution

Storage Dams

Barrages

Bulk watertransmission canals

Tunnels

Pipelines

Pumping Stations

Treatment Plants

Transportation

Roads

Bridges

Tunnels

MRTS

Nuclear &

Special Projects

Nuclear Power

Plants

Ports

UndergroundCaverns

Utility buildings &

industrial structures

EPC

Lump sum turnkey

EPC

Design Build

Engineering Center



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Our track record in Bridge Construction

Experience Expertise Diverse Capability Precast Segmentaltechniques

Cable stayed /conventional bridges Pile / Well foundations River / Land bridges PSC / RCC / Steel /Composite bridges

Design & Construction Complex projects involving

difficult logistics Speedy construction Construction in urbanenvironment

More than 5 decades 300 bridges

34 bridges in Iraq 43 bridges in Nepal Over 50 km of bridge length

Indias leading

Mega BridgeConstructor



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Signature Bridges Built by HCC

Mokameh

Bridge [1959]

Indias first road cum

rail bridge

Length - 1854 M

Godavari Rail

Bridge

Indias first and only

bow string arch

bridge

Length 2745 M

Kaliabhomora

Road Bridge

3 km long bridgeover majestic river

Brahmaputra, one of

the largest river in

Asia

Varanasi Bridge

Prestressed

Concrete Road

bridge across River

ganga

Length 1296.5 M

Cable Stayed

Bridge across

Naini,

Allahabad, UP

Length 1510 M

Badarpur

Elevated Road

Large scale elevatedhighway project built

in congested urban

environment

Length 4.4 Km



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Construction of Mega Bridges withPrecast Segmental Construction

HCCs experience


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Bandra Worli SealinkIndias Engineering marvel

First bridge in India built on open sea

Developed completely by Indian Engineers

One of the most complex andadvanced

construction projects ever to havebeen

undertaken in India.



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Purpose

Existing Route

New Route

To connect 2 suburbs ofMumbai Worli & Bandra

Reduction in travel timebetween the two suburbs

Reduction in traffic congestion



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Situation before Sealink :

Distance from Lovegrove Jn toMahim Junction = 7.7 km

Traffic Signals = 23 Nos

Travel time:

Morning peak hour = 35 min

Evening peak hour = 38 min

Average Journey Speed = 13 kmph

Savings due to Sea Link

Direct Cost savings = Rs 14.11 per car

(fuel, tyre,wear & tear, lubricants,etc)

Travel time savings = 29 min per car

Time value @ Rs 100/ hr = Rs 48.43 / car

Hence, total savings = Rs 62.59 / car

Benefits



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Fuel savings worth Rs. 100 Crs per Annum

Savings in travel time up to 20 - 30 minutes

Reduction in Air, Noise & Sound Pollution

Reduction of Nox by 43% & CO by more than 75%

No adverse effect on Tides, Fisheries and livelihood ofFishermen

Ease in driving with reduced mental tension and overallimprovement in the quality of life

Reduced Accidents

Proper Landscaping Measures along the Approaches andPromenade along Waterfront to enhance Environment of theArea

Other Socio Economic Benefits



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Project Overview

The entire project was originally conceived as one large

project comprising, different components

In order to accelerate the overall construction schedule, the

project has been divided into five construction packages.

Package I: Construction of flyover over Love Grove junction at

Worli

Packag e II: Construction of cloverleaf interchange at Mahim

intersection

Pack age III: Construction of solid approach road from the

Mahim intersection up to the start

of the Toll Plaza on the Bandra side and a public promenade

Packag e IV: Construction of Cable-Stayed Bridges togetherwith viaduct approaches extending from Worli up to the Toll

Plaza at Bandra end, Intelligent Bridge System (IBS).

Package V: Improvement to Khan Abdul Gaffar Khan Road

HCC built Package IV, which is the

largest phase of Bandra - Worli

Sea Link.



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MAHIM BAY

APPROACH ROAD& TOLL PLAZA

BANDRAAPPROACH

600 m BANDRACABLE STAYED

350M WORLICABLE STAYED

WORLI APPROACH

KAGK LINKBRIDGE

WORLI

BANDRA

LAYOUT OF BANDRA WORLI SEALINK PROJECT



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Salient Features of the Project

An 8-lane bridge with 2 lanes dedicated for buses.

Unique bridge design for the Link Bridge

Single tower supported 500 meters long Cable Stayed Bridge at Bandra

Channel and Twin tower supported 350m Cable Stayed Bridge at Worli

Channel for each carriageway.

Modern toll plaza of 16 lanes with automated toll collection system.

