BSCPL Infrastructure Pvt. Ltd

@ CONSTRUCTION OF BRIDGE IN NH-53,

In Arang to Saripali Road, (C.G.)An In-plant Training Report

Submitted by

SUKHDEEP SINGH JATU12CE117

In partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY

IN

CIVIL ENGINEERING

DEPARTMENT OF CIVIL ENGINEERING

BHARATH INSTITUTE OF SCIENCE AND TECHNOLOGY

BHARATH UNIVERSITY

CHENNAI 600073

NOVEMBER 2015

ACKNOWLEDGEMENT

I am grateful to Dr. V. THAMIZHARASAN, Dean and Head of the Department of Civil

Engineering, BHARATH UNIVERSITY, Chennai for his commendable support and

encouragement during the submission of training report.

I owe an immense gratitude to our respected Professor Mr. P. MEIKANDAAN for

giving permission and encouragement for attending the inplant training at DSC Pvt. Ltd. in Delhi

which made a significant contribution in the understanding of practical methods and successful

completion of the training.

I am grateful to our Chancellor Er. J . SUNDEEP ANAND for his commendable support

to achieve successful coarse process.

We thank our beloved Vice Chancellor Dr. M. PONNAVAIKKO for creating an

atmosphere where we can develop our academic skills.

I take this opportunity to express my sincere gratitude towards Project Manager

Shri. DAMODAR for accepting my letter and allowing me to complete my training in BSCPL

Infrastructure Pvt. Ltd.

Lastly I would like to show my gratitude towards my parents for giving me moral support

and my friends who were also undertaking In-plant training in BSCPL Infrastructure Pvt. Ltd.

With their cooperation my industrial training turned out easier and a lot more comfortable.

TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

1. INTRODUCTION 1

1.1 GENERAL 1

1.1.1 About the Company 1

1.1.2 Major Projects Completed 1

1.1.3 Major Projects Ongoing 2

1.1.3.1 Roads 2

1.1.3.2 Railways 2

1.1.3.3 Irrigation 2

1.1.3.4 Building & Construction 2

1.2 BRIDGE CONSTRUCTION 3

ON MAHANADI RIVER (NH-53)

1.2.1 About the Project 3

2. ABOUT SUPERSTRUCTURE 5

2.1 BRIEF DESCRIPTION 5

2.2 PROJECT DETAILS 6

3. DESIGNING DETAILS 7

3.1 DATA NEEDED FOR DESIGNING A BRIDGE 7

3.1.1 Geographical Details 7

3.1.2 Site Details 7

4. MATERIALS AND AMCHINES USED IN CONSTRUCTION 9

4.1 MATERIALS USED 9

4.1.1 Grades of Concretes 9

4.1.2 Materials used in Stressing 11

4.2 MACHINES USED IN CONSTRUCTION 15

5. LAYING OUT ONE WHOLE SPAN 20

5.1 A BRIEF EXPLANATION OF 20

LAYING OUT ONE SPAN

6. CONCLUSION 27

REFERENCES 28

CHAPTER 1

INTRODUCTION

1.1. GENERAL

1.1.1. About the Company

BSCPL Infrastructure Ltd is an ISO 9001: 2000 accredited infrastructure development

company pioneers in execution of Road Projects, Irrigation projects and recently

diversified in Real estate and Hydro Power plants. Started as B> Seenaiah and Co, a

partnership firm in 1982, later it converted into a Public Company in 1998 as B. Seenaiah

and Company (Projects) Ltd and finally in 2008 it was again renamed as BSCPL

Infrastructure Ltd. BSCPL have executed several prestigious projects across India and

abroad including Afghanistan and Bangladesh, sometimes under adverse conditions.

ICRA awarded the CR2+ grade indicating strong capacity to execute projects of up to

Rs. 350 crores in a year.

1.1.2. Major Projects Completed

1. Dubai Project - Arena Apartment (A 14 storied residential apartment having 148 flats)

2. Reconstruction of Ajmer-Bhilwara-Chittorgarh Road

3. Extension of Runway by 5000 fts (1534.39 Mtrs) at Port Blair Airport, Andaman &

Nicobar

4. Upgradation & Development of Amritsar Airport at Amritsar

5. Construction of 5 Nos. Bays and link taxi tracks for Private ATOs at Chennai Airport,

Chennai

6. Construction of New Four Lane Roads (Road Nos.1,3,4,5,6,8 & 9B) in Naya Raipur

Development Area in the State of Chhattisgarh

7. Construction of the Ghazni- Gardez and Gardez - Khost Roads in Afghanistan

8. Construction of Afghan Parliament and Indian Chancery Buildings at Kabul,

Afghanistan.

