Implementation of 4-lane Cable Stayed ROB at Barddhaman – future fast track model for

New ROB over busy yard.

ByRajesh Prasad

Chief Project Manager (M), RVNL, Kolkata

Engineers constructed the first cable-stayed bridges in Europe following the close of World War II, but the basic design dates back to the 16th century.

Today, cable-stayed bridges are a popular choice as they offer all the advantages of a suspension bridge but at a lesser cost for spans of 500 to 2,800 feet (152 to 853 meters).

They require less steel cable, are faster to build and incorporate more precast concrete sections.

CABLE STAYED BRIDGE – few facts

Tension

Compression

CABLE STAYED BRIDGE

Basic Principal :- Pylon

Stay Cables

The advantage of cable-stayed bridges lies in the fact that it can be built with any number of towers but for suspension bridges it is normally limited to two towers.

With span length less than 1,000m, suspension bridges require more cables than cable-stayed bridges.

Moreover, cable-stayed bridges possess higher stiffness and display smaller deflections when compared with suspension bridges.

The construction time is longer for suspension bridges.

VIEW OF MODEL OF PROPOSED CABLE STAYED BRIDGE

Current Picture

RVNL Kolkata PIU is Implementing Agency M/s GPT-RANHILL(JV) are main Contractor M/s Freyssinet are specialized subcontractor M/s Consulting Engineering Services(India) Pvt. Ltd

(JACOB) are the DDC and PMC IIT Roorkee is the proof consultant Mathematical Model prepared by Council of

Scientific & Industrial Research Wind Tunnel Test Being Executed By Council of

Scientific & Industrial Research

AGENCIES INVOLVED

Clear Span(ABT to ABT): 184.428m Main span length : 124.163 m Side span length : 64.536 m No of cable planes : 3 Type of cable in main span : harp pattern No. of cables in main span : 9 per plane No. of cable per side span : 7 per plane Spacing between cables in main span : 12 m Spacing between the cables in side span : 6.881 m Hight of pylon : 62.329 m Clearance above rail track:6500mm Maximum height of road surface from rail track level:

7500MM (Road surface to bottommost part of superstructure =

1000mm)

BARDDHAMAN CABLE STAYED BRIDGE DETAILS

• Engineering Challenge confronted…• Superstructure carries 7.5m carriageway and 1.5 m wide

footpath on each side.

• DECK Geometry:Total Length of the Bridge : 188.431 mCP1 to P1 (Steel composite deck) : 124.163 mP1 to CP2 (RCC Deck) : 64.265 mNumber of Lanes in each Direction : 2Cross Slope : 2 %

GEOMETRY OF THE CABLE STAY BRIDGEBarddhaman yard is one of the busiest yard of Eastern Railway and Rajdhani route over Barddhaman station spanning across 8 platforms and 10 tracks.

• LARSA 4D model for design• Wind tunnel test• Use of precast RCC slabs to avoid scaffolding on

deck• Composite structures for easier construction• Monolithic Back Span• Durable painting by epoxy based paint of Akzonobel• Erection scheme • LUSAS model for Construction Stage Analysis • Geometry Control during execution.

FEATURES

In Larsa 4D these construction stages are simulated so as to get more realistic analysis. As cable elements have been used which are nonlinear in nature, nonlinear analysis is carried out at each stage. The initial structure has been kept with a pre-camber such that after complete construction, the deflection brings the structure to desired finish level.

Fundamental period of vibration of the structure is calculated by creating a 3D model of the structure and carrying out its modal analysis in STAAD Pro V8i/ Midas Civil/ Larsa4D.

