Analysis And Construction of ROB

ANALYSIS & CONSTRUCTION OF RAILWAY

OVERBRIDGE

A SIX MONTHS INDUSTRIAL TRAINING REPORT

IN THE PARTIAL FULFILLMENT FOR THE AWARD OF THE DEGREE

OF

BACHELOR OF TECHNOLOGY
IN

Civil Engineering

SUBMITTED BY

GURPREET SINGH

100610180016

Rayat-Bahra Institute of Engineering & Nano Technology

Hoshiarpur

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 Analysis And Construction of ROB

ACKNOWLEDGEMENT

I would like to express our sense of gratitude from the apex of heart to helpful supervisor Mr.
Rajinder Singh [Executive Engineer,PWD(B&R),Mukerian],Mr. Karanbir Singh [Sub.
Divisional Engineer,PWD(B&R)],Mr.Amarjit Singh,[Junior Engineer,PWD(B&R),Mukerian].
The supervision and support that they gave truly help the progression and smoothness of the
project work. The co-operation is much indeed appreciated.

The project during semester would be nothing without the guidance , support and imagination
from these people.

Besides, this project work makes us realized the value of working together in a team and as a
new experience in working environment ,which challenges us every minute.

Not to forget, great appreciation goes to the rest of Department of Civil Engineering’s faculty
that gives me opportunity to work in practical environment to expand my knowledge . The whole
program really brought us together to appreciate the true value of friendship and respect for each
other.

Last but not least , I would thankful to my parents who provide me required help and guidance
that I needed.

GURPREET SINGH

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 Analysis And Construction of ROB

REPORT INDEX

Sr. No. Content Page No.

1.) Plan of Railway Overbridge

2.) Elevation detail of ROB

3.) Details of ROB

4.) Profile of Company

5.) General specifications

6.) Detailed specifications

7.) Equipment used

8.) Introduction of Stilt portion

9.) Introduction of Solid filled embankment portion

10.) Supervision of substructure

11.) Supervision of superstructure

12.) Other important results &estimate

13.) Problems Faced at Site & Safety Requirements

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 Analysis And Construction of ROB

PLAN OF ROB AT MUKERIAN TO GURDASPUR ROAD

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 Analysis And Construction of ROB

ELEVATION DETAIL OF ROB

Points Ground Level(G.L) Finish Road Level(F.S.L)

TO MUKERIAN SIDE:

1.) Start of ROB 256.974 256.113

2.) Pier (A1) 257.024 263.332

3.) Pier (P1) 256.830 264.198

4.) Pier (P2) 256.975 265.065

5.) Pier (P3) 257.00 265.844

6.) Pier (P4) 256.960 266.378

7.) Pier (P5) 256.980 266.626

8.) Pier (CP2) 257.015 266.711

TO GURDASPUR
SIDE:

1.)Pier (CP1) 256.523 266.708

2.)Pier (P6) 256.420 266.504

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 Analysis And Construction of ROB

3.)Pier (P7) 256.400 266.180

4.)Pier (P8) 256.300 265.712

5.)Pier (P9) 256.180 265.097

6.)Pier (P10) 256.085 264.430

7.) Pier (P11) 256.00 263.763

8.) Pier (A2) 255.860 263.097

9.) End of ROB 255.826 256.003

Note: All levels are in meter.

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 Analysis And Construction of ROB

Details Of Project

1. Client : PWD(B&R) , Mukerian

2. Construction Agency : Deepak Builder Pvt. Ltd.

3. Type of contract : Item rate

4. Total length of ROB : 816 m

5. Total width of ROB : 10 m

6. Cost of the project : 14.22 crores

7. Contract period : 13 month

8. Starting date : 09/03/2012

 Due to some technical and financial constraints it is being delayed.

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Profile Of Company

1. Deepak Builder Pvt.Ltd is one of the leading construction companies in Punjab today.

2. The Deepak Bulidcon Group is a brainchild of Mr. Deepak Singal, who established it in
the year 1987, with focus on the construction and development of luxury apartments in
Ludhiana.

3. The Deepak Buildcon Group constructs with a conscience luxury integrated with superior
quality and understated grandeur. The spirit of creativity and perfection of the
organization is reflected in its endeavors to achieve excellence, a quality perfected in
serving the nation for the past two decades with "Company Turnover more than 600
Million INR".