1.1.3. Major Projects Ongoing

1.1.3.1. Roads

1. 133 km 6-lane EPC Contract on NH5 , AP

2. 87 km 4-lane EPC Contract in Godhra

3. 284 km 2-lane Item Rate Contract in Meghalaya

4. 151 km 4-lane EPC in Chhattisgarh

5. 205 km EPC road works from SPVs

6. 250 km EPC contract on NH-53

7. Lucknow Muzaffar National Highway Project on NH-28

1.1.3.2. Railways

1. 105 km of Dedicated Freight Corridor

1.1.3.3. Irrigation

1. Veligonda Project - Closing of Kakarla Gap

2. Construction of Somasila Swarnamukhi Link Canal

3. Investigation, Design, Estimation and construction of Barrage across

Champavathi river

1.1.3.4. Building & Construction

1. Bollineni Hillside at old Mahabalipuram road

2. OMR Real Estate in Chennai.

1.2. BRIDGE CONSTRUCTION ON MAHANADI RIVER (NH-53)

1.2.1. About the Project

This superstructure falls in between the NH-53 connecting states of Gujarat, Maharashtra,

Chhattisgarh and Orissa. This Bridge is being built on the Mahanadi River near Arang. The

company holds the contract of developing and reconstruction of NH-53 of about 250 km in

length starting from Arang to Saraipaali (Basna) near Orissa border. This highway is undergoing

numerous construction of bridges, flyovers, canals etc,.

This road laid on the bridge has to be of four lane road intensifying the traffic to its

maximum. This road connects the Rajim (District) to the developed cities leading to immense

means of transport. The major objectives of the project is :-

(i) to cover for the damaged bridge shortening the distance between to major cities

for Rajim.

(ii) to broaden the road for the transportation purpose.

(iii) to repair the damaged roads minimizing the road accidents.

The proposed subproject can be viewed as boosting economic growth and poverty reduction,

which will bring substantial social and economic development in the region. The social benefits

arising from the subproject will be due to improved accessibility to various services, such as easy

access to markets, health facilities, schools and workplaces, which in turn will increase the

income of the locals and ultimately elevate their standard of living. Although various positive

impacts and benefits are expected from the proposed subprojects.

Figure 1.1. Index Map Showing the Road (Arang to Sariapali)

CHAPTER 2

ABOUT SUPERSTRUCTURE

2.1 BRIEF DESCRIPTION

Figure 2.1. A Picture Representing Ongoing Construction

The type of bridge that is being constructed over Mahanadi in Chhattisgarh is known as

Segmental Bridge. A Segmental Bridge is type of bridge built in short sections (called

segments).ie., one piece at a time. The bridge is made of concrete that is either cast-in-place

(constructed fully in its final location) or precast concrete structures ( built at another place and

then transported to their final location for placement in the superstructure).

There durability of this type of superstructure is found to be more durable in comparison to the

other bridges as its durability can be increased also, since the whole span of the structure is

constructed by joining the segments and all of these segments are interconnected from each other

with the help of the cables. Thus the segments were provided with the section that connects the

two segments together.

The cables that are made use in this types of super structures are of capable of taking high

tensile load. Thus the cables or strands were commonly known as High Tensile Stressing cable

or strand.

For increasing the durability or the life of the bridge we can just put the HTS (high tensile

stressing) wire through the duct and thus leading to increment to the life span and the strength of

the bridge can be replenished.

The company leading the project of superstructure claims the warranty of 100 years after the

accomplishment of the bridge.

This bridge is being constructed in NH-53. The project is lead by the BSCPL Infrastructure Pvt.

Ltd. {construction company of Hyderabad(A.P.)}.

2.2. PROJECT DETAILS

(I) The bridge which is being constructed is a Segmental Bridge.

(II) This bridge is a part of national highway connecting Rajim and Arang.