DESIGN SIMULATION BY LARSA 4D

Transverse section showing components of Back Span (124.163m)

65mm WEARING COAT

Stage 16•Max moment in Pylon. Utilization ratio <1

Bending Moment diagram

Stage 16•Max moment in Pylon. Utilization ratio <1 Max. deflection is 208 mm (with lane reduction it will become 166mm)

(Dead Load + SIDL) (Two Tracks of 70R wheeled)

NATURAL VIBRATIONAL MODE SHAPE-2 (FREQUENCY = 0.66HZ & T = 1.520 SEC)

Test was physically conducted on 27th May,2014 Model Design and Details of Sectional ModelModel Scale : 1: 40 and blockage:5.9%

Length of model: 1440mmWidth of model : 692.5mmAspect Ratio (length to width ratio): 2.08

Based on the preliminary Aerodynamic Studies by CRRI, the bridge has been found not susceptible to classical flutter and galloping

Buffeting, Vortex Induced Oscillations- Limited Amplitude Oscillation The Amplitude of vortex induced oscillation is vey low and not likely

to cause discomfort to users Using Frequency Domain Approach, peak buffeting response was

estimated as 0.160m for assumed aerodynamic force coefficients terrain roughness (plain terrain, surface roughness parameter =0.005m)

WIND TUNNEL STUDY

CLOSED CIRCUIT WIND TUNNEL OF CRRI LOCATED AT

GHAZIABADTest Section with Size

1.5mx0.5mx2.0m

CONTROL UNIT OF

DC MOTOR

BETZ PROJECTION MANOMETER

•Model Design

•Model Fabrication and mounting

•Instrumentation ( pasting of strain guages in three component balance)

•Calibration of Strain guage balance

•Wind tunnel test at different angle of attack, wind speed

Steps involved in Wind Tunnel Testing

•The basic wind speed for design is to be taken as 47m/s at the location of bridge as per the wind given in IS:875 – Part 3 and IRC:6•The terrain roughness for the bridge design has been taken as TC-I or plain terrain as per IRC:6 and wind forces in the transverse longitudinal and vertical directions have been computed as per IRC:6.•The peak buffeting response of bridge deck at the location of maximum modal ordinate of the main span at a distance of 76m from the pylon has been estimated as 0.2225m using the frequency domain analysis, when the houly mean wind speed at deck level is 39.6 m/s.•The max. amplitude of bridge deck due to vortex excitation in the first bending mode is estimated as 5 mm at a wind speed of 5.93 m/s which is very low compared to the deflection due to dead load and live load and is not likely to cause discomfort to users•The bridge deck is not likely to be susceptible to galloping oscillation in vertical mode and shall flutter in first torsional mode.•The bridge deck is not susceptible to classical flutter.•It is suggested that monitoring of wind speed and wind direction at 10m level may be carried out at bridge site.

CONCLUSION

Construction Stage Analysis using LUSAS model• Analysis has been done using finite element analysis software LUSAS. • Deck is modeled as grillage of longitudinal and transverse members. • Deck is integral at P1 and CP2. At CP1 pin support with longitudinal

free movement is used representing the Guided PTFE bearings. • At P1 and CP2, elastic spring supports representing the pile stiffness

are used.

• Load Cases : 67

Analysis Model

Isometric View of the model Rendered View of the model

Geometry Control to ensure safety

• Height of the pylon is dictated by the stability analysis and economics of the bridge. A tall pylon will minimize the compression introduced into the steel deck system, but may increase the length of cable used while a short pylon will introduce undesirable compressive forces into the steel deck structure.

• The cross section is sized for not only strength and deflection requirements, but also to accommodate a stressing and inspection route.

• Height of the pylon above deck has been fixed as 54.768m. Three steel pylon towers (2.5MX2.0M box) connected by with ties and founded on RCC wall of M50 grade (concrete Part of Pylon).

STRUCTURAL DESIGN

Installation of strands & Stressing Freyssinet’s Parallel Strand System (PSS) stay cables - which

has a design life of 100 years and is the most advanced and durable stay cable system in the world today. There are 3 planes of stay cables with 18 cables each. Vibration control dampers are being installed in long stay cables (> 80m) as per CIP recommendations. Sensors for permanent monitoring of deflections and stresses during service condition, are also being installed in 6 stays subjected to heavy loads. An inspection and maintenance manual for the stay cables during service has been prepared.

Isotension® Method

• In order to avoid the problem of shuttering / de-shuttering for deck slab over electrified tracks and to ensure proper finish of concrete, the deck slab has been designed consisting of a precast slab and a cast-in-situ portion. The precast slab is placed over the cross girders by the Deck Erection Crane (DEC) and the cast-in-situ concrete is poured after completion of reinforcement and shear connector works.