4. The Group is known for its design ingenuity, superior quality , professionalism and on-
time delivery, Today the Deepak Buildcon Group, manned by highly qualified
professionals and equipped with latest technology, has expanded into the creation of
world-class commercial offices , retail complexes , office cum retail projects and hotels.

5. From arch and bowstring girder bridges to balanced cantilever, prestressed concrete and
latest cable-stayed bridges, Deepak's capabilities cover the entire spectrum of
technological advances in bridge engineering.

6. Besides designing and building bridges, Deepak has achieved perfection in the techniques
of launching, underwater concreting development of supporting equipment like
pneumatic caissons, winches, cables, grouting machinery etc., and building of enabling
structures.

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 Analysis And Construction of ROB

Some General Specification

1. Number of arms : Single arm

2. Total number of piles : 68+32(CP1&CP2) = 100

3. Type of piles : Bored cast in-situ

4. Diameter of piles: 1m

5. Depth of each pile : 20 m resp.

6. Total number of piers : 19

7. Number of pier cap : 17

8. Type of superstructure : In-situ RCC deck

9. Number of girders spans : 17

10. Number of girder or beams : 57

11. Grade of Steel used : Fe 415 and Fe 500D

12. Grade of concrete : M45,M35,M40

13. Number of abutments : 2 (A1 & A2)

14. Type of bearing: POT/PTFE

15. Total number of panels used: 1610

16. Type of cement used: OPC43/53,Vikram/ACC cement

17. Type of steel used: TMT bars of SAIL/TATA

18. Type of soil: Sandy soil ( Cohesion=0.01-0.02)

19. Properties of bitumen used: 85/25 grade bitumen,viscosity grade -10/30,modified

bitumen from IOC/HPCL/BPCL.

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 Analysis And Construction of ROB

Some Detailed Specification

From Mukerian Side:

i. Length of solid fill embankment portion : 200.4000m

ii. Length of gradient 1 in 30 : 219.605m
iii. Before gradient , Valley curve length : 50m
iv. Length of toe wall/road kerb length : 53.212m
v. From toe wall ,length of rewall portion : 160m
vi. Length of first span (A1 – P1) : 26m
vii. Length of second span (P1 – P2) : 26m
viii. Length of third span (P2 – P3) : 26m
ix. Length of fourth span (P3 – P4) : 26m
x. Length of fifth span (P4 – P5) : 26m
xi. Length of sixth span (P5 – CP2) : 20m

 Length of Railway portion(CP2 – CP1) : 94m

From Gurdaspur Side:

i. Length of solid fill embankment portion : 221.700m

ii. Length of gradient 1 in 30 : 255.417m
iii. Before gradient , Valley curve length : 50m
iv. Length of toe wall/road kerb length : 34.90m
v. From toe wall ,length of rewall portion : 186.800m
vi. Length of first span (A1 – P11) : 20m
vii. Length of second span (P11 – P10) : 20m
viii. Length of third span (P10 – P9) : 20m
ix. Length of fourth span (P9 – P8) : 20m
x. Length of fifth span (P8 – P7) : 20m
xi. Length of sixth span (P7 – P6) : 20m
xii. Length of sixth span (P6 – CP1) : 30m

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Equipment Used At Site

i. Needle type vibrator (60 mm diameter):-

This type of equipment is used during the
placement of the concrete so that concrete can fit in its position properly and there will be
less void space in between the concrete structure.

ii. Concrete pump (56 m³/hr) :

As the name specified, it is used to lift or pump the
concrete some height. At site concrete pump is used to pump the concrete to the
beams, pier cap and deck slab.

iii. Transit mixer :

The transit mixer is used to transport the concrete from batching
plant to the site of construction without getting concrete dry. The mixer of the truck is

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transit or rotate about fixed axis so that concrete maintain all those properties required
for good strength before placement of concrete.

iv. JCB :
This type of equipment is generally used for the excavation and filling of the
ground. At site , it is generally used at “rewall” portion.

v. Roller:
This type of equipment is generally used for the compaction of the soil so as
to obtain optimum density of soil. At site, it is used at the “rewall” portion.

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vi. Slump cone:

This is a test used to determining the workability of the concrete. The
dimensions of the slump cone is written as following:
Height: 30cm
Top width: 10cm
Bottom width: 20cm
Placing condition Degree of workability Slump(mm)
Heavily reinforced section Medium 75
In-situ piling work High 125

vii. Hydra crane(3 ton):

It is a crane having boom and hooks is attach to boom at its one
end so as to lifting of material to some height. At site, it is used to lift the bundle of
the steel bars and placing the panels in their proper position. The capacity of Hydra
crane is 3 ton.