(II) The road construction for NH-53 is started from Arang till Saraipaali

(Orissa border).

(IV) The road laid in this highway by the BSCPL Infrastructure Pvt. Ltd. is total of

250 kms in distance.

CHAPTER 3

DESIGNING DETAILS

3.1 DATA NEEDED FOR DESIGNING A BRIDGE

3.1.1 Geographical Details

(I) A plan of the site showing all the obstacles to be bridged such as rivers,

streets, roads or railroads, the contour lines of valleys etc..

(II) Required width of the bridge, width of the lanes, walkways, safety rails,

crash barriers etc.( this bridge is designed as four lane of the national

highway).

(III) Soil conditions for foundations, results of boring with a report on the ground

and the soil mechanics data.

3.1.2 Site Details

There can be many ways for Site Exploration :-

(I) Open excavation,

(II) Boring,

(III) Subsurface sounding (it is done making use of penetrometer that is used for

measuring the resistance offered by the soil) and

(IV) Geophysical Methods.

Here the site exploration is done by Boring. The site when explored provided the data are

as follows :-

(I) Depth, extent, and composition of critical soil strata,

(II) Ground water level and its fluctuation

(III) Depth of bed rock(when necessary),

(IV) Estimate of engineering properties of soil,

(V) Initial selection of foundation possibilities,

(VI) Subsurface property of the area,

(VII) Evaluation of settlement characteristics of various soil layers,

(VIII) Evaluation of bearing capacity of the soil.

All the mentioned analysis is done for the purpose of laying out the foundation for the pier that

holds the bridge.

Figure 3.1 Above Diagram representing results of Boring

CHAPTER 4

MATERALS AND MACHINES USED IN CONTRUCTIONS4.1 MATERIALS USED

4.1.1 GRADES OF CONCRETES

1) Piers - M50

Figure 4.1 Piers

Figure 4.2 Pre-Cast Structure (Segment)

2) Substructures - M35

3) Foundations - M35

4) Returns - M35

5) Approach Slab - M30

6) Retaining wall - M35

7) Kerb & Hand rails - M30

8) Crash Barrier - M40

4.1.2 MATERIALS USED IN STRESSING

1) Bearing Plate

Figure 4.3 Plate through which pipes are strands are coming out

2) Live Wedge

Figure 4.4 Live Wedge

3) Collar Plate

Figure 4.5 Cap of the Bearing Plates

4) 7 Ply pipe strand

Figure 4.6 Cable strand used for hooking up all Segments together

5) Resin and Hardener (1:2)

Figure 4.7 Chemical used for Gluing

4.2 MACHINES USED IN CONSTRUCTION

1. LAUNCHING GIRDER

Figure 4.8 Above shown picture is of Launching Girder

Work :- The picture showing above is of Launching Girder which is used for the segment

feeding and laying out the span in a Segmental Bridge construction. The top portion of the

Launching Girder is known as gantry which is used to lift the supports and drag to the

point where it has to be fixed next. The segments were supposed to be hold up by the

clamp attached with the sliders and were moved towards the direction of the next span

being build and aligned.

2. Hydraulic Stressing Jack

Figure 4.9 Multi Strand Hydraulic Stressing Jack

These hydraulic jacks are used to stress the cable strands passed through the ducts to make

the whole span into one. The strands were clamped with the live wedges on one side and

were stressed using the stressing jacks leaving the 5% of slip in length from the rear

portion considering the strands have been stressed properly.

3. Gantry

Figure 4.10 Gantry for lifting the Pre-cast Segments

This is the site photo of the place where the Pre-cast structure were made. The machine shown

in the picture is of Gantry for lifting up the Pre-cast structures formed in the plant. The vibrators

were attached to the moulds of the segments letting the concrete poured in the mould to be

settled properly .

Figure 4.11 Mould of the Segment with attached Vibrators

The moulds were made away from the site of construction and then carried to the place and

loaded to the sliders hinged up with the clamp. The moulds have attached vibrators which allows

the settling of the concrete being poured to its full content providing the proper strength to the

Pre-Cast segment.

4. Water Pump

Figure 4.11 Pumping Limewater into the ducts

Figure 4.11 shows the lime water being pumped to the duct for checking whether the ducts have

any leakages or not. If the ducts is supposed to have and ignored than it will affect the Grouting.