Bed for Precast Slab Casting Precast Slab Reinforcement Trial of Precast Slabs in Yard

Stacked Precast Slabs Erection of Precast Slabs Cast-in-situ Concrete in Progress

PRECAST DECK SLAB

PAINT & PAINTING SCHEME

Maintenance-free painting scheme with a design life of 40+ years.

The painting scheme and supervision by M/s Akzo Nobel and has a warranty period of 25 years for the painted structure.

The painting scheme :• Blasting of the Steel Structure to SA 2.5 with suitable abrasive material.

(Copper slag)• Primer Coat consisting of 2 coats of epoxy zinc dust primer (Interzinc 52)

are applied by brush/airless spray to 75 micron DFT• Intermediate Coat consisting of epoxy polyurethane paint (Intergard 475

HS MIO) applied by brush/airless spray to 75 micron DFT• Finishing with 2 coats of Polysiloxane (Interfine 878) applied by

brush/airless spray to 120 micron DFT

PAINTING SCHEME

2 separate blasting & painting chambers have been constructed where the blasting & painting operations are carried out in a controlled environment.

After the painting is completed, proper slinging and handling arrangement is also ensured so that there is no damage to the members during handling

In case of any damage to the paints during handling, a touch-up/repair scheme has also been proposed by M/s Akzonobel, which is also being followed.

• For monitoring of the structural health of the bridge during its service life, 6 nos. sensors have been installed on the stay cables subjected to maximum loads. The ROBO Control System of M/s Mageba is being used for the purpose.

• The structural monitoring system issues alarm notification based on measurements by the on-structure instrumentation when pre-defined threshold values of structural loads are passed. Alarm criteria will be configured based on the structural design of the bridge

MONITORING SYSTEM

• In order to reduce the effect of fatigue on the stay cables due to oscillations induced by wind or other external phenomena, stay cables of more than 80m length have been provided with Internal Radial Dampers (IRD). 15 such dampers have been installed on the stays

• IRD is composed of three hydraulic pistons placed at 120° angle around the cable. The inner end of the pistons is fixed with a pin joint on a collar compacting the strand bundle. Their outer end is fixed with pin joints to a metallic tube called the guide tube. The damper is fixed rigidly to the guide tube.

• The available stroke for the transverse displacements is +/- 40mm.

INTERNAL RADIAL DAMPERS

• Due to the presence of electrified lines and block working, safety is a critical aspect of the work.

• The safety measures adopted at site go above & beyond merely using Personal Protective Equipment (PPE) at site.

• In preparation of the SHE plan, each activity of the work has been studied minutely and risks have been identified & steps have been taken to address associated risks.

• Some of the aspects of the Safety Plan include:• Provision of Proper Illumination & Safe Access to all working locations• Use of properly designed slings, cranes and handling tools for all erection activities and

regular maintenance and 3rd party checking of the same• Provision of Lifelines & Fall Arrestors for all workers working at height• Emergency Evacuation Plan & Temperature control for working in congested

surroundings (i.e. inside pylon)• Adopting safe work practices & imbibing culture of safety & awareness among workers

SAFETY

Safe Work Practices Adopted during ErectionSAFETY

A. Tower Crane (capacity 32 MT at 20.1 m operating radius) Installation & commissioning : Verticality of masts constantly monitored Mast connections were tested with hydraulic Torque wrench Jib was not at all allowed to swivel towards / over adjacent railway track. Load Testing : Done successfully with 32 MT load at 20.1 m operating radius Visual Inspection : Masts, Level & alignment of jib, motor, brake, gearbox and wire ropes were checked

before erection of each segment of Pylon (31 MT)B. Pylon (53.86 m) : Following precautions were taken during erection of each segment upto 7th segment (37.07m) Safety drills carried out before commencing each activity Tool box talk was religiously conducted before erection of each segment. Lifting attachments like, Hooks, Slings, wire ropes, D shackles etc. were load tested and cross checked with

manufacturer’s certificates Proper illumination inside Pylon Proper ventilation by Exhaust fan provided inside Pylon. Proper access, safe working platform with railing provided outside of each segment. Walky-talky provided to Tower crane operator and skilled signal man for proper communication.