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viii. Batching plant:

This batching plant is used to mix the cement, sand, water and coarse
aggregate in specified proportion according to grade of concrete required as per
design. Some important grade of concrete used at site:
Grade Cement W/C ratio Water Sand Coarse
aggregate
M45 475 0.30 140 536 1210
kg/m³ kg/m³ kg/m³ kg/m³

M40 465 0.30 140 786 1066

kg/m³ kg/m³ kg/m³ kg/m³

M35 335 0.38 130 548 1370

kg/m³ kg/m³ kg/m³ kg/m³

ix. Concrete bucket:

This type of bucket is used to collect the concrete after mixing of
cement,sand,water and coarse
aggregate in batching plant.

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x. Concrete pipeline:
This is a medium through which concrete is transport to the non-
reachable places by transit mixer. At site, concrete pipeline is used for concreting the
beams, deck slab.

xi. Dump truck:

It is used to transport the soil from one place to another at the site as
per requirement. At site, dump truck are generally used at the rewall portion” of the
ROB.

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Introduction Of Stilt Portion

This Railway Over Bridge is constructed on railway LC NO. B-110 at Mukerian to Gurdaspur
road . The purpose of construction of such ROB is to safely bye-pass the highway traffic over
the railway line without interrupting highway traffic . Construction of ROB involve in two
portions which is written as following :

I. Stilt portion: In this portion, major portion of construction is done by RCC and
minor or negligible portion of construction is done by solid or soil. Following are the
processes or construction is done under this head :
a.) Alignment

b.) Piles

c.) Pile cap

d.) Pier

e.) Pier cap

f.) Pedestal

g.) Bearing

h.) RCC girder

i.) Deck slab

i. Stilt portion of Mukerian side: Total length of approach 350.400m, which include
160m stilt portion having average width of 10.00m comprising of 9m carriageway and 0.50m
wide crash barrier on both sides as shown in GAD in gradient of 1:30 with summit curve at the
junction with horizontal portion adjacent to railway bridge.

ii. Stilt portion of Gurdaspur side: Total length of approach 371.700m, which include
160m stilt portion having average width of 10.00m comprising of 9m carriageway and 0.50m
wide crash barrier on both sides as shown in GAD in gradient of 1:30 with summit curve at the
junction with horizontal portion adjacent to railway bridge.

Some important information about stilted portion according to knowledge obtained at site:

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a.) Alignment: It is the process of align the component bridge as per design drawing. The

alignment is done before the construction of ROB is to be start.

b.) Pile: It is the long slender member that carrying and transfer the load of the structure to the

ground located at some depth below the ground level and earth surrounding the pile.
The piles used at site is Bored cast-in-situ having diameter of each pile is 1m and sinking of the
pile into the ground is 20m approx. Grade of concrete used in pile is M45 and Grade of steel
used is Fe415 and Fe500. The clear cover used is 75mm The piles are used at site in group as
following:

Sr. No. Type of pier No. of piles in group per pier

1.) Free pier (P1.P2,P4,P7,P8,P10,P11) 4

2.) Fixed pier (P3,P9) 6

3.) Expansion joint pier (P5,P6) 4

4.) Abutment (A1&A2) 4

c.) Pile cap: It is the structural element of ROB that tie a group of piles together and used to

transmit forces from pier to the pile foundation. The grade of concrete used for pile
cap is M35. The grade of steel used is Fe500. The clear cover used is 75mm. The dimensions of
pile cap written as following:

For Free pier: 4500mm×4500mm

For Fixed pier: 9000mm×4500mm

Height of each pile cap is 1.5m

d.) Pier : It is the intermediate vertical load bearing member of ROB which has transfer the load

to the pile cap from the pier cap. The grade of concrete used for pier is M45. The grade
of steel used is Fe500. The clear cover used is 50mm.The diameter of pier is 1.8m. The height of
each pier is variable generally more near railway span and less near the rewall portion of the
ROB. The picture of pier is shown below:

