cep-construction of railway over bridge by ishan kaushal

8/7/2019 CEP-Construction of Railway Over Bridge by Ishan Kaushal

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CONSTRUCTION OF RAILWAY OVERBRIDGECONSTRUCTION OF RAILWAY OVERBRIDGE

AT DOMORIA PULL, JALANDHARAT DOMORIA PULL, JALANDHAR

BY ISHAN KAUSHALBY ISHAN KAUSHAL

ROLL NO. 1040252ROLL NO. 1040252


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ROB AT DOMORIA PULL, JALANDHARROB AT DOMORIA PULL, JALANDHAR


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Details of the ProjectDetails of the Project

ClientClient MunicipalCorporation, JalandharMunicipalCorporation, Jalandhar

ConstructionagencyConstructionagency M/S Gammon India Ltd.M/S Gammon India Ltd.

TypeofcontractTypeofcontract ItemrateItemrate

TotallengthofROBTotallengthofROB 1.65 K m1.65 Km

CostoftheprojectCostoftheproject Rs 20 croresRs 20 crores

ContractperiodContractperiod 15 months15 months

StartingdateStartingdate 2828--0606--20042004

Duetosometechnicalandfinancialconstraintsitis beingdelayed.Duetosometechnicalandfinancialconstraintsitis beingdelayed.


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Key Plan Of the ProjectKey Plan Of the Project


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Company ProfileCompany Profile

Gammon India LimitedisoneoftheleadingconstructionGammon India Limitedisoneoftheleadingconstructioncompaniesin Indiatoday.companiesin Indiatoday.

Thecompany wasestablished bylateMr. J. C. GammoninThecompany wasestablished bylateMr. J. C. Gammonin1919 asafirmofCivil Engineers & Contractor.1919 asafirmofCivil Engineers & Contractor.

Fromarchand bowstringgirderbridgesto balancedFromarchand bowstringgirderbridgesto balancedcantilever,prestressedconcreteandlatestcablecantilever,prestressedconcreteandlatestcable--stayedstayed

bridges, Gammon'scapabilitiescovertheentirespectrumofbridges, Gammon'scapabilitiescovertheentirespectrumoftechnologicaladvancesin bridgeengineering.technologicaladvancesin bridgeengineering.

Besidesdesigningand building bridges, GammonhasBesidesdesigningand building bridges, Gammonhas

achievedperfectioninthetechniquesoflaunching,achievedperfectioninthetechniquesoflaunching,underwaterconcretingdevelopmentofsupportingequipmentunderwaterconcretingdevelopmentofsupportingequipmentlikepneumaticcaissons, winches,cables,groutinglikepneumaticcaissons, winches,cables,groutingmachineryetc.,and buildingofenablingstructures.machineryetc.,and buildingofenablingstructures.


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When I joined.When I joined.

Allthepiling workwasover.Allthepiling workwasover.

Allthepilecaps werecastexcepttheoneatlocation DPG7.Allthepilecaps werecastexcepttheoneatlocation DPG7.

Allthepier,piercaps,pedestals werecastexceptattheAllthepier,piercaps,pedestals werecastexceptatthe

location DPG7.location DPG7.

Fillingofthe backfillintherampportionshad beendone.Fillingofthe backfillintherampportionshad beendone.


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Training ScheduleTraining Schedule

11 Juneto 16 June11 Juneto 16 June Understoodthe WorkUnderstoodthe Work

Culture.Culture.

18 Juneto 21 June18 Juneto 21 June StartedCollecting DataStartedCollecting Data

aboutthe Projectaboutthe Project

21 Juneto 21 July21 Juneto 21 July Estimation WorkAndEstimation WorkAnd

SupervisionofSite (PileSupervisionofSite (Pile

cap)cap)23 Julyto 10 dec23 Julyto 10 dec Castingyard (SupervisionCastingyard (Supervision

Ofpretensioned IOfpretensioned I--Girders)Girders)


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Some Important SpecificationsSome Important Specifications

Numberofarms :Numberofarms : 7(A,B,C,D,E,FO AND FI)7(A,B,C,D,E,FO AND FI)

Totalnumberofpiles :Totalnumberofpiles : 248248

Typeofpiles :Typeofpiles : BoredcastinBoredcastin--situsitu

Diameteranddepthofpiles :Diameteranddepthofpiles : 1000 mmand 20 mresp.1000 mmand 20 mresp.

