Training report done on Bridge Construction

1. 1. 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 JAT U12CE117 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
2. 2. 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.
3. 3. 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. 4. 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
5. 5. 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
6. 6. 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.
7. 7. 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.
8. 8. Figure 1.1. Index Map Showing the Road (Arang to Sariapali)
9. 9. 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
10. 10. 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.
11. 11. 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),
12. 12. (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
13. 13. CHAPTER 4 MATERALS AND MACHINES USED IN CONTRUCTIONS 4.1 MATERIALS USED 4.1.1
GRADES OF CONCRETES 1) Piers - M50 Figure 4.1 Piers
14. 14. 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
15. 15. 4.1.2 MATERIALS USED IN STRESSING 1) Bearing Plate Figure 4.3 Plate through which pipes are
strands are coming out
16. 16. 2) Live Wedge Figure 4.4 Live Wedge
17. 17. 3) Collar Plate Figure 4.5 Cap of the Bearing Plates
18. 18. 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
19. 19. 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.
20. 20. 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.
21. 21. 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 .
22. 22. 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.
23. 23. 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,.
24. 24. CHAPTER 5 LAYING OUT ONE WHOLE SPAN 5.1 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.
25. 25. 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.
26. 26. Here are some of the photos showing the auto launching process:- Figure 5.3 (a) Figure 5.3 (b)
27. 27. 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.
28. 28. 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".
29. 29. 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.
30. 30. 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
31. 31. CHAPTER 6 CONCLUSION This 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.
32. 32. 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