Suhas P Khedkar

Hindustan Construction Co Ltd
Erecting Long Span Briges to suit Indian Conditions and Requirements

Presentation by
Suhas P Khedkar (AVP- Engineering,) Hindustan Construction Company To 3rd Annual Bridges India Summit 2012 On 17th May 2012
2 28 May 2012 Presetation to 3rd annual Bridges India Summit 2012
Table of Contents
Different Methods of erection of Superstructure Cast in Situ Construction Comparison of Conventional and Cantilever Construction Method Innovative Construction of III rd Godavari Railway Bridge at Rajamahendri Bandra Worli Sea Link Superstructure Construction entirely by Precast segmental Construction. Segment Casting and Erection of Appraoch Spans Specaial Challenge during Construction- Relocation of LG Construction of Cable stayed bridge Conclusions
28 May 2012
Presetation to 3rd annual Bridges India Summit 2012
Different Methods of Erection of Superstructure
Different methods of Superstructure Erection

Cast in situ construction
1. Conventional method for normal spans by use of staging 2. Using specialized technology for longer span bridges:
e.g.. Use of centering girders, and bridge builders for cantilevering superstructures
Construction using Precast elements
Construction using precast girders of entire length, Construction using precast segments to be assembled during erection to form girders of complete length
Special techniques like Incremental launching method

28 May 2012 Presetation to 3rd annual Bridges India Summit 2012
Different methods of Superstructure Erection

Method of Erection of Superstructure is site specific. And also design specific. In fact design should suit the method of erection dictated by site conditions and other constraints Final Choice is to be made from cost considerations. Evaluation of a couple of alternatives is many times necessary for major projects to decide cost effectiveness.
28 May 2012
Cast in Situ Construction
Cast in Situ Construction for Superstructure

Conventional casting on staging

Method suitable for normal spans
1. More suitable for normal span viaducts as staging can be supported on

ground
2. Has been used for both I girders and Box Girders. 3. If number of spans are small , use of precast girders and launching
system is not cost effective
4. For box girders conventional casting can not be avoided as launching

system may not be feasible due to excessive weight of span.
28 May 2012
Conventional casting on staging of long span superstructure is generally not feasible beyond about 50 m span due to
excessive weight, Large quantity of staging and increased cycle time and concrete pour size. Especially difficult for River Bridges as staging needs to be supported
on temporary piles.
28 May 2012
Cast in Situ Cantilever Segmental Technique
10
28 May 2012
Cast in Situ Cantilever Segmental Technique
Method suitable for long span box girders. Advantages as follows:
1. Each stage of construction is self supporting after completion. The

erection system or the bridge builder can be erected on the tip of units cast earlier.
2. Construction is done in segments of convenient length, so that formwork

and bridge builder frames supporting the formwork can be optimally designed.
3. Construction progresses from pier in both directions towards centre of

span. This allows maintaining feed lines for concrete and access for men and material from the pier location up to the working point.
Conventional Casting Vs Cantilever Construction

Comparison of two methods: Yamuna bridge at Naini Allahabad 60 m spans Cast in Situ on Conventional staging Elaborate staging arrangement needed for the span at 20 m from water level
Bridge over River Brahmaputra at Tezpur Compare the small Bridge Builder on the tip of the cantilever with the staging of Naini Bridge
12
28 May 2012
Yamuna Bridge Staging Elevation and Side View

Tezpur Bridge Bridge Builder Elevation and Side View

Cast in Situ Cantilever Construction for Long Span River Bridges
Tezpur Bridge over River Brahmaputra Different spans in different stages of construction
Ganga Bridge at Varanasi - Bridge Builder in Elevation and Side

16
ViewMay 2012 28
Ganga Bridge at Varanasi after Completion
17
28 May 2012
Innovative Construction for III Godavari Railway Bridge at Rajamahendri
Innovative Construction for III Godavari Bridge Superstructure
III Godavari Railway Bridge 28 spans of 98 m each 94 m C/C of bearings


III Godavari Railway Bridge near Rajamahendri has been constructed using an innovative technique. The design itself was developed for the innovative erection technique, under typical constraints posed in the tender specifications. The foundations and substructure was designed to suit standard railway span of 94.0 m using steel girders. The tender for superstructure invited alternatives with prestressed concrete (PSC) superstructure. Challenge to design a PSC superstructure within the design capacity of the substructure and foundations, which were designed and constructed for the lighter loads of the steel superstructure.
20
A bow string girder design was proposed by HCC.

