A PROJECT REPORT ON

CONSTRUCTION OF FLYOVER

For

Bihar Rajya Pul Nirman Nigam Limited.

Guided by :-

Mr. Arvind Prasad Gupta

( Project Engineer )

Project Name

Lohia Path Chakra

Submitted by:-

Prabhat Kumar Prashant Shaurabh

Civil Engineering VIIth Sem Civil Engineering VIIth Sem

Roll No:-14102024 Roll No:-14102025

DEPARTMENT OF CIVIL ENGINEERING

INSTITUTE OF TECHNOLOGY,GURU GHASIDAS VISHWAVIDYALAYA

BILASPUR, C.G.

REASON BEHIND GOING FOR A FLYOVER

As the traffic on the road goes on increasing and we don’t have any space left in both the dimensions, then

the only option left will be to go to the third dimension and that is done through Flyover construction.

There is so much traffic in the city so it takes around 45 to 60 minutes to go from saguna more to patna high

court even they are 12 kms apart,and of being the lifeline road of the city it is important to control the traffic

on this road.So the decision has been taken to construct a flyover so to reduce the travelling time to 15

minutes from 45 minutes.

Contents

Aknowledgement

Abstract

SECTION -A

Different stages of project

Topographic survey and analysis

Traffic survey and analysis

Geotechnical aspects and analysis

Planning and design

SECTION –B

Features of project Salient features

Physical features

SECTION –C

Components involved

Foundation

Substructure

Superstructure

SECTION –D

Machines and equipments used Air compressor

Backhoe loader

Crawler crane

Excavator

Genset

Hydraullic rig machine

Hydraullic crane

Mini roller

Pneumatic concrete breaker

Transit mixer

Tanks

Augur

Casing

Treamie pipe

Funnel

Goliath Gantry Crane

SECTION –E

Construction Procedure & dimensions Pile

Pile cap

Pier

Pier cap

Girder

Deck

Bearing

Crash barrier

Installation of light

SECTION –F

Quality Control Test on aggregates

Crushing test

Impact test

Shape test

Bitumen adhesion test

Test on Cement

Date of packing

Colour

Rubbing

Hand Insertion

Float test

Shape test

Strength test

Performance test

Load test

Capacity test

Stress test

Cube strength

Slump cone test

SECTION –G

Conclusion

Acknowledgement

A vocational training is a golden opportunity for learning and self development.I consider myself very lucky

and honored to have so many wonderful people lead me through in completion of this project.

First of all I would like to thank all the families and friends that participate on my life and get me in this

intensityand individuals who support and share idea and also helping me to be like this.

I am very thankful to BIHAR RAJYA PUL NIRMAN NIGAM LIMITED(BRPNNL) and its managing director

RANJAN KUMAR for having given me the opportunity to undertake my one month summer training in their

working area.It was a very good learning experience for me to have worked at this area.I would like to

convey my heartiest thanks to Chief Engineer ARVIND KUMAR and all the Faculty members at Department

of Civil Engineering at Guru Ghasidas Vishwavidyalaya,who made it all possible.

I would also thank SUJEET SIR for his endless support at site and in his office by consulting me how to do

things at site,all teachers of Civil Engineering who brought me to my present performance and shape me

like this during the last Three successive years, special thank to my prof NIKHIL KUMAR VERMA for guiding

me to do training at BRPNNL.

Before I finish I would like to give my deepest thanks to all workers from thr contractor, S P Singla

Construction Private Limited and the consultant side starting from Engineers to daily labours.Also for those

who do not listed in the above but support me in different areas I would like thank all.

ABOUT BIHAR RAJYA PUL NIRMAAN NIGAM LTD.

Constitution and objectives Bihar Rajya Pul Nirman Nigam (BRPNN) was formed on 11th June, 1975 under Indian Company Act, 1956 as a Govt. Company.

Its main objectives are -

Construction of Bridges/Roads Maintenance of Bridges Toll Collection

The Nigam is registered as a Public Company under Indian Company Act, 1956 and it is a Govt. Company as total share capital of Rs.500 Lakhs is pledged in the name of Governor of Bihar. The Nigam is governed by Managing Director on behalf of Board of Directors nominated by the Govt. under guidelines set by Memorandum of Association and Articles of Association along with work rules mentioned therein.

Concept of Working

Bridges are constructed departmentally by the Nigam on the basis of current Schedule of Rates (SoR) sanctioned for Works Department. As the work is done departmentally, cost incurred is less as compared to work done by contractors.

ABOUT S P Singla Construction Pvt Ltd.