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e.) Pier cap: It is the structural element used to support the beams or girders. It is used to transm-

it the load from beams to the pier. The pier cap is provided some jack locations so
as to lift up the beams for the purpose of maintenance of the bearing. The dimensions of the pier
cap is 7000mm×2000mm and the height of pier cap is 1200mm. The clear cover to the pier cap is
40mm.Grade of concrete used for the pier cap M45. Grade of steel used is Fe500. The lap length
of the bars is 76×d.Where d= diameter of lapping bar.

f.) Pedestal & Seismic stopper: Pedestal is the structural member of the bridge whose length is

not exceeds the three times the least laterial dimensions. The
dimensions of the pedestal are 850mm×800mm. It is provide base for the girder. . The pier cap is
provided with the traverse stopper and longitudinal stopper so as to maintain the beams or girder
in its proper position during seismic load. The dimension of traverse stopper is 800mm×550mm
and dimension of longitudinal stopper is 800mm×1400mm. Grade of concrete used for pedestal
and Seismic stopper is M45. Grade of steel used for both is Fe500.

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g.) Bearing: It is the provision made in the ROB to allow the span to certain displacement

due to the temperature changes. The type of bearing provided is POT/PTFE. The structure shall
also be checked for reduce value of coefficient of friction(i.e. 0.01) at movable bearing as higher
coefficient of friction may not realized during initial period of loading. Use of mortar pad
bearing shall not be permitted.

h.) RCC girder: It is the tension member of the ROB used to transfer the loads from the deck slab

to the pier cap through the bearing and pedestal. The grade of concrete used for

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Section at End Section at Middle

girder is M45 and grade of the steel is Fe500.Other dimensions are shown in above two pictures.

i.) Deck slab: It is the horizontal member of ROB which construct the most important part of the

superstructure and providing a platform to the highway traffic. The slab have dim-

ensions shown in figure. Total length of deck slab is 10000mm having center to center beam
distance is 2500mm. The length of cantilever portion is 2500mm on both sides. At beams, total
depth of deck slab is 300mm and at middle of the beams is 220 and at outer end of cantilever,
depth of slab is 200mm.So the average depth of deck slab is 240mm. The grade of concrete used
for deck slab is M45 and grade of the steel is Fe500. The deck slab is two-way slab. The clear
cover of the deck slab is 40mm.

a. Expansion joint : The expansion joint must be durable , specified size and replaceable. It
must
be provided over the full width of the superstructure including kerb, footpaths
and crash barrier. Following are the same additional essential features:

i. The expansion joint of 50mm is provided in deck slab for design movement.

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ii. It shall be either from elastrometric or shall be cushion of elastometric to enable

the absorption of shock transmitted by vehicles.
b. Construction joint : The construction joint shall be provided only at the location shown in
the
drawing. The concrete surface at the joint shall be brushed with a stiff
brush after casting while the concrete is still fresh and it has only slightly hardened . Before new
concrete is poured, the surface of old concrete shall be prepared as under:-

i. For hardened concrete, the surface shall be thoroughly cleaned to remove debris
and laitance and made rough so that ¼ the size of aggregate is expose without
structurally damaging the concrete.
ii. For partially hardened concrete, the surface shall be cleaned by wire brush
followed by an air jet the old surface shall be soaked with water without leaving
puddles, immediately before starting concreting to prevent absorption of water
from new concrete. The new concrete shall be thoroughly compacted is region of
the joint.

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Introduction Of Solid Fill Embankment Portion

II. Solid fill embankment portion : In this portion, major portion of construction is
is done solid or soil and minor or negligible portion
of construction is done by RCC . Following are the processes or construction is done
under this head :

a) Alignment & Excavation

b) Pad
c) Panel cast
d) Erection of panel
e) Filling
f) Compaction
g) Geo-grid
h) Geotextile
i) PCC
j) Frictional slab
k) Toe wall
i. Solid fill portion of Mukerian side: Length of solid fill is 190.40m in reinforced earth

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wall/RCC wall and having 10.00m with comprising of 9.00m wide carriageway and
0.50m wide crash barrier on both sides as shown in GAD in gradient of 1:30 with valley
curve at the bottom. The crust as per specification will be extended to a length of 50m
beyond solid fill for regarding of the existing carriageway with the solid fill portion.
ii. Solid fill portion of Gurdaspur side: Length of solid fill is 211.70m in reinforced earth
wall/RCC wall and having 10.00m with comprising of 9.00m wide carriageway and
0.50m wide crash barrier on both sides as shown in GAD in gradient of 1:30 with valley
curve at the bottom. The crust as per specification will be extended to a length of 50m
beyond solid fill for regarding of the existing carriageway with the solid fill portion.
Some important information about stilted portion according to knowledge obtained at site:

a.) Alignment: It is the process of align the component bridge as per design drawing. The

alignment is done before the construction of ROB is to be start. In this portion,

alignment of panel is before the placing and erecting.