28 May 2012 Presetation to 3rd annual Bridges India Summit 2012

Salient Features: 1. Structural System Bow String Girder in Prestressed Concrete 2. Span of Girder: 94.0 m 3. Arches in Reinforced concrete Constructed using Cast in situ segmental technique 4. Suspenders in High tensile Steel BBR Dyna hangars 5. Tie Girder in Prestressed Concrete Box shaped
Innovative Features: 1. Top down Construction Arch was constructed first 2. Tie girder constructed using formwork supported on suspenders 3. Arch was constructed using cast in situ cantilevering segmental technique in 7 stages 4. Arches from the two piers progressed to meet at the midspan, connected by a closure pour
22
28 May 2012
Stages of Construction of Arch: 1. Erect central tower 2. Cast starting stubs 3. Erect formwork for typical segment supported by stay cables 4. Cast first segment 5. Repeat stages 3 and 4 for balance 6 segments 6. Erect formwork for closure pour on the last segment at crown 7. Cast closure pour
Stage 1 Cast starting stubs

24 28 May 2012
Stage 2 Erect Formwork for first segment on starting stubs
Itermediate Stage: Formwork supported on completed arch ready to receive for concrete for the next segment
Itermediate Stage: Formwork supported on completed arch ready to receive for concrete for the next segment
Closure Pour: Formwork supported on the last segment of 1/2 arch

Arches for various spans completed

Construction of Tie Girder

Completed Bridge
Bandra Worli Sea Link Project Superstructure Construction entirely by Precast Segmental Technique, for both Cable Stayed and Approach Spans.
Bandra Worli Sea Link Project special Features

First Sea Link in India and with Precast Segmental construction The entire sea link, including the cable stayed bridges has been constructed using precast segments for the superstructure.
32
28 May 2012

Many Firsts in our country First Cable Stayed Bridge across sea: Indias first open sea and longest cable stayed bridge. First Cable Stayed Bridge with a Single Central Pylon.
33
28 May 2012

Many Firsts in our country The entire sea link, including the cable stayed bridges has been constructed using precast segments for the superstructure. Total 2342 segments have been cast and used. The precast segments used for this sea link are one of the widest and heaviest in our country; - 18.1 m & 20 m in width , weight 120 to 140 MT
Needing a very large casting yard with short line casting cells, large capacity gantries, matching capacity multi axle trailer for segment transportation, and specially designed gantries for segment erection.
34
28 May 2012
Special Features of the Project

Engagement of Asian Hercules, one of the largest floating shear leg crane in the world for shifting 1260 MT launching truss from Bandra end to Worli end of the main cable stay bridge Up to 25-m high piers in open sea, giving ample headroom to marine traffic Use of Politron Disc bearings for the first time in India Piling through rocks exceeding 120 Mpa crushing strength Use of Automatic Climbing Formwork for Pylon Construction
35
28 May 2012
Bandra Worli Sea Link Salient Design Features

