Department Of Civil Engineering

Rajapeth ROB (Non railway portion … Dastur nagar side ...

Submitted by: Guided by:Mr. Akash S. Kolamkar (4CA44) Prof. A. R. Bijwe

Department Of Civil Engineering

Rajapeth ROB (Non railway portion … Dastur nagar side ...

Submitted by: Guided by:Mr. Akash S. Kolamkar (4CA44) Prof. A. R. Bijwe

Department Of Civil Engineering

“Rajapeth ROB”(Non railway portion)

… Dastur nagar side... Under the guidance of

Prof. A. R. Bijwe

Content’s Introduction When I joined…. Some important Specification’s Structural drawing’s Concrete work’s Curing Stressing Bearing’s Traffic operation’s Problems Faced at Site Safety measure’s When I Resigned…. References Animated Presentation of Rajapeth ROB.

Introduction

a) When gate is closed b) when gate is opened

Amravati railway station is placed just side of Rajapeth crossing hence daily

many trains are crossed over this section.

Therefore, every times need to closed it, hence traffic operation are completely

stopped , and possibility of accidents are increased.

After train will crossed over this section , then large traffic complication should be formed.

Some people are try to cross this section under

the gate, then possibility of accidents was not

ignored.

Sometimes , emergency services like

Ambulance , Fire services are also need to stop

there.

Possibility of accidents was increased between

traffic from ‘Ram mandir to Rajapeth’ and traffic

from ‘Rajapeth square to Shankar nagar’

Rate of accident should be high with in this

area, because of this project reduction of

accidents are possible.

a) People’s try to cross under section

b) Traffic after crossing this section

Current status of crossing

b) Important information about project

Name of project :- Design & Construction of Approaches (Non Railway portion) to

ROB in of level Crossing No.S-4 on BD-AMI Section, Near Rajapeth,Amravati.

Amount of Contract :- 4053.28 lakh’s

Date of work order :-01/10/2015

Period of Completion :- 24 Month’s (Upto 30-09-2017)

Defect Liability Period :- 60 Month’s

Name of Client :-

Amravati Muncipal Corporation (AMC).

Name of Contractor :-

M/S. Chaphekar and company, Nagpur.

Project Management Consultant (PMC):-

S.N. Bhobe and Associates Pvt. Ltd. Mumbai.

Designer and provider of Stressing Materials:-

Dynamic Prestress (I) Pvt.Ltd. Nashik.

c) Authorities

Designer of steel :-

Crescent Engineer’s Mumbai.

Material testing & designer:-

Geotech services Pvt. Ltd, Nagpur

Designer of bearing’s:-

Tefcon Bearing Pvt. Ltd Pune.

D ) General Arrangement Drawing of Project The G.A.D. plan whose

show arrangement of bridge

i.e name of arm, name of

pier , name of abutment

,type of bearing and there

location, slope , and general

instruction also.

This is the first drawing of

Rajapeth ROB.

‘C’ Arm

‘A’ Arm

‘B’ Arm‘D’ Arm

e ) Constructional Area’s

Area whose

highlighted with yellow

color this area was

construction by

another company. For

that work a separate

tender should be

invited by IRCTC.And remaining construction was done by

m/s Chaphekar and company Nagpur.

The whole work is

divide in two parts :-

1) railway portion

2) Non Railway portion.

f ) Some important Specification’s

All units is in:-

1)dimension – MM 2)Levels -M

Clear cover to R/f :-

for all type of concrete work use only 40 mm cover.

Grade of steel Fe 500

Laps :-

1)min . Lap length 50 X dia of bar.

2)Lapping shall be staggered suitably.

3)Not more than 25 % of bars shall be lapped at one section.

Slope for ‘C’ arm is designed as 1 : 25.64 ( 1 M = 39 MM )

When I joined…...

I will joined on this project as an designation of assistant site engineer on ‘C’ arm at Dastur

nagar side , when I join there then following work should be completed :-

The foundation of CA-02 , CP-10 , CP-11 , CP-09 should be done. At ‘C’ Arm of

Dastur nagar side.

The pier cap and pedestal of CA-02 , CP-11 , CP-10 are already casted.

The bearing at CA-02 , CP-11 , CP-10 are fixed.

Cable pipe’s are laid at there position .

The diaphragm of CA-02 and CP-10 are completely casted.

Bearing plate’s are fixed but clamp should not be opened.

Continuing the Process of inserting cable’s in pipe.

Continuing the work of fixing formwork and reinforcement of soffit & rib .

a) PSC Girder at Support

Pier 1800 dia.