b.) Pad : After the excavation, PCC of M10 is laid so as to provide hard base for the pad. The pad

is made of RCC provide a solid base for erecting the panel and providing the stability.
Grade of concrete used is M15. Width of pad is 500mm and thickness is 200mm.

c.) Panel cast: The panels are cast at mixing-batching unit. Commonly used panel are

i. F-panel
ii. S-panel

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iii. P-panel
iv. Q-panel
v. R-panel
vi. HB-panel
vii. HT-panel
Mould size of all above panels are written in table shown below:

Sr. No. Type of panel Mould size(m3)

1. F- panel 1.480×1.480×0.180

2. S- panel 1.480×1.750×0.180

3. P- panel 0.500×1.480×0.180

4. Q- panel 1×1.480×0.180

5. R- panel 1.250×1.480×0.180

6. HB- panel 1.480×0.750×0.180

7. HT- panel 1.480×0.750×0.180

Basically two types of hooks are used in the panel:

i. Lifting hooks: These are the hooks used to lift the panel and place it in proper position.
The diameter of bars is 12mm. Size of the lifting hooks is
220mm×220mm×50mm.
ii. Geo-grid hooks: These are the hooks used to attach geo-grid. The diameter of geo-grid
bar is 10mm. Size of these hooks is 135mm×120mm×40mm.

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d.) Erection of panel: The cast-in-situ panel bring to site of construction and erected upon pad in

its position by using the Hydra crane so as to built up the “rewall portion”

of solid fill embankment portion. Erection of panels is continue till the deck slab and as per
design.

e.) Filling: After erection of the panel, filling of the “rewall portion” of solid filled embankment

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is done with the help of sandy soil. The bulk density of sandy soil used id varies from
0 to 18 kg/m³ and cohesion according to test perform is 0.01-0.02. The filling of “rewall portion”
is done with the help of JCB and Dump truck.

f.) Compaction: It is the process of rearrangement of the soil particles so as to achieve maximum

dry density and optimum water content. At site, compaction of the sandy soil is
mostly done with the help of vibrating type roller.

g.) Geo-grid: Multiple layer of geo-grid have been placed horizontally within the filling and fold-

ed at sides to form facing to geo-grid hooks of panel with the help of steel bar. It
has moderately high modulus and low elongation to break, stiffer approach fill was created
which could distribute traffic loads over a wider area and thus provide stability to erected panel
and also provide outward displacement of 0.165mm to 0.170mm.

The filter media in the form of the coarse aggregate is used near erecting panel so that moisture
of the soil is drain down and drain through the drainage hole provided at the regular interval in

erecting panel.

h.) Geotextile: It is the polymer cloth type material provided at the junction or joints of the
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panels so as to prevent water leakage from the joints of the erecting panel. The
binding material used to bind the geotextile to the joint is fevicol.

i.) PCC : Plain concrete cement of grade M10 is used before the frictional slab have been laid out

It is used to provide the solid base for the frictional slab.

j.) Frictional slab & Crash barrier: The frictional slab is sometimes also refer as the sidewalk.

Thickness of frictional slab is 300mm and total length of

slab is 1775mm.Grade of concrete used in slab is M40 and clear cover to reinforcement is 40mm.

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Grade of steel used is Fe500.Hight of crash barrier above the frictional slab is 850mm and width
is 500mm of which 275mm is horizontal and 225mm inclined upto 350mm height from slab. The
75φ PVC pipe for carrying electric cables for illumination of ROB provided at height 200mm
from slab. The electric pole of 8000 high from road surface.

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SUPERVISION OF SUBSTRUCTURE

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Pile Foundation

Introduction : Piles are long slender members that carry and transfer the load of the structure
to the ground located at some depth below the ground and the earth surrounding the piles.
Bored cast in-situ friction RCC piles of diameter 1000 mm. M45 grade of concrete was used
at our site.Average depth of the piles was 20 m.