Precast Segmental superstrucure except KAGK Link Bridge Aesthetically pleasing deck profile, with uniform depth for all
bridges - Bandra approach , Bandra Cable Stayed, Worli Cable Stayed, Worli Approach.
Unique Design of Bandra Cable Stayed - 250 m spans on either

side , supported on a Central Pylon,
NORTH APPROACH BRIDGE 16x50 = 800m PRECAST SEGMENTAL (SPAN-BY-SPAN)
600m 350m BANDRA CABLE STAY WORLI CABLE STAY 500m 4X50=200m PRECAST SEGMENTAL 150m (BALANCED CANTILEVER) (SPAN-BY-SPAN) PRECAST SEGMENTAL P19 (FORWARD CANTILEVER)
BANDRA
SOUTH APPROACH BRIDGE 28X50 = 1400m PRECAST SEGMENTAL (SPAN-BY-SPAN)
WORLI
A1
R AD ND RO BA 6m CH ZA 54 OA LA P PR L L AP T O &
P6
P12
P17
A1
AP PR OA CH
BR IDG E
P19
600m BANDRA CABLE STAY 200m 350m WORLI CABLE STAY 1400m SOUTH APPROACH BRIDGE
36
28 May 2012
811m LINK BRIDGE

H RT NO 0m 80
A
WORLI
Bandra Worli Sea Link Project Segment Casting and Erection
Casting Yard and Erection Gantry at BWSLP

The project needed a very large casting yard, and two specially designed LGs, which needed to to be supplemented by one more LG from Worli end in the last season.
38
28 May 2012
Advantages of Precast Superstructure Vs Cast in Situ
Construction of Superstructure in parallel with Foundation construction. When Foundations are being constructed at various site locations, superstructure elements can be precast in a separate casting facility. Advantages of factory production, with ease in quality control, and dimensional accuracy, due to easy acces, and dedictaed equipment, and survey stations. Good quality control due to planned facilities like proper curing arrangement, dedicated supervision. The above are relatively much difficult at actual site locations due to difficult access, great heights and different locations.
39
28 May 2012
Principles of Precast Segmental Construction
Span is divided into a number of segments of full deck width The segments are match cast to attain the final geometry as of the erected span. Match casting and geometric control are of great importance as the bridge is virtually built in the casting yard. Any error in match casting will be difficult to correct during erection, as the span will not fit on the piers. Precision Survey in casting yard to attain desired geometry Precast Segmental Construction offers use of industrialized, repetitive construction procedures, which contribute to improved quality control as well as reduction in construction time .
40
28 May 2012
Importance of Precision in Precast Segmental Construction

Span is divided into a number of segments which are match cast to attain the final geometry as of the erected span.
The bridge is virtually built in the casting yard. Any error in match casting will be difficult to correct during erection, as the span will not fit on the piers. The bridge has both vertical gradient, and Horizontal curvature. The bridge deck therefore follows a space curve.
41
28 May 2012
SEGMENT : MATCH CASTING
Precast Segmental Construction for Bandra Worli Sea Link Project, Mumbai CEMCON 2007
February, 23 - 2007
Page 42
Planning and Management for Casting Yard
(REBAR JIGS)
(CASTING CELL) (STORAGE BAY 1) TYPICAL CROSS SECTION AT CASTING CELL AND STORAGE AREA (TRANSVERSE DIRECTION)
(STORAGE BAY 2)
TYPICAL CROSS SECTION AT SEGMENT STORAGE AREA (LONGITUDINAL DIRECTION)
CASTING YARD & STACKING YARD CROSS-SECTION
43
28 May 2012
Precasting Yard at BWSLP- Capacity to stack 400 segments. And 9 casting cells.
44
28 May 2012
Prefab Reinforcement Cage handling
45
28 May 2012
Match casting at Precasting Yard
46
28 May 2012
Precast Segment Pour Sequence

2.52 CUM 7 2.19 CUM 9 2.69 CUM 8 4.28 CUM 10 2.69 CUM 8a 2.19 CUM 9a 2.52 CUM 7a
6 1.66 CUM 5 1.26 CUM 3 1.26 CUM 2 3.17 CUM 1 5.33 CUM 2a 3.17 CUM 4 1.66 CUM 4a 1.66 CUM
6a 1.66 CUM 5a 3a 1.26 CUM 1.26 CUM
CONCRETE PLACING SEQUENCE

TOTAL CONCRETE QUANTITY = 44.30 CUM
47
28 May 2012
Segment Handling at Precast Yard
48
28 May 2012
Segment Transportation on Special Trailer
49
28 May 2012
Launching Girder at BWSLP