SAFETY DURING ERECTION & LAUNCHING OPERATION

C. Crawler Crane (capacity 270MT). Load chart & Load Testing : Crane Load Chart checked through TPI at different angles and operating radius. Physical Inspection : Counter weight, motor, Boom, gearbox, Bridle rope, wire rope, Pulley, Lifting hook and

other accessories are tested & certified through TPI. Crane Operator : Validity of license checked PPE : Wearing of PPE enforced on all erection workers including safety harness and fall arrester /

life line etc. Communication : Signaling to crane operator by a skilled foreman

SAFETY DURING ERECTION & LAUNCHING OPERATION

D. Deck Erection Crane : Load tested with 45 T at Fabrication yard through TPI Safety drills carried out before commencing each activity All tools and tackles checked before erection. Periodical checking of test certificate by TPI Earthing of feeding track, trolleys and girders with DEC Fire extinguisher near electric panel Locking arrangement of wheels, pins and bottom trolley system Bolt connection and anchoring of bottom rail over longitudinal joists and rail track of Gantry trolleys Wheel and pins of Gantry trolleys with locking arrangement Marking of maximum travelling distance of trolleys Lifting Hook with safety latch Condition of wire rope and its anchoring with winch drum Limit switches, Break system and smooth movement of trolleys Slings, attachment of final adjustment of line and level of the object to be lifted. PPE of all workers engaged in erection including safety harness and fall arrester and life line.

SAFETY DURING ERECTION & LAUNCHING OPERATION

Girders are covered all around by Plywood with a 350 mm solid Toe guard to prevent strand from falling off.

Protective casing for wire rope attached to winches, wherever required Proper illumination for work after dusk Life line fixed inside pylon for any eventuality Emergency rescue team supported with collapsible stretcher Adequate training to the workers Appropriate PPE provided to the worker Automatic circuit breaker like MCB and RCCB fitted in electrical connection to the

relevant machineries Adequate lighting and ventilation inside Pylon for comfortable working condition Protective barrier on main span around cable anchor

SAFETY DURING STAY CABLE STRESSING

Proper Access Platforms, Staircases & Illumination for Night Work

Trial conducted at site for evacuation from inside pylon

Trial of fall arrestor in progress for height working

Workers taking “Safety Pledge”

SAFETY

Inspection and Test Plan (ITP)CONCRETE

Item Description Frequency of test Test Centre

Inspection Agency

Documentation No. Approved by

Acceptance CriteriaTest MethodGPT-

RANHILL (JV)RVNL/ PMC

1 Fresh Concrete

 1.1) Slump Test For each Concrete Transit Mixer Inhouse  Testing  Witness Lab Register / Pour / 

Delivery Card RVNL/PMC IS 1199

 1.2)  Temperature For each Concrete Transit Mixer Inhouse  Testing  Witness Lab Register / Pour / 

Delivery Card RVNL/PMC IS 456

 1.3) Air Content  As directed by Engineer Inhouse  Testing  Witness DOC/QA-QC-FORM RVNL/PMC IS 456

 1.4) Yield  As directed by Engineer Inhouse  Testing  Witness DOC/QA-QC-FORM RVNL/PMC IS 1199

 1.5) Sampling of Cube As per IS 456 / MORTH Inhouse  Testing  Witness - RVNL/PMC IS 456 / IS 4926

2 Hardened Concrete

 2.1) Compressive strength As per IS 456 / MORTH Inhouse  Testing  Witness DOC/QA-QC-FORM RVNL/PMC IS 516