An intelligent bridge with state - of - art systems for traffic monitoring,surveillance, information and guidance, instrumentation, emergency support

Development of promenade and landscaping to enhance the environment.



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Project Implementation Entities

Project Owner : Maharashtra State Road Development Corporation

Main Contractor : Hindustan Construction Co. Ltd [HCC]

Design Consultants : Sverdrup Asia Ltd. (India)Stup Consultants India Pvt. LtdDar Consultants UK in JV with Dar Consultants India

Proof Consultants : Construma ConsultancyMott Mc DonaldSchlaich BergermanTY Lin International

Consultants to Main Contractor : VSL, Singapore



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Scope of Work in Package IV executed by HCC

449m long embankment with 20m wide promenades for 16-lane toll plaza

800m long Precast Segmental Approach Bridge on Bandra side

600m long Cable Stayed Bridge with 125m high Towers including transition spans

200m long Precast Segmental Approach Bridge between Bandra & Worli Cable

Stayed Bridge

350m long Cable Stayed Bridge on Worli Side with Pylons including transition spans

1400m long Precast Segmental Approach Bridge on Worli Side

811 m long link bridge to KAGK road comprising 510m Precast Segmental Bridge and301m Cast-in-Situ Bridge

Setting up Traffic Monitoring, Surveillance, Information & Control Systems, Drainage, Street

Lighting, Signage Marking, Landscaping & Arboriculture


P t Y d


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Precast Yard

Located on Reclaimed Land

Total storage requirement 2342 Nos Original storage 470 Nos Precast Segments.

As the area available is limited, the segments are to be stored in stacks of threelayers.

The bearing capacity of existing ground was very poor and found to be less than2 T/Sqm.

Limitation to storage capacity requirement of 2342 nos.

Detailed Ground Stabilization was done to improve Bearing Capacityof Soil

Excavation of the ground to a depth of ~ 2.5Mtrs.

Strengthening the ground using rubble soling and filling the voids with sand The soling thus done was compacted layer by layer using vibratory rollers

Total area of the Pre-cast Yard was covered with a layer of PCC

RCC Footing done to facilitate storing of segments



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Precast Yard



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Super Structure Construction

Precast Segmental Construction for

the Prestressed girder :

Superstructure construction in thisproject is very complex due tofollowing reasons :

Construction across deep sea.

The deck girder in this project is one

amongst the heaviest.

Deck girder cross section - Triple cell

precast box girder

Girder

width

M

No. of

spans

Span

lengths

MBandra

Approach

Bridge

18.10 17 50

Cable stayed

bridge 1

22.70 1 500

2nd approach

bridge

18.10 4 50

Worli cable

stayed bridge

22.70 1 250

Worli

approach

bridge

18.10 28 50



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Segment ProductionCasting Yard



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Segment casting activities

Method: - Short line match castMajor activities involved in the casting ofsegments

Rebar cage tying.

Alignment of cell.

Concreting

TPT stressing

Lifting & Storage



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Rebar Cage tying in the Jig



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Rebar cage lifting from the Jig


Lif i f R b


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Lifting of Rebar cage



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Rebar cage Lowering in the Cell



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Concreting Pour Sequence

CONCRETE PLACING SEQUENCE

1

5.33M

22a

3.17M 3.17M

3a 3

1.26M 1.26M

44a

1.66M1.66M

5a 5

1.26M 1.26M

66a

1.66M1.66M

7a 7

4.39M 2.52M

8a 8

2.69M 2.69M

9a 9

2.19M 2.19M

10

4.28M

TOTAL CONCRETE QUANTITY = 44.30 CUM



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Match casting



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SITE PHOTOGRAPH SEGMENT LIFTING



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SEGMENT : TRANSPORTATION



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LAUNCHING TRUSS



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Relocation of Launching Trusses using 1600 MT


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capacity Barge Mounted Crane Asian Hercules

Various options examined :

1. Dismantling of the trusses at present locations & reassembling them at new locations

2. Lowering the trusses on a suitable floating craft & shift erect them.

3. Shifting the total truss using a floating crane.

Factors considered to decide on solution :

i. Limited working period available to executed the work in sea,

ii. Effect of open sea on dismantling & re-erection, etc

iii. Relocation of the trusses in one piece using a floating crane was selected as the best

option.




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g gcapacity Barge Mounted Crane Asian Hercules



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Project Implementation is a collective responsibility

Owner

Developer

Consultant

RegulatoryEntities

Contractors

Vendors

Value Engineering

Meticulous planning

ModernConstructionManagementTechniques

Cutting EdgeTechnologies

Risk Management

World ClassProjectManagementpractices



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Documents

Mega Bridges Using Precast Technology SKD