Suspension Frames Front Leg Main Truss Rear Leg
Rear Trolley Front Pylon
Front Trolley Connection Beam Rear Pylon

Center Leg
Segment Transportation in Sea on Barge
51
28 May 2012
Main Challenge During Construction of Approach Span: Relocation of LG from Bandra Approach spans beyond Bandra Cable Stayed bridge: Shifting by 500 m in the sea.
Text (Font Arial 16, Color Black, Line Spacing 30 points). Text (Font Arial 16, Color Black, Line Spacing 30 points).
Need for Relocation
54
28 May 2012
Relocation of Launching Trusses using 1600 MT capacity Barge Mounted Crane Asian Hercules
55
28 May 2012
56
28 May 2012
Entire LG weighing 1260 MT , of length 105 m was physically lifted and shifted from P17-P18 to P20-P21
57
28 May 2012
Construction of Cable Stayed bridge
Need for detailed Construction Stage Analysis
59
28 May 2012
Results of stage-by-stage Analysis

Stage-by-Stage Analysis
Tower Construction Deck Erection
Precamber Values
Fibre Stresses
Strutting Requirements and Force Levels
Casting Curve, Erection Curve and Control Lines
Stay Cable Forces for Installation, Tensioning and fine tuning Forces
Stage Deformations
Temporary PT
Casting Curve
61
28 May 2012
Stage by Stage Deck Camber Curves

Deck Camber Curves for Bandra Bridge Stage by Stage
450 440 430 420 410 400 390 380 370 360 350 340 330 320 310 300 290 280 270 260 250 240 230 220 210 200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60 -70 -80 -90 -100
-300
-275
-250
-225
-200
-175
-150
-125
-100
-75
-50
-25
Elevation y [mm]
25
50
75
100
125
150
175
200
225
250
275
Chainage x [m]
62
28 May 2012
300
Stage Deflections
Lift Non-stay Segment
28 27 26 25 24 23 22 21 20 19 18
42 41 40 39 38 37 36 35 34 33 32 31 30 29
S7
17 16 15 14 13
S8 S9 S11
S10 S13
S12
S14 S15
S16 S17
S18 S19
S20 S21
S22 S23
S24 S25
S26 S27
S28 S29
S30 S31
S32 S33
8 7 6
12 11 10 9
3 2 1 0 1 2 3 6 7 8
S33
9 10 11 12 13
66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Segment Node No. 5090

5 4 3 2 1
7 6
Def ormation at previous stage
Def ormation af ter completion of this stage : LC1190
420 Def ormation at handover f or traf f ic movement (Design Camber) @ T=0 : LC1298
370
320
270
220
170
120
70
20
-300
-294
-288
-282
-276
-270
-264
-258
-252
-246
-240
-234
-228
-222
-216
-210
-204
-198
-192
-186
-180
-174
-168
-162
-156
-150
-144
-138
-132
-126
-120
-114
-108
-102
-96
-90
-84
-78
-72
-66
-60
-54
-48
-42
-36
-30
-24
-18
-12
-6 -30
12
18
24
30
36
42
63
28 May 2012
-80
Stage Deflections
Stress Previous Cable to Ft
27 26 25 24 23 22 21 20 19 18
42 41 40 39 38 37 36 35 34 33 32 31 30 29 28
S7
17 16 15 14 13
S8 S9 S11
S10 S13
S12
S14 S15
S16 S17
S18 S19
S20 S21
S22 S23
S24 S25
S26 S27
S28 S29
S30 S31
S32 S33
8 7 6
12 11 10 9
3 2 1 0 1 2 3 6 7 8
S33
9 10 11 12 13
66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

5 4 3 2 1
7 6
420
Def ormation at previous stage
Def ormation af ter completion of this stage : LC1191
Def ormation at handover f or traf f ic movement (Design Camber) @ T=0 : LC1298