Totalnumberofpiers :Totalnumberofpiers : 5151

Numberofabutments :Numberofabutments : 66 Typeofsuperstructure :Typeofsuperstructure : InIn--situdeckwithpresitudeckwithpre--

tensioned I girdersandtensioned I girdersandRCC/postRCC/post--tensioned boxtensioned boxgirdersgirders

Numberofboxgirdersspans :Numberofboxgirdersspans : 1010 Earth workinvolved :Earth workinvolved : 10,000 m10,000 m

Steelused :Steelused : Fe 415 and Fe 500Fe 415 and Fe 500

High Tensionstrands (HT strands) : 15.2 mmdiameter(7 ply)High Tensionstrands (HT strands) : 15.2 mmdiameter(7 ply)

Bearings :Bearings : POT PTFEPOT PTFE

NumberofI girders :NumberofI girders : 144144


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Equipments Used at SiteEquipments Used at Site

NeedletypevibratorNeedletypevibrator(60 mmdia)(60 mmdia) Concretepump (56 mConcretepump (56 m/hr)/hr)

GantrygirderGantrygirder( 60 ton)( 60 ton) Transitmixer(7 mTransitmixer(7 mcapacity)capacity)


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SlumpConeSlumpCone JCBJCB

Batching PlantBatching Plant

PrestressingPrestressingPumpPump


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Pipeline Bucket (0.5 mPipeline Bucket (0.5 mcapacity)capacity)

Hydracrane( 3 ton)Hydracrane( 3 ton)


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PROJECT NO. 1PROJECT NO. 1

SUPERVISION OF SUBSTRUCTURESUPERVISION OF SUBSTRUCTURE


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Foundation : PilesFoundation : Piles

PilesarelongslendermembersthatcarryandtransferthePilesarelongslendermembersthatcarryandtransferthe

loadofthestructuretothegroundlocatedatsomedepthloadofthestructuretothegroundlocatedatsomedepth

below thegroundandtheearthsurroundingthepiles.below thegroundandtheearthsurroundingthepiles.

BoredcastinBoredcastin--situfriction RCCpilesofdiameter1000 mm.situfriction RCCpilesofdiameter1000 mm.

M35 gradeofconcrete wasusedatoursite.M35 gradeofconcrete wasusedatoursite.

Averagedepthofthepiles was 20 m.Averagedepthofthepiles was 20 m.


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Estimation of Steel in PilesEstimation of Steel in Piles

Steel quantitySteel quantity

Diaof onepile = 1000 mmDiaof onepile = 1000 mm

Clearcover= 75 mmClearcover= 75 mm

Diaofthe barusedforpilerings = 10 mmDiaofthe barusedforpilerings = 10 mm

Diaofpilering,d = 1000Diaofpilering,d = 1000-- 2*75 = 850 mm2*75 = 850 mm

Circumferenceofpilering = *d = *850 =2.669 mCircumferenceofpilering = *d = *850 =2.669 mNo. ofringsinthepile = 100No. ofringsinthepile = 100

Sototallengthof10 mm bar= 100*2.669 = 266.9 mSototallengthof10 mm bar= 100*2.669 = 266.9 m

Vertical barsVertical bars

Diameter= 20 mmDiameter= 20 mm

Lengthofonesingle barfromtopto bottomofthepile = 20.9 mLengthofonesingle barfromtopto bottomofthepile = 20.9 mNumberofthe bars = 15Numberofthe bars = 15

Sototallength = 15*20.9 = 313.5 mSototallength = 15*20.9 = 313.5 m

Total weightofsteelusedinonepile = 10/162266.9 + 20/162*313.5Total weightofsteelusedinonepile = 10/162266.9 + 20/162*313.5

= 938.8 kg= 938.8 kg

Forpilegrouphaving 4 pilestotal weightofsteel = 4*938.8 = 3755.3 kgForpilegrouphaving 4 pilestotal weightofsteel = 4*938.8 = 3755.3 kg

Forpilegrouphaving 6 pilestotal weightofsteel = 6*938.8 = 5632.96 kgForpilegrouphaving 6 pilestotal weightofsteel = 6*938.8 = 5632.96 kg


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Pile CapPile Cap

Structuralelementsthattieagroupofpilestogether.Structuralelementsthattieagroupofpilestogether.