Cut portion of piles for making Pile cap

Estimation of Steel in Piles:-

Steel quantity:-

Diameter of one pile = 1000 mm

Clear cover = 75 mm

Diameter of the bar used for pile rings = 10mm (External) & 18mm(Internal)

External diameter of pile ring, d(ext) = 1000- 2×75 = 850 mm

Internal diameter of pile ring , d(int) = 850 – 2×20 = 810 mm

Circumference of external pile ring = П × d = П×850 =2.669 m

Circumference of internal pile ring = П × d = П×810 =2.543 m

No. of external rings in the pile = 134

No. of internal rings in the pile = 134

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So total length of 10 mm bar = 134×2.669 = 357.64 m

So total length of 18 mm bar = 134×2.543 = 340.76 m

Vertical bars:

Diameter = 20 mm

Length of one single bar from top to bottom of the pile = 20.3m

Number of the bars = 19

So total length = 19×20.3 = 385.7 m

Total weight of steel used in one pile = d21× L1/162 + d22× L2/162 + d23× L3/162

= 10²×357.64/162 + 18²×340.76/162 + 20²×385.7/162

= 1854.62 kg

For pile group having 4 piles total weight of steel = 4×1854.62 = 7418.48 kg

For pile group having 6 piles total weight of steel = 6×1854.62 = 11127.72 kg

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Pile Cap

Structural elements that tie a group of piles together. Used to transmit forces from piers to the
pile foundations. At my site I studied the construction of the pile cap for the fixed pier P3.
Abutment(A1&A2) , Free pier(P1,P2,P4,P7,P8,P10,P11) and pier having expansion joint
(P5,P6) have 4 group of piles while fixed pier (P3&P9) have 6 group of piles. It was
constructed to connect 6 piles. Concrete mix of M35 was used in the pile cap. Total of 60.5
m³ of concrete was used in this pile cap. Clear cover to reinforcement is 75mm. Height of the
pile cap was 1.5 m.

Plan of the Pile Cap:

Elevation of the Pile Cap:

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Estimation of the Pile Cap P3:

Shuttering quantity of pile cap :

Dimensions of the pile cap are shown in the figure

Height of the pile cap = 1.5 m

Area of shuttering = 1.5×2× (9+4.5)

= 40.5 m²

Concrete quantity:

Volume of concrete to be used = 9×4.5×1.5

= 60.75 m3

Concrete Mix Proportion for Pile Cap:

Different grades of concrete were used for the bridge construction.

M35 was used for the pile cap.

Steel used : Fe 415 and Fe500

Cement used : ACC/Vikram cement (OPC 43 grade)

Aggregates used : 10 mm, 20 mm and sand.

Admixture used : FORSOC CONPLAST SP 430.

Cement W/C ratio Water Sand 20mm 10mm

335 0.38 130 548 786 484
kg/m³ kg/m³ kg/m³ kg/m³ kg/m³

1 0.38 1.63 2.34 1.4

Cement : Sand : Coarse Aggregate = 1 : 1.63 : 3.74

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Pier

Estimation of Steel in Pier8:-

Steel quantity:-

Diameter of one pier = 1800 mm

Clear cover = 50 mm

Diameter of the bar used for pier rings = 12mm@100mmc/c & 12mm@200mmc/c (External)

External diameter of pier ring, d(ext) = 1000- 2×50 = 900 mm

Circumference of external pier ring = П × d = П×900 =2.826 m

No. of external rings in the pier of 100mmc/c = 60

No. of external rings in the pier of 200mmc/c = 30

So total length of 12 mm@100mmc/c bar = 60×2.826 = 169.59 m

So total length of 12 mm bar@200mmc/c = 30×2.826 = 84.78m

Vertical bars(L-type):

Diameter = 20 mm

Length of one single bar from top to bottom of the pier = 6m approx

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Number of the bars = 49

So total length = 49×6 = 294 m

Total weight of steel used in one pier = d21× L1/162 + d22× L2/162 + d23× L3/162

= 12²×169.59/162 + 12²×84.78/162+ 20²×294/162

= 951 kg

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Pier Cap
Elevation of the pier cap:

Plan and Estimate of pier cap:

All dimensions in mm

Concrete quantity

Ar1 = 600×7000 mm² = 4.2 m²

Ar2 = 1/2×2×2600×600+1800×600 mm² = 2.64 m²

Total area = 4.2+2.64 = 6.84 m²

Thickness of the pier cap = 2000 mm

So total volume of concrete to be used = 6.84×2 = 13.68 m³

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SUPERVISION OF THE SUPERSTRUCTURE

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RCC I-Girder
Cross section of the I-girder:

Methodology for the construction of I-Girder:

1) Form work for RCC girder:-

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2) Making of reinforcement cage:-

3) Preparing the shuttering:-

Grooves for bearing

4) Closing of the side shutters:-

5) Concreting:- Automatic batching plant,Concrete pump : 56 m³/hr,Concrete of M45 grade.