Anticrash Side Barrier

PSC GirderBearing

Deck SlabRib

Soffit RCC Pedestal

Pier Cap

RCC) Depth Foundation (7000X5500X2000

PCC 150 thick

Structural drawing’s (CA-02 to CP-10) 60 m only

Drawing of PSC Girder at Support

Actual Site Photograph of

PSC Girder at Support

Captured on 19 06 2016

a) Pier (CP-10) b) Abutment (CA-02)

Pier 1800 dia.

PSC Girder

Pier Cap

Diaphragm at support

abutment

bearing

End block

Abutment(CA -02)

Pier (CP-11)

Pier (CP-10)

b ) Showing Plan & C/S of PSC Girder C/C Bearing of 30 MT & 29 MT @ Arm “C” from CA-02 to CP-10

c ) Reinforcement detail in PSC Box Girder at center

d ) Reinforcement detail in PSC box Girder at Intermediate Support

e ) variation in width of Rib reinforcement

60 m span

End blockCA-02

End blockCP-10

f ) detail’s of Anticrash barrier

Barrier’s Rebar16 mm dia. bars

Drain water collector.

Anticrash barrier is designed to restrain vehicles

from crashing off the side of a bridge and falling onto

the roadway.

While barriers are normally designed to minimize

injury to vehicle occupants, injuries do occur in

collisions with traffic barriers.

It keep vehicles within their roadway and prevent

vehicles from colliding with dangerous obstacles such

as buildings, walls or large storm drains.

This bar provided for holding the formwork of

Anticrash barrier.

a ) Grade of Concrete to be used in Concreting

RCC Abutment - M-35

RCC Pier - M-35

RCC Anticrash Barrier - M-40

RCC Deck Slab - M-40

Pedestal - M-45

Foundation of

Abutment and pier - M-30

Pier cap - M-30

Leveling coarse - M-25

Concrete work’s

concrete

b ) Ready Mix Concrete Plant

RMC plant is located at Shankar nagar . Just 10

min. travelling Distance from Site.

This area say as “Camp”

All the worker’s are lived at

camp. b) Operating panel

Sand Aggregate

Supply of cement

Discharge ofconcrete

Ready-mix concrete is

concrete that is manufactured in

a factory or batching plant,

according to a set recipe, and

then delivered to a work site by

truck mounted in transit mixers.

a) RMC Plant

C ) Transportation of concrete Transportation of concrete

should done by Transit Mixer’s (TM)

The capacity of TM is 6 m3

Maximum rotation speed of TM is

up to 21 RPM.

TM Should be present on site within

10 min.

Company operate 4 transit mixer’s

Within four two mixer’s from “Tuli

Concrete movers”

And another two mixer’s are own by

Company .Transit Mixer

d ) Concrete testing

Slump cone test appratus

i ) Slump Cone test

The value of slump cone test

should not be less than 25 MM and

more than 75 MM.

Slump cone test should be perform

both at plant and site .

Tamping rod 16 mm dia.609.6 mm in length

Slump should be

recorded with time also .

This test should be perform

under the execution of

company’s engineer and PMC

engineer .

When transit mixer is present on

site . Then firstly slump cone test was

performed to check workability of

concrete .

ii ) Compressive Strength of concrete

b) Concrete cubes

After slump cone test . Iffound satisfied result then cubes should be filled.

For every TM six cubes to be filled. from this six cube , Three cube’s are sendto PMC and remaining cubes send toAMC Laboratory at Prashant nagar .

Both of slump cone test and filling of cube should be done under execution ofcompany’s engineer and PMC’s engineer.

A separate record should be maintain onsite which include’s 1) portion of construction2) grade of concrete3) time when slump perform4) value of slump (both plant and site)7) no. of cube’s filled and many more.

a) Universal testing Machine

Concreting on 09 06 2016 for PSC Girder’s

e ) Movement of concrete on site

After testing of concrete , if

slump is maintained, then concrete

will be allow to concreting work .

Otherwise TM will be returned.

Concrete pump.(56 m³/hr)

Pipe for transporting Concrete.

f ) Placing of concrete

Pipe should be directly placed on formwork where concrete is

required .

If the pipe is placed at there

position then concrete pump give

Stroke to Discharge the concrete

from pipe at there location .

Concrete coming out of the pipe line

g ) Compaction of concrete Compaction of concrete is the process

adopted for expelling the entrapped

air from the concrete.

Compaction of concrete is done by

using electric Vibrators .

This is a type of needle vibrator .

This vibrator is operated by

electrically .

Company have seven number of

vibrator’s .

In them five are electrically

operated and two are operated by

Diesel engine .

h ) finishing This is last process of concreting , it’s

need for slab , soffit. And not need for

web concreting. After vibrating the

surface should be make well leveled and

give necessary slope under execution of

engineer.