Grouting is done to elongate the life of the stands which were passed through the ducts and to

prevent them from corrosion etc,.

CHAPTER 5

LAYING OUT ONE WHOLE SPAN5.1 A BRIEF EXPLANATION OF LAYING OUT ONE SPAN

Figure 5.1 Construction Of Bridge on Mahanadi River

1. The machine shown in the above provided picture is known as Launching Girder.

2. It stands on the pier of the bridge with the supports placed at the piers .i.e., front,

middle and rear support.

3. Front support is provided at edge of the span from where the next span has to be

started and the second support is provided at the second last pier from the where

the next span to be made while the rear support is provided for stabilizing the

girder

4. The entire weight of the launching girder is hold on the hydraulic jack.

Figure 5.2 Hydraulic Jack

5. This hydraulic jack has the capacity of holding up to 500 ton of the load by itself.

6. Then the next step comes .i.e., Auto launching. It refers to the moving of the

entire launching girder to the next pier. The middle support was held by the

gantry and it's sliding through the structure moving for the next support.

Here are some of the photos showing the auto launching process:-

Figure 5.3 (a)

Figure 5.3 (b)

Figure 5.3 (c)

All the above photos representing Figure 5.3 (a),(b) and (c) shows the auto launching

process

7. Level checking and support fixing:- While the erecting of the segment middle

support and front support should be at the same level. Middle support on

temporary tower. The levelling for the middle and front support is done using

Dumpy Level.

8. When the auto launching is done and support for the girder is settled than the

segment feeding is done ,.i.e., the segment is lifted by the gantry and then it is

transferred to the slider which holds up the pre-cast concrete structures as a

temporary.

Figure 5.4 Pre-Casted Structure

The above picture is a segment that is aligned in a order to make one span.

a) Dry matching:- It is the alignment of the segment in their places.

b) Gluing:- pasting of two segments with the calculated load with the mixture of

hardener and the resin with the ration of 1:2.

c) When the structures are held by the sliders and the segments are joined then the

strands of 7 ply pipe( used in this bridge as prescribed in the drawings) is inserted

through the ducts joining all the segments.(one strand can approx. carry the load

of 20 ton). This process is known as "Threading".

This is how it looks after threading all the clamps holding the segments are held by the

sliders and the structure is balanced and the total load is transferred to the jacks.

I. Stressing is done once the span is been held temporary making the span

still after the removal of clamps holding the bridge.

II. When once the stressing is done then we move on to the "Grouting",

which means applying the cement and cebexes mixture with water with

the applied air pressure into the ducts.

III. Grouting is done to prevent the corrosion that may occur in the stressing

pipe and maintains its property for a long period.

IV. But before grouting it has to be made sure if the ducts have any leakage

holes or not because if there will be a leakage then the mixture applied

throughout the duct may not be settled properly. Thus, it is checked by

applying the limewater though the duct within a applied water pressure.

V. After grouting the two span is joint with the expansion joint and after

putting the expansion joint cast-in-situ is done.

VI. First three span is made into one by joining them together. Length of the

first , second and third span are as follows 46m ,41m and 46m.

VII. It's as per the design provided. The pier at the middle of the span are kept

close so as to reduce the deflection at the centre.(in a simply supported

beam the deflection is maximum at the centre).

VIII. Once the span is completed than the whole span is made single by the

cable laid through the ducts making whole in one

CHAPTER 6

CONCLUSIONThis training helped me to gain knowledge by experiencing various works taking place in the

site. By this In plant training I had an opportunity to witness various situations in the site and

practically and innovatively overcoming them. In brief I learned about various new Construction

Technologies and more importantly I experienced the whole Construction of laying out a span of

a Segmental bridge. This helped me in clearing various theoretical and practical doubts and made

me somewhat realize the future scope of Civil Engineering.

REFERENCES

1. Soil Mechanics and Foundation by Dr. B.C. Punmia.

2. Structural Analysis by S.S. Bhavikatti.

3. Head of the Project Eng. Narendra Mishra in BSCPL Infrastructure Pvt. Ltd.

4. Jr. Engineer Sourabh Sinha at BSCPL Infrastructure Pvt. Ltd.

5. Wikipedia