S. P. Singla Constructions Pvt. Ltd. collaboratively facilitate, engineer, and disseminate

construction services fostering the world’s ethical, social, economic, and intellectual growth,

using progressive and diverse techniques on the cutting edge of the construction industry.

Every aspect of how we work has been built to fulfil our mission to make lasting contributions to

our people, our communities, and the construction industry. From company’s commitment for its

valuable employee’s teamwork to a continued commitment to hard work and performing with

excellence, our values are obvious in every office and on every project site.

S. P. Singla Constructions Pvt. Ltd. collaboratively facilitate the construction services fostering

the world’s geographical growth, using progressive and diverse techniques on the cutting edge of

the construction industry and provides healthy professional environment which is unanimously

accepted by every associated employee of S. P. Singla Constructions Pvt. Ltd. we filter excellent

from best.

VISION To build a progressive and creative organisation that constantly strives to improve its business &

construction practices and win clients’ trust by exceeding their expectations.

MISSION To be pioneers in the field of Bridge construction by application of innovative solutions and

knowledge to work.

S. P. Singla Constructions Pvt. Ltd. is a company pioneering spirit. That pioneering spirit drives us to

constantly find new and smarter ways to build. Our construction services have been fine-tuned over

a century of building and during that time have embraced advances in technology that help us build

better and safer infrastructure and for a lower cost. Our experienced team applies today’s

technology to proven building principles.

WE ARE SPECIALISTS IN CONSTRUCTION OF: R.C.C. bridges

Pre-stressed concrete bridges

Cantilever bridges for construction of long span bridges

Well foundations

Pile foundations

Flyovers

Road / Rail over bridges

Steel bridges including fabrication & launching

Launch of pre-cast & pre-stressed concrete girder

Roadwork with asphaltic concrete and mastic asphalt surfaces

Segmental constructions

At S. P. Singla Constructions Pvt. Ltd., we are always striving to bring on board the latest of

technologies and equipment to meet the demands of today’s clients. While listed above are few of

the technologies we are presently working with, in near future we will be adding more to our list.

The technologies are updated time-to-time to deliver today what others hope to do tomorrow.

Abstract

The training report in broad spectrum contains six sections in which I try to explain my one month

learning experience in the running project, construction of LOHIA Path CHAKRA as a part of Bailey

Road Flyover. The content of all section is broadly explained and it is made from the practical basis

of the site work of weekly basis.

In section A I give all the details of different stages of the project. In this section I put all the details

of the work done in the same manner at the site for the completion of the project.

In section B I try to explain the features of the project like the project details, the cost involved, the

length of the flyover, no of piles involved, cost involved .etc.

In section C I try to explain the components involved in the Flyover construction. It has been

categorized into three parts the foundation part, the sub structure and the superstructure part.

In section D I try to explain all the machines and equipments used in the whole construction with

their respective pictures.

The section E is the most important chapter in which explains all the dimensions and the

construction procedure of the components involved with some practical images whatever I clicked

during the whole training period.

In the section F I try to explain all the related tests on the materials involved in the construction the

tests on the aggregates, cement, soil and, model testing of pile on the basis of which we decide the

size of different part of the bridge, which type of material is suitable for the construction process,

how we can minimize the cost on that particular project and also the load carrying capacity of pile.

After reading all the sections one can easily understand basics of flyover construction procedure,

dimension and minimization of the cost of the project.

SECTION –A

DIFFERENT STAGES OF PROJECT

1.SURVEY AND ANALYSIS

Each and every civil engineering project starts with survey. There are various stages of survey. The

first step of surveying is reconnaissance Then after that various maps of the site is studied. Only

after this detail survey of proposed project site is done.

Here in this project a detail survey of the site is done by the Total Station and various other

instruments of surveying and layout is drawn in Autocad. With help of this total space available for

construction, alignment of flyover and no. lanes of flyover & total carriageway.

It should be noted that surveying not only plays an important role in the design of the project but

also in the execution.

2. TRAFFIC SURVEY AND ANALYSIS

The main purposes of traffic survey are: traffic monitoring, traffic control and management, traffic

enforcement, traffic forecasting, model calibration and validating etc. The purposes of carrying out

traffic volume count are designing, improving traffic system, planning, management etc.

Traffic forecast predicts the future traffic volume levels on the project road. In this project, the

flyover is designed to meet the requirements of traffic for next 25 years.

From traffic survey it was decided to design the flyover for live load for a single lane of class 70R

or 2 lanes of class -A.