Actual Photograph .Captured on 09 06 2016

Concreting of rib

Concrete is

fill in rib up to

this level only .

and remaining

concreting

should be done

at the time of

concreting of

deck .

Diaphragm

End block must be cast beforecasting the rest of the

bridge girder.

Curing Method of Curing is select

as per situation , but try to

make a better curing for

newly casted member.

Curing by Gunny bags should

be preference For pier ,

abutments & soffit also .

Ponding method are select

for curing the deck slab.

And when both

of these curing

method are not

applicable then

manually curing

should be

preferred.

a) Manual curing

c) Ponding method

Stressing Stressing of all cables should be done after 10 days of concreting.

But not before the concrete has attained a works cube strength of 28 Mpa.

Follow the sequence of cable stressing cable no:- 1,5 then 3,7 and 2,6

Cable shall be stressed from both ends simultaneously.

The values of extensions given in the cable extension chart are applicable at

each end.

Initial slack should be eliminated while measuring the extension.

Stressing should be continued till the desired extension is reached.

The cables shall be grouted immediately after all the cable’s are

stressed.

The grouting shall be done according to I.R.C.18

Cable’s nos. 4 & 8 are dummy cable’s

The slip at each end shall not Exceed 6mm.Stressing

Abutment (CA-02)at Dastur nagar

This Cable’s should be open for Stressing.

The hole provided for filling pipe by cement Slurry ,After Stressing.

Situation on 09th June 2016

a ) One side for stressing

Grout tube

Prestressing has two types:-1. Pre-tensioning. 2. Post tensioning

On Rajapeth ROB the post-tensioning method useas method of stressing.

1 cable orDummy

Abutment (CA -02) Dastur nagar side Situated on 09th June 2016

b ) No. of stressing cable’s

If incase some problem was standingat time of stressing then dummy cable should

be used.

19 cable’sNO. 02

1 cableor

Dummy. NO. 04

14 cable’s NO . 03

19 cable’sNO. 06

14 cable’sNo. 07

1 cableor

DummyNO. 08

19 cable’sNO. 01

19 cable’sNO. 05

The Cable’s should be Covered by this pipes , for protection of cable

from concrete and easy movement of cable’s at time of stressing.

After stressing this pipes are completely fill by cement slurry .

Total 8 pipes are provided at both sides.

In case of interference of rebar & the cable duct ,the rebar shall be

adjusted or kinked away to clear the interference.

c ) Protection of cable’s

Pipe’s in rib

d ) Components of Stressingi ) Wedges & Anchor Head’s

wedges Anchor head

Cables are locked using the wedges and barrels. These wedges and barrels provide such arrangement that cable can come out of it, but can’t go back.

a) Sheet for components of stressing & its location By Dynamic prestress Pvt.Ltd

b) Arrangement’s

ii ) jack

Jack are use for stressing the cable’s

from one end and same jack should be

placed at another end.

Jack’s are lift by using cranes.

This steel pipe’s are provided for

easily Inserting the cable’s in anchor

head.

a) Specification of jack used.Specification’s by manufacturer.

b)steel pipe’s c) Jack

iii ) location of cable’s

Pipes Grout tube

Bearing plateCables

a) Anchor head

Wedge’s

Stressing block

trumpet

Wedge’s

b) Prestressing system conewith recess Dimension c) Arrangement's

iv ) Prestressing pump

Monostrand hydraulic jack

Cables

Wedges and barrels

Prestressing pump

Prestressing pump are displaying that how many

pressure is applying to cables for stressing.

Pressure is given at same time form both sides of bridge.

Pressure is applying after interval of every 50 kg/cm2

points and also measure the elongation of both

side cable’s.

Elongation at both end should

be restrictly same.

Least count of the

prestressing pump : 5 kg/cm².

e ) Cable Profiling in PSC girder’s

Normally in post-tensioning one

side should be fix and another side

will be stressed, but on Rajapeth

ROB “cable profiling” should be

provided hence both side stressing

should be needed.

Cable Profiling in girder

f ) Location of cable’s in center of span

Cable Profiling in girder

g ) after stressing work

After stressing wedges are lock the cable’s at anchor head.

Removed the jack from cable’s.

And remaining cables are cut except 50 mm distance

from anchor head.

Whole block are packed by concrete, only grout tube having

25 mm pipe are carried out from this concreting for filling

slurry in pipe.

h ) Grouting work

Grout is a particularly fluid form of concrete.

Grout is generally a mixture of water, cement, sand,

Grouting can be defined as the filling of duct, with a material that that provides an

anti-corrosive alkaline environment to the prestressing steel and also a strong bond

between the tendon and the surrounding concrete.