370 320
270
220
170
120
70
20
-300
-294
-288
-282
-276
-270
-264
-258
-252
-246
-240
-234
-228
-222
-216
-210
-204
-198
-192
-186
-180
-174
-168
-162
-156
-150
-144
-138
-132
-126
-120
-114
-108
-102
-96
-90
-84
-78
-72
-66
-60
-54
-48
-42
-36
-30
-24
-18
-12
-6
-30
12
18
24
30
36
42
64
28 May 2012
-80
42
Stage Deflections
Lift Stay Segment
27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 28
41 40 39 38 37 36 35 34 33 32 31 30 29
S8 S7 S9 S11
S10 S13
S12
S14 S15
S16 S17
S18 S19
S20 S21
S22 S23
S24 S25
S26 S27
S28 S29
S30 S31
S32 S33
8 7 6
12 11 10 9
3 2 1 0 1 2 3 6 7 8
S33
9 10 11 12 13
67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

5 4 3 2 1
7 6
Deformation at previous stage
Deformation after completion of this stage : LC1192
Deformation at handover for traffic movement (Design Camber) @ T=0 : LC1298

370 320
420
270
220
170
120
70
20
-300
-294
-288
-282
-276
-270 -264
-258
-252
-246
-240
-234
-228
-222
-216
-210
-204
-198 -192
-186
-180
-174
-168
-162
-156
-150
-144
-138
-132 -126
-120
-114
-108
-102
-96
-90
-84
-78
-72
-66
-60
-54
-48
-42
-36
-30
-24
-18
-12
-6 -30 0
12
18
24
30
36
42
65
28 May 2012
-80
Stage Deflections
Install Cable and stress to Fi
27 26 25 24 23 22 21 20 19
42 41 40 39 38 37 36 35 34 33 32 31 30 29 28
S6
18 17 16 15 14 13
S8 S7 S9 S11
S10 S13
S12
S14 S15
S16 S17
S18 S19
S20 S21
S22 S23
S24 S25
S26 S27
S28 S29
S30 S31
S32 S33
8 7 6
12 11 10 9
3 2 1 0 1 2 3 6 7 8
S33
9 10 11 12 13
67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

5 4 3 2 1
7 6
Deformation at previous stage
Deformation after completion of this stage : LC1194
420 Deformation at handover for traffic movement (Design Camber) @ T=0 : LC1298 370 320 270 220 170 120 70 20
-300
-294
-288
-282
-276 -270
-264
-258
-252
-246
-240
-234
-228
-222
-216 -210
-204
-198
-192
-186
-180
-174
-168
-162 -156
-150
-144
-138
-132
-126
-120
-114
-108
-102
-96
-90
-84
-78
-72
-66
-60
-54
-48
-42
-36
-30
-24
-18
-12
-6 -30 0 -80
12
18
24
30
36
42
66
28 May 2012
Erection Monitoring
67
28 May 2012
P19 tower Pilecap
Tower Leg Construction in Progress
Isometric View of Piertable
Piertable Truss Erection
Pier table Truss Erection
Lifting Frame Operations
Lifting Frame Operations
Segment Transportation on Barge
Piertable Segment Lifting with Lifting Frame
Pier Table Segment Alignment
Segment Supported on Pier Table Truss
Pier Table Segments Alignment in Progress
Diaphragm Concreting
Isometric view of Middle Tower Legs
Construction of Middle Tower with ACS
P19 Middle tower leg in Progress
Strutting at Junction Top
Strutting at Junction Top
Assembly of tower head formwork prototype
Alignment of Anchorage Boxes at 100m above MSL
Construction of Tower Head
Erection of Deck
Erection of Deck
Erection of Parallel Wire Stay Cables
Erection of Precast Segmental Deck
Erection of Precast Segmental Deck Deck Closure
Completed View of Bandra CSB
Conclusions
Indian Engineers are Well Experienced in Construction of loang
Span Bridges, and Erection of Bridge Decks, using various methods
Choice of the method is Site Specific and Design Specific Bridge Design should Suit Erection Method
112
28 May 2012
I acknowledge with Thanks opportunity given to me for presentation of a very important and interesting topic. I thank the organizers, and the audience.
Disclaimer
This presentation contains certain forward looking statements concerning future business prospects and profitability of HCC, which are subject to a number of risks and uncertainties and actual results could materially differ from those in such forward looking statements, important developments that could affect the company's operations include a downtrend in the infrastructure sector, significant changes in political and economic environment in India, tax laws, labor relations, litigation etc. The company does not undertake to make any announcement in case any of these forward looking statements become materially incorrect in future or update any forward looking statements made from time to time by or on behalf of the company.