.3. GEOTECHNICAL ASPECTS AND ANALYSIS

It is very necessary to carry out thorough soil investigation of the site as the whole load of the

structure is ultimately taken by soil through foundation. Feasibility, design and safety of the

structure all depends upon load bearing capacity of the soil strata at the site.

For this purpose bore holes were drilled in the ground to get information about the sub-soil

strata. Boring was done at an interval of 40m along the alignment and depth of exploration was

39m. Samples were taken from the bore hole and tested in the laboratory and engineering

properties of the soil was investigated. Also some field test was carried out.

From these tests & investigations, it was concluded that the Soil Bearing Capacity (SBC) of the site

was 230 MPa.

4. PLANNING & DESIGN

All the results were taken into account and with help of Various IS Codes detailed planning and

design were prepared according to which execution is going through and the flyover is under

construction. From all available data a pile was designed and Initial Load Test for pile was done to

confirm the load carrying capacity of the single pile.

TECHNICAL DATAS :-

SAGUNA MORE TO PATNA HIGH COURT

Diameter of Pile 1200 mm

Verticle load capacity of pile 250T

Horizontal load capacity of pile 20T

Depth of pile cap 1800 mm

SECTION – B

Salient Features:-

Project Cost : 391.47cr

Agency : BRPNNL

Date of commencement : 9 Dec 2015

Target date of completion : 18 Dec 2017

Physical Features:-

Total length of Project 3.2 kM

Length of elevated part 1.7 kM

No.of piers 16

Type of superstructure PSC GIRDERS

Slope across bridge length 1 in 30

No.of underpasses 4

Elevated Bridges 1

Average traffick movement 2000 Vehicles/hour.

SECTION :-

COMPONENTS INVOLVED

FOUNDATION

Piles and the Pile cap comes under the Foundation part.

Piles:- The function of pile is to transfer the load to the soil.

Three types of pile are there:-

1. End bearing pile

2. Friction pile

3. End bearing and friction pile

In this project we used End bearing Pile,some parts of the load transferred by the pile by end of pile

and remaining load is by the friction between pile and the surface of soil around the pile.

Arrow in the above image denotes how load transferred to the ground

Pile cap reinforcement

Piles usually exists as a group which are all integrated by means of a pile cap as shown in figure.

Piles carrying very heavy point loads tend to produce high tensile stress at the pile cap.

Reinforcement is thus designed to provide: -

1.Resistance to tensile bending forces in the bottom of the cap.

2.Resistance to the vertical shear.

SUBSTRUCTURE

Pier and Pier-cap

Support of superstructure, transfer dead and live load to pile.It also carries its own considerable

weight.

Pier

It is a raised structure typically supported by well-spaced piles or the pile cap. It can be made by wooden

concrete, steel, mixed, but in this project we use concrete pier with well-maintained iron rod.

Pier cap The upper or bearing part of the pier, usually made of concrete or hard stone; designed to distribute

concentrated loads evenly over the area of pier.The width of pier cap depends upon the width of

carriageway, its size depends upon the live load and dead load bridge capacity.

SUPERSTRUCTURE

Wearing surface consists of the deck structure itself, which support the direct loads due to traffic and all the other

permanent and variable leads to which the structure is subjected. Also known as carriageway.

Width of carriageway depends upon number of lane of flyover. For intermediate carriage -5.5 m and

for two lane-7.5 m.

Bearing Bridge bearings are used to transfer forces from the superstructure to substructure, allowing the

following types of movements of the superstructure :-

Translational movements; are displacements in vertical and horizontal directions due to in-place or out-of-

place forces like wind and self-weight.

Rotational movements; cause due to moments. Until the middle of this century, the bearings used

considered of following types: - pin, roller, rocker, metal sliding etc.

Girder It is support of carriageway between two piers, it is of many types like box shape, Z shape,I-shape and many

other forms.

In this flyover, I-shape pre-stressed beam used .

Crash barrier A strong fence at the side of carriageway, intended to reduce the risk of serious accidents.

It is of various types ex: - wooden, tin, steel, cable, wire, concrete.

Concrete barrier is strongest one and cheap as well.

Now these days in flyover concrete crash barrier is preferred generally.

SECTION -D Machines and equipments used

Air Compressor Backhoe Loader

Crawler crane Excavator

Genset Hydraullic Rig Machine

Hydraullic Crane Mini Roller

Pneumatic concrete breaker Transit Mixer

Tanks Bullet Augur

Bucket Augur Casing

Treamie Pipe Funnel

Goliath Gantry Crane

SECTION -E

CONSTRUCTION PROCEDURES AND DIMENSIONS

PILE :-

In this particular project, we use rotary hammer machine for drilling purpose.