 2.2) Chloride Penetration Test As directed by Engineer Independent house

Testing/ Review

Witness/ Review

DOC/QA-QC/ EXTERNAL RVNL/PMC IS 456

2.3) Permeability Test For each Grade of Concrete (RCC) / As required

Independent house

Testing/ Review

Witness/ Review

DOC/QA-QC/ EXTERNAL RVNL/PMC MORT&H

QUALITY ASSURANCE - CONCRETE WORK

RAW MATERIALRAW MATERIAL SCOPE AS PER

BOQ (IN MT)GRADE VENDOR REMARKS

MS Plate 1720.000 IS-2062, 2006, E410 .Fe540 SAIL Testing of material as per approved QAP

Rolled Section 150.000 IS-2062, 2006, E250 .Fe410 SAIL & RINL Testing of material as per approved QAP

Fastener 17450 Nos High Strength Friction Grip Bolt

Gr. 10.9

UNBRAKO Material inspected at manufacture’s workshop.

Shear connector 31500 Nos IRC22-2008

BS 5400 ,P5, UTS-495

UNBRAKO Material received at site.

Anchor Bolt 286 Nos Gr. 8.8 UNBRAKO

END Plate machining

60 nos IS-2062, 2006, E410 .Fe540 Suprime Industry Howrah

Protective coating 1870.000 Abrasive copper blasting , Epoxy zinc rich Primer , MIO, Polyslloxan paint –Total DFT -

320 microns.

AkzoNobel

QUALITY ASSURANCE - FABRICATION

QUALITY ASSURANCE PLAN ( QAP) Prepared based on project  technical specifications and  codal provisions  

Approved by PMC, DDC & RVNL

WELDING PROCEDURE SPECIFICATION

( WPS)

PROCEDURE QUALIFICATION RECORD ( PQR)

As per AWS D1.1,

1.SAW (Submerged Arc Welding )

2.GMAW/ MIG ( Gas Metal Arc Welding/Metal Inert Gas)

3.SMAW ( Shielded Metal Arc Welding )  

Approved by PMC/DDC/RVNL

Welding consumable.

Filler wire/ electrodes and Flux  - By approved vendor - ESSAB

WELDER QUALIFICATION TEST ( WQT) Qualified welders

SAW : 5 nos 

MIG/ SMAW : 7 nos.

SAW welders tested in 1G Position

MIG/ SMAW welders tested in 3G position

NDT (NON DESTRUCTIVE TEST) Tension Joints – 100 % UT

Compression Joints  - 25 % UT

Double V butt joints – 100 % RT

 

Raw material Testing at Outside laboratory 49 nos HT Steel Plate Samples and 5 nos. Rolled Steel Sections Tested so far

NABL Accredited laboratory

QUALITY DOCUMENTS

QUALITY ASSURANCE - CONCRETE WORK

CONTROLLED EXERSISE CARRIED OUTRaw Material:1. Coarse Aggregate: Physical Test : Sieve Analysis, Specific Gravity & Water Absorption, Impact Value,

Flakiness, LAA Value etc. Test Frequency : As per approved ITP. Chemical Test : Chloride & Sulphate Content, Alkali reactivity etc. Test Frequency : One for change of source/every 6 Months from independent

laboratory2. Fine Aggregate: Physical Test : Sieve Analysis, Moisture Content, Specific Gravity & Water Absorption,

Silt Content etc. Test Frequency : As per approved ITP. Chemical Test : Chloride & Sulphate Content, Alkali reactivity, Organic Impurity etc. Test Frequency : One for change of source /every 6 Months from independent

laboratory.

CONCRETE WORKS: INSPECTION TEST PLAN (ITP)

3. Cement: Physical Test : Normal Consistency, IST & FST, Fineness, Soundness, Compressive Strength

etc. Test Frequency : As per approved ITP. Chemical Test : Chloride, Total Sulphate, Lime Saturation factor, Insoluble Residue,

Magnesium, Loss of Ignition etc. Test Frequency : One for change of source/every 6 Months from independent laboratory. Manufacturers Test Certificate: Each production week4. Water: Quality Test : PH Value, Total Organic Solids, Inorganic Solids, Chlorides, Sulphates,

Suspended matter, Acidity, Alkalinity etc. Test Frequency : One for change of source/every 6 Months from independent laboratory.5. Admixture: Quality Test : Specific Gravity, PH Value, Solid Content, Chloride & Ash Content etc. Test Frequency : One for change of source/every 6 Months from independent laboratory

CONCRETE WORKS: INSPECTION TEST PLAN (ITP)

6. Concrete: Fresh Concrete : Slump Test, Temperature, Yield Test, Sampling etc. Hardened Concrete : Compressive Strength, Permeability Test, Chloride Penetration

Test etc. Test Frequency: As per approved ITP.