Usedtotransmitforcesfrompierstothepilefoundations.Usedtotransmitforcesfrompierstothepilefoundations.

Atmysite I studiedtheconstructionofthepilecapnamedAtmysite I studiedtheconstructionofthepilecapnamedDPG7DPG7..

It wasconstructedtoconnectIt wasconstructedtoconnect99 piles.piles.

ConcretemixofConcretemixofM35M35 wasusedinthepilecap.wasusedinthepilecap.

TotalofTotalof93.293.2 mm ofconcrete wasusedinthispilecap.ofconcrete wasusedinthispilecap.

Heightofthepilecap wasHeightofthepilecap was1.75 m1.75 m..


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Reinforcement Detailing of the Pile CapReinforcement Detailing of the Pile Cap


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Elevation of the Pile CapElevation of the Pile Cap


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Bar bending ScheduleBar bending Schedule

Sr. no.Sr. no. BarBar

markmark

BarBar

dia(mm)dia(mm)

SpecificationsSpecifications TypeType

11 b1b1 2525 150 c/c

22 b2b2 2525 110 c/c

33 b3b3 1616 110 c/c

44 b4b4 1616 150 c/c

55 b5b5 1212 sets of 7 stirrups @

250 c/c

66 b6b6 1616 2 sets of6 bars


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Estimation of the Pile Cap DPG7Estimation of the Pile Cap DPG7

Shuttering quantity of pile capShuttering quantity of pile cap

DimensionsofthepilecapareshowninthefigureDimensionsofthepilecapareshowninthefigure

Heightofthepilecap = 1.75 mHeightofthepilecap = 1.75 m

Areaofshuttering = 2*1.75*(3388+3388+847+847+2998+3000+790)Areaofshuttering = 2*1.75*(3388+3388+847+847+2998+3000+790)

= 54.403 m= 54.403 m

Concrete quantityConcrete quantity

Volumeofconcreteto beused = ((7.693*7)Volumeofconcreteto beused = ((7.693*7)--0.5929)*1.750.5929)*1.75

= 93.2 m= 93.2 m


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Concrete Mix Proportion for Pile CapConcrete Mix Proportion for Pile Cap

Differentgradesofconcrete wereusedforthe bridgeDifferentgradesofconcrete wereusedforthe bridgeconstruction.construction.

M35M35 wasusedforthepilecap.wasusedforthepilecap.

Steelused :Steelused : Fe 415Fe 415..

Cementused : Vikramcement (OPC 53 grade)Cementused : Vikramcement (OPC 53 grade) Aggregatesused : 10 mm, 20 mmandsand.Aggregatesused : 10 mm, 20 mmandsand.

Admixtureused : FORSOCCONPLAST SP 430.Admixtureused : FORSOCCONPLAST SP 430.

Cement : Sand : Coarse Aggregate = 1 : 1.36 : 3.24Cement : Sand : Coarse Aggregate = 1 : 1.36 : 3.24

CementCement W/CW/C

RatioRatio

WaterWater SandSand 20 mm20 mm 10 mm10 mm AdmixtureAdmixture

400400

kg/mkg/m

0.370.37 148148

kg/mkg/m

684684

kg/mkg/m

592.5592.5

kg/mkg/m

592.5592.5

kg/mkg/m

0.40.4

11 0.370.37 1.361.36 1.941.94 1.31.3 0.0010.001


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Estimation of the pier capEstimation of the pier cap

AlldimensionsinmmAlldimensionsinmm

Concrete quantityConcrete quantity

Ar1 = 9477600 mm = 9.477 mAr1 = 9477600 mm = 9.477 m

Ar2 = 5.4882 mAr2 = 5.4882 m

Totalarea = 9.477+5.4882 = 14.96 mTotalarea = 9.477+5.4882 = 14.96 m

Thicknessofthepiercap = 3600 mmThicknessofthepiercap = 3600 mm

Sototalvolumeofconcreteto beused = 14.96*3.6 = 53.8 mSototalvolumeofconcreteto beused = 14.96*3.6 = 53.8 m