1.Pile boring procedure

Set up the Location of Bored Pile.

We use Total Station instrument to survey each pile point.

The dia of the pile is 1.2m and the depth is 32m.

2. Drilling Using MAIT machine

3. Insert Casing

After Casing is inserted the bore is filled

W with the bentonite clay mixed with water to

Prevent the soil from the sides to fall down to

Bottom.

4. Insertion of Steel Cage

5. Insertion of Tremie Pipe & Pouring of Concrete

Number of piles: number of piles required for a particular pier is depends upon the spam, length

number of lane of carriage way, capacity of a particular pile and type of bridge it is.

Capacity of each pile in this project is 230 tones

PILE CAP

A pile cap is thick concrete mat that rests on piles to provide a suitable foundation.

It forms the part of the foundation of structure.

This pile cap distributes the load to piles uniformly.

Pile capping Procedure 1. Shuttering and Reinforcement

2. Concreting 3. Curing

Dimension of pile cap varies as number of piles and type of soil at that particular

place, Carry a height in the rage of 10-15 feet. In this project the height is taken as

10feet.

DESIGN AND SPECIFICATIONS OF FOUNDATION Pile foundation with pile cap No. of piles – 4 for Abutments & 9 for piers M35 Grade Concrete is used for casting piles & pile cap Depth of pile 32000 mm & Dia of pile 1200 mm Depth of pile cap is 3000 mm Bars used – Fe 500 Tor Steel Bar of Dia 28 mm & Dia 32 mm Sand filling is done around pier caps to control & minimize expansion & contraction of

structure and sand is economical also.

PIER :-

A part of substructure which transfers the load to pile followed by pile cap, its construction is a normal process of filling concrete mixture with steel rod arranged in particular manner as shown in picture . The dimensions and construction details of the cast-in-situ piers are given below.

Every single pier consists of Reinforcement bars of different dia (max upto 32mm)

Casted by using M35 grade Concrete. Internal vibrators are used for compaction of concrete.

PIER CAP –

Main function is to distribute concentrated loads evenly over the area of pier.

Pier cap carry a standard shape of inverse triangle shape, which behave like a truss of compression

and tension member. I tried to show it in the picture below, tension member by dotted line and

compression member by bold line. P1, P2, P3, P4, P5 shows the vehicle load of the carriageway.

Its dimension varies as number of lane required for that particular carriageway. Also calculation of length

and width can be done by using the length of tension and compression member.

I-GIRDER –

It is a pre-stressed beam of having a shape of I. that’s why also called as I-girder. There are so

many factor are considering for its construction.

Its dimension varies as the dead and live load of carriageway. It is only for low spam Length Bridge.

Its length varies 20- 40 m.

Here are some pictures which explain how to assemble it in bridge.

Lower part of I girder is of 600 mm, upper part is of 700 mm and middle part is 500 mm.

DECK –

The part of superstructure which carry the load of vehicle, also known as wearing surface.

Also support the crash barrier and light installation.

Its construction is of simple molding of concrete and steel bar (in well-arranged manner).

Takes 28 days in fully settings of concrete. Daily and enough water is required for setting.

CRASH BARRIER –

Main purpose is to prevent the vehicle by ride of from the road, prevent the accident and also used as

holder of light installation.

It is of size lower part 500 mm and upper part is of 200 mm in parabolic shape w.r.t vertical line.

LIGHT INSTALLATION –

Installation of light is different aspects of bridge construction, but we have to leave space

according to its decoration. But in some project it comes in under it.

I haven’t seen the process of installation of light,construction of crash barrier and installation of

deck in this one-month training period so don’t have too much idea about the processes.

SECTION -F

QUALITY CONTROL

Test on aggregates: -

Aggregate plays an important role in pavement construction, pile construction, pile construction.

Aggregates influence, to a great extent, the load transfer capability of pavements. Hence it is

essential that they should be thoroughly tested before using for construction. Not only that

aggregates should be strong and durable, they should also possess proper shape and size to make

The pavement act monolithically. Aggregates are tested for strength, toughness, hardness, and

shape and water absorption.

1. Crushing test - Used to determine the strength of aggregates.

The test consists of subjecting the specimen of aggregate in standard mould to a compression test

under standard load conditions. Dry aggregates passing through 12.5mm sieves and retained 10 mm

sieves are filled in a cylindrical measure of 11.5 mm diameter and a8 cm height in three layers. Each

layer is tamped 25 times with at standard rod. The test sample is weighted and placed in the test

cylinder in three layers each layer being tamped again. The specimen is subjected to a compressive

load of 40 tones gradually applied at the rate of 4 tones per minute. Then crushed aggregates are

then sieved through 2.36 m sieve and weight of passing material is expressed as percentages of the

total sample which is aggregate crushing value.