7. Reinforcement Steel: Mechanical Test : Yield Strength, Ultimate Tensile Strength, %age Elongation, Bend &

Re-bend Test etc. Test Frequency : As per approved ITP. Chemical Test : Carbon, Sulphur & Phosphorus etc. Test Frequency : One for change of source /every 6 Months from independent

laboratory.

CONCRETE WORKS: INSPECTION TEST PLAN (ITP)

Sampling of concrete workability test

Sampling of concrete

Temperature Measurement of concrete

Step by Step clearance of subsequent activities :-A.Request for Inspection (RFI)B.Inspection of raw material [conforming to IS:2062 – E410, Fe540]Dimension measurement Non destructive test [NDT] – Ultrasonic TestDestructive test [DT] – Ultimate Tensile Stress, Yield Stress, Bend Test : At Independent Laboratory Chemical Properties : At Independent Laboratory Frequency of Test : 1 test from each Heat No. for DT as per approved QAP C.Cutting of plates and Edge preparation as per approved shop drawing.Marking, cutting and edge preparation as per ‘Notes’ in approved drawing.Frequency of Test : on each Item Mark as per Bill of Material.D.Fit-up of structural segments : Checking of fitted up componentFrequency : 100% check.

Controlled exercise carried out for fabrication of superstructure

E. Welding : Types of welding adopted – as per approved welding procedure

specification [WPS] Submerged Arc Welding [SAW] Metal Inert Arc Welding [MIG] Shield Metal Arc Welding [SMAW] Visual Inspection : on each run of weld : Internal Dye Penetration Test [DPT] : 100% Internal Ultrasonic Test [UT] : 100% check for all Groove joints : Inspection by

Independent Agency Radiography Test [RT] : 10% on each double beveled Butt joints F. Machining of End plates of Main Girders : Outer surface machining of End plate – 100% contact required for High

Strength Friction Grip [HSFG] bolts.

Controlled exercise carried out for fabrication of superstructure

G. Trial Assembly : Trial Assembly of 2 corresponding panels Dimensional check, level check, verticality check Checking of geometry as per design profile Frequency : each pair of panelsH. Protective coating with airless spray machine : Painting is carried out when humidity is

less than 85% Surface preparation : blasting with copper slag to achieve Sa 2.5 grade. Roughness compared with surface gauge. Primer coat : Application of Epoxy - Zinc based primer coat – Dry Film Thickness [DFT] :

75 Micron DFT checked by digital Elcometer Intermediate coat : Polyurethene based intermediate coat – DFT 125 micron DFT checked by digital Elcometer Final coat [2 coats – 120 micron] Application of polysiloxan based final coat – DFT 60 micron each. DFT checked by digital Elcometer

Controlled exercise carried out for fabrication of superstructure

1. Anchorage: Anchorage Block, Wedge, Anchorage Tube, Injection Cap etc Quality Test : Dimension, Mechanical Properties of Raw material, Hardness,

Galvanization & Protective Coatings etc. Test Frequency: As per approved ITP. A team visited France to witness tests of various components2. HT Strand: Quality Test : Geometrical Property, Mechanical Property, Relaxation at 1000 Hrs,

Monostrand Fatigue Strength, Deflected Tensile Strength, Galvanization, Various quality test for HDPE Sheathing, Bond Strength, Static & Dynamic Water Tightness Test, Impact Test & Rotative Flexion Test etc.

Test Frequency: As per approved ITP. Tests conducted at manufacturer’s premises, M/s Usha Martin, Ranchi. A team visited France to witness Monostrand Fatigue Strength & Rotative Flexion

Test.

