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Bridge Designer™: Case Study #3

The Third Narmada Extrados Bridge in India

Delivery Method: Design-Build
Owner: National Highway Authority of India
Contractor: Larsen and Toubro, ECC Division, India
Authority Engineer: Aarvee Associates, India
Design Consultant: Precast BridgeTech, Co. Ltd., Thailand
Independent Checking Consultant: Roughan & O’Donovan, Ireland
Date of Services: January 2010 to June 2013
Total Construction Cost: $25 million

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Precast BridgeTech Co. Ltd. (PBT) is an engineering firm incorporated in Thailand, dedicated to bridge
design. PBT’s services cover the complete bridge engineering process from concept development to
detailed design, construction engineering and field supervision, and often offer optimized detailed design
with their use of advanced technology tools and experience.

Engineers at Precast Bridge Tech. have been involved in large design/build bridge projects, mostly in India.
They have specialized in value engineering and detailed design of span-by-span and cable stayed/
extradosed girder bridges, for which they used the Bridge Designer software successfully to optimize design
and manage construction.

These projects are documented in the News page of the Interactive Design web site and on Precast Bridge
Tech. upcoming web site.

The engineers at Precast Bridge Tech. have been using the Bridge Designer software for several years and a
variety of Bridge Design projects, from span-by-span to balanced cantilever, extradosed and cable-stay
bridges.

For precast segmental bridges, they use BD2 in order to evaluate structures under construction, including
time-dependent staged construction and final stress redistributions and deflections due to time dependent
material properties of concrete and steel.

Precast Bridge Tech. used Bridge Designer for construction analysis of this project.

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General Description:
The bridge is 1.344km long (96m+8x144m+96m long). The superstructure has 4 lane carriageway and
single walkway and consists of precast segmental three-cell box girder with two planes of cable stays. Link-
Saddles are utilized to transmit the stay forces to upper pylon. Expansion joints are located at mid span of
every other span. Upper and lower pylons are built with cast-in-place construction. Foundation consists of
12×1.5m diameter drilled shafts. The construction period is 30 months.

Key Features:
Precast Bridge Tech’s Managing Director, Egemen Ayna says “The bridge articulation is such that we have a
mid-span expansion joint (EJ) at every other span. Mid-span EJ utilizes a steel shear key that can only
transmit vertical shear and torsion. It is installed after all SDL loads are placed and all stay stressing and
post-tensioning are completed. It does not experience any permanent loads apart from shear associated
with level adjustment at the EJ cantilever tip with strong backs and creep redistribution of expansion
cantilevers. Creep distribution of expansion cantilevers at either side of EJ are carefully and accurately
determined by using BD2 computer model of two continuous frames, separated by an EJ in between (a
frame is two pylons combined with CIP closure at mid-span).”

Precast Bridge Tech Role:

Our role for Their Narmada Extradosed Bridge is the detailed or final design of the bridge and its
construction support, said Egemen A. Ayna.

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Because the bridge is on a straight line alignment, PBT engineers were able to use the 2D engine of Bridge
Designer for planar analysis of the construction stages. Modeling this way for 2D analysis allowed them to
create a model on a straight line, with equivalent cross-section properties as the three void actual bridge
section, one line of stays and each post-tensioning tendon representing multiple tendons with similar
elevation and plan-view layouts.

The Designer Larsen & Toubro describes this bridge as “a greener bridge”. From L&T’s web site:

“ “This is the first bridge of its kind in Gujarat. And it also has another distinction: the bridge is
greener than many others, built with a commitment to the key principles of sustainability –
Recycle, Re-use, Reduce. At the site, all surplus concrete was used in casting of crash barriers.
These barriers are built for the road as well as for the survey reference pillars. A small step in
recycling and ruins that has contributed to conservation of resources.”

See L&T web site: http://www.larsentoubro.com/corporate/a-greener-bridge/

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The bridge models include balanced cantilever stages

at each pier. The Bridge Designer software computes
construction deflections and stresses under all load
cases (self-weight, superimposed loads, post-
tensioning initial and final forces, creep, shrinkage and
any temperature effects such as linear and non-linear
thermal gradients). The software provides the
capability to assemble all cantilever “sub-structures” at
the proper dates according to the contractor schedule,
and computes the continuity effects for all load-cases as well as final conditions (support reactions,
deflections and stresses) after long-term redistributions according to the local code (material properties,
concrete and steel short and long term rheological properties.

Bridge Designer models post-tensioning tendons in 3D

in all cases for the purpose of properly evaluating
friction losses. One interesting feature of the Bridge
Designer software is that it can easily convert tendon
geometry from a 2D model to a 3D model, taking into
account the structure horizontal curvature.

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PBT engineers first created a 2D version of the model for longitudinal analysis and sizing of the post-
tensioning layout. This first model was also used to evaluate long term stress redistributions (creep &
shrinkage, and steel relaxation) and final deflections in order to obtain casting curves for geometry control.

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The Bridge Designer User Interface provided the tools to quickly generate a 3D model. Even though only 2D
(linear structure) analysis was used for this project, it is possible to quickly define an accurate 3D model of
the structure as well as the Post-Tensioning tendons, usable for 3D analysis.

In addition the transverse can be accurately modeled for exact mechanical cross-section properties as well
as exact geometry and topology for non-linear thermal gradient evaluation.

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Precast Bridge Tech. also used the Bridge Designer software (2D engine) to evaluate transverse effects of
post-tensioning, in initial and final conditions.

Transverse model with post-tensioning

The following diagrams obtained in the Bridge Designer graphical interface, show transverse force and
displacement distributions under self-weight, post-tensioning, creep and shrinkage.

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Axial stress on top fiber due to post-tensioning

Deflections under all applied loads

The 3rd Narmada Extrados Bridge, Baruch – India was inaugurated and subsequently opened to traffic on
March 7, 2017.

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See article in Indian media from last October: http://deshgujarat.com/2016/10/04/new-narmda-river-bridge-

in-bharuch-on-hn-8-to-be-operational-early-next-year/

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