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AlldimensionsinmmAlldimensionsinmm

Shuttering quantityShuttering quantity

A1 = 2*14.96 = 29.92 mA1 = 2*14.96 = 29.92 m

A2 = 4203.4*3600 = 15.132 mA2 = 4203.4*3600 = 15.132 mA3 = 600*3600*2 = 4.32 mA3 = 600*3600*2 = 4.32 m

A4 = 3018.87*3600 = 10.868 mA4 = 3018.87*3600 = 10.868 m

A5 = 100*3600*2 = 0.72 mA5 = 100*3600*2 = 0.72 m

Totalsurfaceareaforshuttering = A1+A2+A3+A4+A5 = 60.96 mTotalsurfaceareaforshuttering = A1+A2+A3+A4+A5 = 60.96 m


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PROJECT NO. 2PROJECT NO. 2

SUPERVISION OF THESUPERVISION OF THE

SUPERSTRUCTURESUPERSTRUCTURE


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Pretensioned IPretensioned I--GirderGirder


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Cross section of the ICross section of the I--girdergirder


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Methodology for the construction of IMethodology for the construction of I--Girder:Girder:

1.1. Preparingtheshuttering:Preparingtheshuttering:

Bearingplates Dowel barsBearingplates Dowel bars

GroovemadeforbearingsGroovemadeforbearings

B

earingplate

dowels

grease

Dowel bars

200 mm length

Outer dia 50 mm

Inner dia 22 mm


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2.2. Loweringofthereinforcementcage:Loweringofthereinforcementcage:

Gantrygirder: 60 tonand 35 tonGantrygirder: 60 tonand 35 ton

3.3. Cablethreading:Cablethreading:

Reinforcement

cage

cables

Wedges

and

barrels


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4.4. Stressing:Stressing:

Leastcountofthepump : 5 kg/cmLeastcountofthepump : 5 kg/cm..

5.5. ClosingofthesideshuttersClosingofthesideshutters

6.6. Concreting:Concreting:

Automatic batchingplantAutomatic batchingplant

Needletypevibrator: 60 mmdiaNeedletypevibrator: 60 mmdia

Concretepump : 56 mConcretepump : 56 m/hr/hr

7.7. Deshuttering:Deshuttering:

After24 hrsAfter24 hrs

Concrete coming out of

the pipe line

CementCement W/CW/C

RatioRatio

WaterWater SandSand 20 mm20 mm 10 mm10 mm AdmixtureAdmixture

435435

kg/mkg/m

0.300.30 130.5130.5

kg/mkg/m

652652

kg/mkg/m

741741

kg/mkg/m

494494

kg/mkg/m

0.8%0.8%

Deshuttered beam


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8.8. DestressingDestressing

Usingthegrinder.Usingthegrinder.

9.9. LiftingofthegirdersLiftingofthegirders

10.10. CuringCuring

Fornext 25 daysatleast.Fornext 25 daysatleast.Hessian

clothCables

after

cutting at

top

Cables after

cutting at bottom


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Prestressed ConcretePrestressed Concrete

Prestressedconcreteis basicallyconcretein whichinternalstressesofaPrestressedconcreteis basicallyconcretein whichinternalstressesofa

suitablemagnitudeanddistributionareintroducedsothatthestressessuitablemagnitudeanddistributionareintroducedsothatthestresses

resultingfromexternalloadsarecounteractedtoadesireddegree.resultingfromexternalloadsarecounteractedtoadesireddegree.

Concreteisstrongincompression but weakintension. ThetensilestrengthConcreteisstrongincompression but weakintension. Thetensilestrength

ofconcreteisaboutoneofconcreteisaboutone--tenthofitscompressivestrength. Sinceconcreteistenthofitscompressivestrength. Sinceconcreteis

weakintension,an R.C.C beamattimesdevelopsminutecracksinconcreteweakintension,an R.C.C beamattimesdevelopsminutecracksinconcrete

ontensionsideofthe beam,even whenthestressdevelopedintensilesteelontensionsideofthe beam,even whenthestressdevelopedintensilesteel

ismuchlessthanitspermissiblevalue.ismuchlessthanitspermissiblevalue.