For grouting work a separate grout tube

should be provided.

Grouting instrument

h ) diff. between before and after stressing .

Grout tube

b) After stressing worka) Before stressing work

Open for Grout tube

Surface filled by concrete

Bearing’s The bearing whose use in Rajapeth ROB these are

designed and provided by Tefcon Bearing Pvt. Ltd Pune.

Bearing’s are designed for 1)Design load :- 1860 KN , 2)Dead load :- 857 KN , 3) Hori. load :- 186 KN

PTFE Bearing are very sensitive for sliding due to very low coe. Of friction between PTFE and SS surfaces. Hence it is very essential to insert Wooden blocks between the girders and pedestals after installation of bearing . These wooden blocks should be removed when the bridge is open to traffic.

When bearing was send from manufacturer then the both top and bottom surface of join by weld ,this says as clamp. This clamp was removed after installation of bearing at there position.

Once when this bearing are received at plant, and company engineer are try open this ,then it’s opened but its not possible to again closed it , then finally send it to the manufacturer for repairing.

Material in contact with bearing :-1)top (soffit) – M40 2) bottom (pedestal) – M45

Clamp

a ) Sheet of free bearing

Sheet of bearing By Crescent engineer’s Mumbai

b ) type’s of bearing

Clamp

POT plate

Bearing’s are divide into two type’s1) fix end bearing 2) free end bearing

This is a type of fix bearing.

POT plate

This is a type of free bearing. Free in longitudinal direction. PTFE means Poly tetra fluro ethylene.

PTFE Base

A ) Fix end bearing B) Free end bearing

c ) Location of bearing’s in bridges

Pedestal

Free Bearing

PSC Girder

Free bearing’s in CA-02

Traffic operation’s Diversion plan when gate will closed during period of construction

Diversion plan of traffic during construction period .

This fig. shows

traffic diversion plan

during period of

construction , when

gate will closed.

This plan give’s

diversion option for

traffic without

crossing gate , with

safe traffic movement.

Problems Faced at Site… Due to construction site is in main area of Amravati . Hence large traffic problem

should be faced.

Very small space are remaining for movement of traffic , then traffic should be

congested at just side of site, Hence main problem stand as safely movement of

traffic .

One accidental moment I would like to share with you :-

at the time of concreting of rib , work is going to complete but because of TM will

empty and some minute’s are remaining for new TM , within this period concrete will jammed in pipe ,

and concrete pump give stroke of concrete , but concrete will jammed, then accidentally last pipe

whose completely filled with concrete this is forcely throw on main traffic road , luckily at that time

intensity of rainfall is very high , hence there have no traffic on road , and no anyone get injured.

Safety measure’s Providing the first aid.

Banners.

Providing the vehicle.

Using the safety equipments.

Minimum access for public in inside of project.

Training the workers.

All safety measure under execution of PMC officer.

Watchman’s are appointed to operate movement of traffic in construction

area, on the day of concreting.

Service road whose nearby site was repaired by company.

When I Resigned….

The whole work are stopped for one month between 11 July to 16 august.

Casting of all diaphragm’s should be done , within the span between CA-02 to CP-10.

Concreting of soffit are complete for 60 m span.

Concreting of rib should be done.

Pier of CP-09 & CP-08 are casted upto the level of pier cap.

Deck slab from CA-02 to CP-10 are casted with cantilever portion.

Stressing of all eight pipe cable’s are completed with grouting.

Clamp of all bearing’s are opened & wooden block are removed .

Cutting of cable’s except 50 mm and concreting of block should be done.

Reinforcement are placed for casting of anticrash barrier’s , it’s base are already fix to

concrete of deck with it’s reinforcement.

Conclusion Construction of the project link will provide an additional fast

and Safe moving outlet from the Dastur nagar & Shankar nagar to

the badnera road and thereby providing much needed relief to the

congested traffic. The entire project was executed by Amravati

municipal corporation .

Because of these project traffic movement of traffic will flow

without any Disturbances.

The rate of accident’s are reduced up to lowest amount.

References

I will work on Rajapeth ROB during period of 10th of June to 10th of July as

assistant site engineer.

Structural drawings submitted by Crescent Engineer’s Mumbai.

Official photograph’s of project.

www. Wikipedia. Com

A Textbook of Concrete Technology by M. S. Shetty.

A Textbook of Pre-stressed Concrete by N. Krishna Raju.

Animated Presentation of Rajapeth ROB

Rajapeth project.mp4

Thank you…Quarries ???

ASeminar Presented

by Mr. Akash Surendra Kolamkar

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