A value less than 10 signifies an exceptionally strong aggregate.

2. Impact test: -

The aggregate impact test is carried out to evaluate the resistance to impact of aggregates.

Aggregate passing 12.5 mm sieve and retained 10 mm sieve is filled in a cylinder steel cup of internal

diameter 10.2 mm and depth of 5 cm which is attached to a metal base of impact testing machine.

3. Shape test: - Flakiness and Elongation test

Flakiness index is defined as the percentage by weight of aggregate particles whose least dimension

less than .6 times their size. Flakiness gauge is used for this test.

The elongation index of an aggregate is defined as the percentage by weight of particles whose great

dimension is 1.8 times their mean dimension. This test is applicable to aggregate larger than 6.3 mm.

Elongation gauge is used for this test.

4. Bitumen adhesion test: - Bitumen adheres well to all normal types of road aggregates provided they are dry and free from

dust. In the absence of water there is practically no adhesion problem of bituminous construction.

Adhesion problems occur when the aggregate is wet and cold. This problem can be dealt with by removing

moisture from the aggregates by drying and increasing and mixing temperature.

TEST ON CEMENT

A. Date of packing: - Date of manufacturing should be seen on the bag, it is important because the

strength of cement reduces with age.

B. Color: - The cement should be uniform in color. In general, the color of cement is grey with a

light greenish shade. The color of cement gives an indication of excess lime or clay and the

degree of burning.

C. Rubbing: -we take a pinch of cement between fingers and rub it. It should feel smooth while

rubbing. If it is rough, that means adulteration with sand.

D. Hand insertion: - Thrust hand into the cement bag and it should give cool feeling. It indicates

that no hydration reaction is taking place in the bag.

E. Float test: - throw a small quantity of cement in a bucket of water. It should sink and should not

float on the surface.

F. Shape test: - Take 100g of cement and make a stiff paste prepare a cake with sharp edges and

put on the glass plate. Immerse this plate in water. Observe that the shape shouldn’t get disturb

while setting. It should be able to set and attain strength. Cement is capable of setting under

water also and that is why it is also called “hydraulic cement”.

G. Strength test: - A block of cement 25 mm* 25 mm and 200 mm long is prepared and it is

immersed for 7 days in water. It is then placed on supports 15000 mm apart and it is loaded with

a weight of 340 N. The block should not show any sign of failure.

PERFORMANCE TEST Load test: load tests on piles are conducted on completion of 28 days after casting of piles. Two

types of tests namely initial and routine test, for each type of loading ex: - vertical, horizontal are

performed

Initial test on pile: The test is performed to confirm the design load calculation and to provide

guidelines for setting up the limits of acceptance for routine tests. It also gives an idea of the

suitability of the pilling system. Test on pile are to be carried out at one or more locations depending

on the number of piles required. Load test for the initial load test is 2.5 times (safety factor) the safe

carrying capacity of the pile.

Routine test: selection of piles for the routine test is done based on the number of piles required

subjected to maximum of ½ of total number of piles required. The number of test may be increased

to 2% depending on the nature/type of structure. The test load applied 3/2 times the safe carrying

capacity of pile.

This test will be performed for the following purpose:

a) To ensure the safe load capacity of the piles

b) Defection of any unusual performance contrary to the finding of the initial test.

Vertical load test:

Pile head- The pile head shall be chipped of till sound concrete is met wherever applicable. The

reinforcement shall be cut and head leveled with plaster of Paris. A bearings plate with a hole shall

be placed on the head for the jack to rest.

Initial tests: it can be done in two steps;

1. 2/3 of the final load at which the total displacement attains value of 12 mm unless otherwise

requires on the basis of nature and type of structure in which case, the safe load should be

corresponding to the stated total displacement permissible.

2. 50 % of the final load at which the total displacement equals 10 % of the pile diameter in case

of uniform diameter piles or 7.5 % of the bulb diameter in case of under reamed piles.

SECTION -G

CONCLUSION

After the completion of this project, flyovers would benefit the commutators going to kankarbagh , Gandhi Maidan ,Mithapur Bus Stand From Danapur, IIT, AIIMS . Anyone can travel from R Block to Gandhi Maidan without facing heavy traffic jam in between. This project will prove a great asset to mankind as it will prevent chronic jams in traffic gridlock in areas like

New Market, Patna Junction & Bailey Road and hence will save considerable amount of fuel & time.

*********************************THANKS**********************************

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