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Prestressing has two types:Prestressing has two types:--

1.1. PrePre--tensioning.tensioning.

2.2. PostPost--tensioning.tensioning.

PrePre--tensioning:tensioning:

Inthepretensioningthetendonsarefirsttensioned betweenrigidanchorInthepretensioningthetendonsarefirsttensioned betweenrigidanchor

blockscastonthegroundorinacolumnorunitmouldtypetensioning bed,blockscastonthegroundorinacolumnorunitmouldtypetensioning bed,

priortothecastingofconcreteinthemoulds. Thetendonscomprisingpriortothecastingofconcreteinthemoulds. Thetendonscomprisingindividual wiresorstrandsarestretched withconstantorvariableindividual wiresorstrandsarestretched withconstantorvariable

eccentricity withtendonanchorageatoneendandjacksattheotherend.eccentricity withtendonanchorageatoneendandjacksattheotherend.

Withtheformsinplace,theconcreteiscastaroundthestressedtendon.Withtheformsinplace,theconcreteiscastaroundthestressedtendon.

PostPost--tensioning:tensioning:

Inposttensioningtheconcreteunitsarefirstcast byincorporatingductsorInposttensioningtheconcreteunitsarefirstcast byincorporatingductsor

groovestohousethetendons. Whentheconcreteattainssufficientstrength,groovestohousethetendons. Whentheconcreteattainssufficientstrength,

thehightensile wiresaretensioned bymeansofmeansofjackbearingonthehightensile wiresaretensioned bymeansofmeansofjackbearingon

theendfaceofthememberandanchored by wedgesornutstheendfaceofthememberandanchored by wedgesornuts


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Stressing report:Stressing report:

GIRDERMARK P1GIRDERMARK P1--P2 (10 AND 11)P2 (10 AND 11)

Forstrand NO. 1 TO 21Forstrand NO. 1 TO 21

ELONGATION (mm) MIN. = 292 MODIFIED= 307 MAX. = 322ELONGATION (mm) MIN. = 292 MODIFIED= 307 MAX. = 322

PRESSURE (kg/cm) MIN. = 382PRESSURE (kg/cm) MIN. = 382 MODIFIED= 402 MAX. = 422MODIFIED= 402 MAX. = 422

Forstrand No. 22 and 23Forstrand No. 22 and 23

ELONGATION (mm) MIN. = 273ELONGATION (mm) MIN. = 273 MODIFIED= 287 MAX. = 301MODIFIED= 287 MAX. = 301

PRESSURE (kg/cm) MIN. = 382PRESSURE (kg/cm) MIN. = 382 MODIFIED= 402 MAX. = 422MODIFIED= 402 MAX. = 422


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PRESSURE

(kg/cm)

0 50 100 150 200 250 300 350 402 Elg Reqd 100 reading Total Elg Zerocorrection Net Elg

Strandno. 1 20 40 75 115 160 190 235 265 300 307 75 225 85 310

2 20 50 75 120 160 190 240 270 310 307 75 225 85 310

3 15 50 85 120 160 195 235 270 315 307 85 230 75 305

4 20 48 80 120 155 190 220 270 310 307 80 230 75 305

5 10 25 65 105 145 180 225 260 300 307 65 235 80 315

6 20 45 80 120 160 200 245 225 320 307 80 240 80 320

7 20 80 120 160 200 235 280 320 360 307 120 240 80 320

8 20 70 100 140 175 225 265 310 360 307 100 260 65 325

9 20 65 105 145 180 225 260 305 350 307 105 245 75 320

10 32 70 115 150 185 230 280 320 365 307 115 250 70 320

11 25 75 110 155 195 230 275 310 345 307 110 235 85 320

12 25 50 90 125 165 200 245 285 320 307 90 230 75 305

13 20 55 75 130 155 200 245 280 315 307 75 240 80 320

14 20 40 75 115 150 190 230 265 305 307 75 230 75 305

15 25 55 100 135 175 210 250 285 330 307 100 230 75 305

16 10 50 90 130 175 200 240 280 315 307 90 225 85 310

17 25 65 100 140 180 215 255 295 330 307 100 230 80 310

18 20 80 120 155 200 240 280 320 355 307 120 235 80 315

19 35 80 115 155 190 235 275 310 350 307 115 235 75 310

20 25 75 115 150 190 230 270 310 350 307 115 235 75 310

21 25 65 105 145 185 225 265 300 335 307 105 230 80 310

22 25 50 82 120 150 185 220 255 305 287 85 220 68 288

23 25 40 75 105 140 175 210 245 295 287 75 220 65 285


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Box GirderBox Girder

II--girderscan beusedonlyforthespanssmallerthan 20girderscan beusedonlyforthespanssmallerthan 20--25 morwhichare25 morwhichare