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Cement W/C ratio Water Sand Coarse Admixture

aggregate
475 0.30 140 536 1210 0.8%
kg/m³ kg/m³ kg/m³ kg/m³

6) Deshuttering:- After 72 hrs

7) Curing:- For next 20 days at least. Using Hessian cloth for curing.

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Some Important Soil Test Results

Following are the test performed in laboratory as per Indian standard specification:-

1. Grain size analysis

2. Liquid limit, Plastic content
3. Natural moisture content
4. Specific gravity
5. Bulk density & Dry density
6. Chemical test of water
At bore hole no.-01:

S.No. Sample Atterberg’s Moisture Dry Cohesion Angles of

depth limit content density (Kg/cm2) internal friction
(m) (%) (gm/cc) (Degree)

1.) 3 Non-plastic 17.27 1.582 0.03 30.50

2.) 6 Non-plastic 17.85 1.583 0.03 320

3.) 9 Non-plastic 17.85 1.565 0.04 290

4.) 12 Non-plastic 17.85 1.593 0.02 330

5.) 15 Non-plastic 17.60 1.596 0.02 32.50

6.) 18 Non-plastic 18.15 1.579 0.02 320

7.) 21 Non-plastic 18.07 1.590 0.02 330

8.) 25 Non-plastic 17.65 1.577 0.02 310

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At bore hole no.-02 :

S.No. Sample Atterberg’s Moisture Dry density Cohesion Angles of

depth limit content (gm/cc) (Kg/cm2) internal
(m) (%) friction
(Degree)
1.) 3 Non-plastic 17.21 1.573 0.04 28.50

2.) 6 Non-plastic 17.54 1.578 0.03 30.50

3.) 9 Non-plastic 17.96 1.582 0.03 30.50

4.) 12 Non-plastic 17.66 1.586 0.02 320

5.) 15 Non-plastic 17.79 1.592 0.02 32.50

6.) 18 Non-plastic 16.88 1.591 0.02 310

7.) 21 Non-plastic 17.85 1.583 0.02 310

8.) 25 Non-plastic 17.84 1.573 0.03 300

Chemical Analysis:

I. Chemical analysis result of soil sample:

S.No. Bore hole no. Depth (m) PH

1. 1 10 6.95

2. 1 25 6.85

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II. Chemical analysis result of water sample:

S.No. Bore hole no. Depth (m) PH

1. 2 10 6.98

2. 2 25 7.16

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Other Important Estimate

Following percentages will govern the price adjustment for entire contract:-

S.No. Type of Work Percentage (%)

1. Labour 17

2. Cement 16

3. Steel 17

4. Bitumen 6

5. POL (fuel & lubricant) 6

6. Plant & Machinery 6

7. Other material 32

8. Total 100

i. Adjustment of labour component:- Adjustment of cost of labour is done by the

following formula:-
VL = 0.85 × PL/100 × R × (Li-Lo)/Lo

Where VL = Increase or decrease in cost of work during the month under consideration

due to changes in rates for local labour.

R = Value of work

Lo = Consumer price index for industrial worker (Base year 2004-05 = 100) for

Punjab state on 28 days preceding the date of opening of Technical bid as

Published by Bureau, Ministry of labour, Government of india.

Li = Consumer price index for industrial worker (Base year 2004-05 = 100) for

Punjab state for the month under consideration as Published by Bureau,

Ministry of labour, Government of india

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PL = Percentage of labour component of the work.

ii. Adjustment of cement component:- Adjustment of cost of cement is done by the

following formula:-
Vc = 0.85 × Pc/100 × R × (Ci-Co)/Co

Where Vc = Increase or decrease in cost of work during the month under consideration

due to changes in rates for cement

R = Value of work

Co = All india wholesale price index worker (Base year 2004-05 = 100) for 28

days preceding the date of opening of Technical bid as published Ministry

industrial development, Government of india.