STAY CABLE WORKS: INSPECTION TEST PLAN (ITP)

3. Petroleum Wax: Quality Test : Density, Pour Point, Penetration, Flash & Fire Point, Viscosity etc. Manufacturers Test Certificate: Each production batch as imported 4. HDPE Stay Duct: Quality Test : Various quality tests like Density, Melt Flow Index, Tensile Strength,

Elongation, Shore D Hardness etc. Manufacturers Test Certificate: Each production batch as imported

STAY CABLE WORKS: INSPECTION TEST PLAN (ITP)

2 MILLION CYCLE FATIGUE TEST

COMPLETION OF 2 MILLION CYCLE FATIGUE TEST ON 12.05.2014

TENSILE LOAD TEST OF THE STRAND AFTER 2 MILLION CYCLES

1

1

COMMENCEMENT OF FATIGUE TEST SECOND STRAND ON 13.05.2014

52

INSPECTION OF ANCHORAGES

53

CHECKING HARDNESS OF WEDGES

54

ROTATIVE FLEXION TEST (12.05.2014)

55

Typical Deck Erection Cycle For One Panel

SL No. Action Day

1. Erection of MG2 1

2. Erection of MG1 1

3. Erection of 6 nos. cross girder 3

4. Fixing of working platform, safety net and installation & stressing of cable

3

5. Erection of precast panels 2

6. Fixing of reinforcement, side formwork and concreting 3

7. Curing & Moving of DEC and other preparatory works 14

TOTAL 27

Pile : 14 Nos , 1.5 m dia @ 25M length

Pile cap: Length : 28.9 m Width : 6.7 m Height : 2.5 m

Pier : Length : 27.7 m Width : 4 m

Height : 7 m

(Site before execution) (After Construction)

Common Pier 1

Common Pier-2

Pile : 21 Nos., 1.5m dia @ 25M length

Pile cap: Length : 28.9 m Width : 10.9 m Height : 2.5 m

Pier : Length : 28.2 m Width : 2 m Height : 7 m

(Site before execution) (After Construction)

Common Pier 2

PYLON

Pile : 27 Nos., 1.5 m dia @ 35 M length

Pile cap: Length : 37.9 m Width : 10.9 m Height : 2.5 m

Pier : Length : 28.2 m Width : 2.5 m Height : 7 m

(Site before execution) (During execution)

PYLON

WELDING- SAW

WEDLING- MIG

Trial of Girders at site

Trial of DEC at Fabrication

Trolley loaded with Girders/slabs

USFD Checking of Track over Deck

PYLON SEGMENTS ERECTION WITH TOWER CRANE

Placement of Middle girder

Placement of 2 end girder

Placement of 2 more cross girder (power/traffic block)

Special arrangement of temporary P/F for tightening of HSFG bolts.

Tightening , Checking of HSFG bolts followed by painting at site.

Night picture

Installation of strand

SITE INSPECTION AND VISIT

• A Cable Stayed Bridge looks majestic as it spans through a large expanse of space over the land or water mass. The experience of constructing/designing a Cable Stayed Bridge in India is rather limited.

• Pylon Kept Outside the Yard for– Back span construction independent of Railway yard.– Easier Construction– In case of any derailment in yard, pylon will remain

safe.• Faster construction without much of effect over yard.

• Future Yard remodeling possible.• Erection started in August 2015 to Feb. 2016 for erection

of 12 panels.

FUTURE FAST TRACK MODEL

View after placements of all girders for panel no. 8 over track.

• RVNL Kolkata PIU is Implementing Agency• M/s GPT-RANHILL(JV) are main Contractor• M/s Freyssinet are specialized subcontractor• M/s Consulting Engineering Services(India) Pvt. Ltd are the

DDC and PMC• IIT Roorkee is the proof consultant• Wind Tunnel Test Being Executed By Council of Scientific &

Industrial Research• M/s Stup Consultant for Geometry Control.• Railways and CRS for blocks and approval.

AGENCIES INVOLVED

RVNL MANPOWER • Chief Project Manager• Jt. General Manager (retired Dy. Chief Engineer)• Asst. Manager (retired AEN)