notcurved. Forcurvedspansandspans whicharegreaterthan 20notcurved. Forcurvedspansandspans whicharegreaterthan 20--25 m, box25 m, box

girdersareused.girdersareused.


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CrossCross--section of the box girder near the supportsection of the box girder near the support


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Methodology for the construction of postMethodology for the construction of post--tensioned box girder:tensioned box girder:

1.1. ConstructingthetemporaryfoundationforthetemporarystructureforConstructingthetemporaryfoundationforthetemporarystructureforsupportingthe boxgirdershuttering.supportingthe boxgirdershuttering.

2.2. Erectingthetrestles.Erectingthetrestles.

3.3. Placingtheshuttering.Placingtheshuttering.

4.4. Placingthereinforcement.Placingthereinforcement.

5.5. Passingthecablesthroughsheathingpipes.Passingthecablesthroughsheathingpipes.

6.6. Concreting.Concreting.

7.7. Curing.Curing.

8.8. Constructingthedeckslab.Constructingthedeckslab.

9.9. PostPost--tensioning.tensioning.10.10. Grouting.Grouting.

11.11. Removingthetrestles.Removingthetrestles.


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Safety RequirementsSafety Requirements

1.1. Trainingthe workers.Trainingthe workers.

2.2. Providingthefirstaid.Providingthefirstaid.

3.3. Listofnearbyhospitals.Listofnearbyhospitals.

4.4. Safetymanual.Safetymanual.

5.5. Banners.Banners.

6.6. Usingthesafetyequipments.Usingthesafetyequipments.

7.7. Providingthevehicle.Providingthevehicle.


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Problems Faced at SiteProblems Faced at Site

1.1. Sometimethestrengthofthegirdersdidntcomeontime.Sometimethestrengthofthegirdersdidntcomeontime.

RemedyRemedy::

Firstoffall,aggregates were washed beforeusingthem. It wouldFirstoffall,aggregates were washed beforeusingthem. It would

increasetherateofbondformation betweentheaggregatesandincreasetherateofbondformation betweentheaggregatesandcement.cement.

alsoifuseahighergradeofcement, I willhelpinearlyachievementalsoifuseahighergradeofcement, I willhelpinearlyachievement

ofstrength.ofstrength.

2.2. Whiletransportingtheconcrete bytransitmixers,trafficcreateda bigWhiletransportingtheconcrete bytransitmixers,trafficcreateda big

problem.problem.RemedyRemedy::

Threetransitmixers wereusedattimetoreducethetimegap.Threetransitmixers wereusedattimetoreducethetimegap.


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Problems Faced at SiteProblems Faced at Site

3.3. Powerfailureand batchingplantfailuredelayedtheprocesses.Powerfailureand batchingplantfailuredelayedtheprocesses.

RemedyRemedy::

Properandregularmaintenancehelpedtoreducethisproblem.Properandregularmaintenancehelpedtoreducethisproblem.

4.4. Whileshiftingthe IWhileshiftingthe I--girders,traffic wasaproblem.girders,traffic wasaproblem.

RemedyRemedy::

thegirders wereshiftedatnighttoavoidthisproblem.thegirders wereshiftedatnighttoavoidthisproblem.

5.5. Insummerdays, waterforcuringdriedtooearly.Insummerdays, waterforcuringdriedtooearly.

Remedy:Remedy:

Hessiancloth wasusedtoretain waterforlongerperiod. ContinuousHessiancloth wasusedtoretain waterforlongerperiod. Continuous

curing wasalsodone.curing wasalsodone.


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THANKSTHANKS


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End NoteEnd Note

This presentation is for educational useThis presentation is for educational use

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cep-construction of railway over bridge by ishan kaushal

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