Ci = All india wholesale price index worker (Base year 2004-05 = 100) for the
month under consideration as Published by Ministry industrial development,
Government of india.
Pc = Percentage of cement component of the work.

iii. Adjustment of steel component:- Adjustment of cost of steel is done by the following
formula:-
Vs = 0.85 × Ps/100 × R × (Si-So)/So
Where Vs = Increase or decrease in cost of work during the month under consideration
due to changes in rates for steel.
R = Value of work
So = All india wholesale price index worker (Base year 2004-05 = 100) for 28
days preceding the date of opening of Technical bid as published Ministry
industrial development, Government of india.
Si = All india wholesale price index worker (Base year 2004-05 = 100) for the
month under consideration as Published by Ministry industrial development,
Government of india.
Ps = Percentage of steel component of the work.

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iv. Adjustment of Bitumen component:- Adjustment of cost of steel is done by the

following formula:-
Vb = 0.85 × Pb/100 × R × (Bi-Bo)/Bo
Where Vb = Increase or decrease in cost of work during the month under consideration
due to changes in rates for bitumen.
R = Value of work
Bo = The official retail price of bitumen ( Base price of viscosity Grade – 30) at
the IOC depot at nearest centre on the 28 days prior to date of opening of
Technical bid.
Bi = The official retail price of bitumen ( Base price of viscosity Grade – 30) at
the IOC depot at nearest centre for the 15th day of the month under
consideration.
Pb = Percentage of steel component of the work.
v. Adjustment of POL ( fuel & lubricant) component:- Adjustment of cost of POL ( fuel
& lubricant) is done by following formula:-
Vf = 0.85 × Pf/100 × R × (Fi-Fo)/Fo
Where Vf = Increase or decrease in cost of work during the month under consideration

due to changes in rates for fuel and lubricant.

R = Value of work
Fo = The official retail price of High speed Diesel (HSD) at the existing

consumer pump of IOC/BP/HPCL at nearest centre on the 28 days prior to

date of opening of Technical bid.

Fi = The official retail price of High speed Diesel (HSD) at the existing
consumer pump of IOC/BP/HPCL at nearest centre for the 15th day of
month under consideration.
Pf = Percentage of fuel and lubricant component of the work.
vi. Adjustment of Plant & Machinery Spares component:- Adjustment of cost of Plant &
Machinery Spares is done by following formula:-

Vp = 0.85 × Pp/100 × R × (Pi-Po)/Po

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Where Vp = Increase or decrease in cost of work during the month under consideration

due to changes in rates for Plant & Machinery Spares

R = Value of work.

Po = All india wholesale price index worker (Base year 2004-05 = 100) for Construction

Machinery for 28 days preceding the date of opening of Technical bid as published

Ministry of industrial development, Government of india.

Pi = All india wholesale price index worker (Base year 2004-05 = 100) for the

Construction Machinery for month under consideration as Published by Ministry

of industrial development, Government of india.

Pp = Percentage of Plant & Machinery Spares component of the work.

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Problems Faced at Site & Safety Requirements

Problems & their Remedy:

1) Sometime the strength of the girders didn’t come on time.

Remedy: First off all, aggregates were washed before using them. It would increase the
rate of bond formation between the aggregates and cement. Also if use a higher grade of cement,
I will help in early achievement of strength.

2) While placing the concrete by transit mixers through concrete pipeline, concrete pipeline
is block due to remaining concrete in previous use.

Remedy: Pipeline is wash properly after use .

3) Power failure and batching plant failure delayed the processes.

Remedy: Proper and regular maintenance helped to reduce this problem.

4) While placement of the panel, traffic was a problem.

Remedy: Panels were placed at night to avoid this problem.

5) In summer days, water for curing dried too early.

Remedy: Hessian cloth was used to retain water for longer period. Continuous curing
was also done.

Safety requirements:

1) Training the workers.

2) Providing the first aid.

3) List of nearby hospitals.

4) Safety manual.

5) Banners.

6) Using the safety equipments.

7) Providing the vehicle.

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Bibliography

Books:-

1) Indian Standard codes

2) Design drawings provided by organization
3) Bridge Engineering Handbook
4) Soil mechanics & foundation Engineering By Dr. P.C Punima

Software Used:-

1) MS-WORD

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