Suhas P Khedkar

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Hindustan Construction Co Ltd

Erecting Long Span Briges to suit Indian Conditions and Requirements

Presetation to 3rd annual Bridges India Summit 2012

Different Methods of Erection of Superstructure

Different methods of Superstructure Erection

Construction using Precast elements

Special techniques like Incremental launching method

Different methods of Superstructure Erection

Presetation to 3rd annual Bridges India Summit 2012

Cast in Situ Construction

Cast in Situ Construction for Superstructure

Conventional casting on staging

1. More suitable for normal span viaducts as staging can be supported on

4. For box girders conventional casting can not be avoided as launching

Presetation to 3rd annual Bridges India Summit 2012

Cast in Situ Construction for Superstructure

Presetation to 3rd annual Bridges India Summit 2012

Cast in Situ Construction for Superstructure

Cast in Situ Cantilever Segmental Technique

Presetation to 3rd annual Bridges India Summit 2012

Cast in Situ Construction for Superstructure

Cast in Situ Cantilever Segmental Technique

Method suitable for long span box girders. Advantages as follows:

1. Each stage of construction is self supporting after completion. The

2. Construction is done in segments of convenient length, so that formwork

3. Construction progresses from pier in both directions towards centre of

Conventional Casting Vs Cantilever Construction

Presetation to 3rd annual Bridges India Summit 2012

Conventional Casting Vs Cantilever Construction

Yamuna Bridge Staging Elevation and Side View

Conventional Casting Vs Cantilever Construction

Tezpur Bridge Bridge Builder Elevation and Side View

Cast in Situ Cantilever Construction for Long Span River Bridges

Cast in Situ Cantilever Construction for Long Span River Bridges

Ganga Bridge at Varanasi - Bridge Builder in Elevation and Side

Presetation to 3rd annual Bridges India Summit 2012

Cast in Situ Cantilever Construction for Long Span River Bridges

Ganga Bridge at Varanasi after Completion

Presetation to 3rd annual Bridges India Summit 2012

Innovative Construction for III Godavari Railway Bridge at Rajamahendri

Innovative Construction for III Godavari Bridge Superstructure

III Godavari Railway Bridge 28 spans of 98 m each 94 m C/C of bearings

Innovative Construction for III Godavari Bridge Superstructure

A bow string girder design was proposed by HCC.

Innovative Construction for III Godavari Bridge Superstructure

Innovative Construction for III Godavari Bridge Superstructure

Presetation to 3rd annual Bridges India Summit 2012

Innovative Construction for III Godavari Bridge Superstructure

Innovative Construction for III Godavari Bridge Superstructure

Stage 1 Cast starting stubs

Stage 2 Erect Formwork for first segment on starting stubs

Presetation to 3rd annual Bridges India Summit 2012

Innovative Construction for III Godavari Bridge Superstructure

Innovative Construction for III Godavari Bridge Superstructure

Innovative Construction for III Godavari Bridge Superstructure

Closure Pour: Formwork supported on the last segment of 1/2 arch

Innovative Construction for III Godavari Bridge Superstructure

Arches for various spans completed

Innovative Construction for III Godavari Bridge Superstructure

Construction of Tie Girder

Innovative Construction for III Godavari Bridge Superstructure

Bandra Worli Sea Link Project special Features

Presetation to 3rd annual Bridges India Summit 2012