mega bridges using precast technology skd
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Hindustan Construction Co Ltd
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Construction of
Mega Bridges using Precast
Segmental Methodology
Mr S.K.DharmadhikariGroup Technical OfficerHCC Group of Companies
December 14, 2012
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Mega Bridges
Current Scenario
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Mega Bridges by nature have significant
Design & Construction Challenges
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Mega Bridges by nature have significant
Design & Construction Challenges
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Mega Bridges by nature have significant
Design & Construction Challenges
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December 14, 2012 Precast Segmental Construction in Mega Bridges7
Mega Bridges by nature have significant
Design & Construction Challenges
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Requirements of Mega Bridge Projects
Constructability Faster Construction Ease & flexibility inConstruction Cutting Edge Technologies Value Engineering Specialised skills & resources
AestheticsMost Mega Bridges are Signature structuresThe Bridges dominate the local landscapeThe layout to be in harmony with Environment Innovative Design
DurabilityHigh Construction Investments.High Quality & High precision Low maintenance costShould be strong & durable during its life
time.SecurityHigh value projects - potential terrortargetsDesign to mitigate the security risks
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Precast Segmental construction provides solutions
to these challenges and exceeds Project Requirements
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Precast Segmental Bridges are highly durable
structures for a number of reasons
Superstructure is Post-tensioned in both the Transverse and Longitudinal directions, placing
the bridge deck in compression at all times
This eliminates the possibility of cracking of the bridge deck and intrusion of corrosive agentsthat would damage the mild steel reinforcement and the post-tensioning in the deck
These factors combined with low-maintenance detailing of the bearings and expansion joints
enable the structure to easily achieve its design life with minimal maintenance by the owner
When building over water, efficiency is achieved through the simplification of operation.
Allows off-site casting that removes complicated casting procedures and unpredictableweather from the critical path.
Once the segments are cast, they can easily be barged to the erection site, lifted onto theerection truss using a barge-mounted crane, and assembled
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This is the most suitable method for Long Span
Bridges across River / Sea / Creeks
ReducesIntermediatePiers & thusObstructions
to flow
Avoidsystem of
staging fromriver bed
level
Faster &economical
technique asit saves
time.
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Construction Planning has to be Meticulous and needs
lot of Care
Delicate process and needs fine balance.
Careful and Systematic Approach needed for
Segment Casting as any Imbalance can causesevere damages
Proper Sequencing of Key ConstructionOperations should be clearly established.
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HCC A brief profile
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Business Lines
Hydro
Dams & Barrages
Tunnels
Powerhouses
Shafts & Penstocks
Water Solution
Storage Dams
Barrages
Bulk watertransmission canals
Tunnels
Pipelines
Pumping Stations
Treatment Plants
Transportation
Roads
Bridges
Tunnels
MRTS
Nuclear &
Special Projects
Nuclear Power
Plants
Ports
UndergroundCaverns
Utility buildings &
industrial structures
EPC
Lump sum turnkey
EPC
Design Build
Engineering Center
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Our track record in Bridge Construction
Experience Expertise Diverse Capability Precast Segmentaltechniques
Cable stayed /conventional bridges Pile / Well foundations River / Land bridges PSC / RCC / Steel /Composite bridges
Design & Construction Complex projects involving
difficult logistics Speedy construction Construction in urbanenvironment
More than 5 decades 300 bridges
34 bridges in Iraq 43 bridges in Nepal Over 50 km of bridge length
Indias leading
Mega BridgeConstructor
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Signature Bridges Built by HCC
Mokameh
Bridge [1959]
Indias first road cum
rail bridge
Length - 1854 M
Godavari Rail
Bridge
Indias first and only
bow string arch
bridge
Length 2745 M
Kaliabhomora
Road Bridge
3 km long bridgeover majestic river
Brahmaputra, one of
the largest river in
Asia
Varanasi Bridge
Prestressed
Concrete Road
bridge across River
ganga
Length 1296.5 M
Cable Stayed
Bridge across
Naini,
Allahabad, UP
Length 1510 M
Badarpur
Elevated Road
Large scale elevatedhighway project built
in congested urban
environment
Length 4.4 Km
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Construction of Mega Bridges withPrecast Segmental Construction
HCCs experience
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Bandra Worli SealinkIndias Engineering marvel
First bridge in India built on open sea
Developed completely by Indian Engineers
One of the most complex andadvanced
construction projects ever to havebeen
undertaken in India.
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Purpose
Existing Route
New Route
To connect 2 suburbs ofMumbai Worli & Bandra
Reduction in travel timebetween the two suburbs
Reduction in traffic congestion
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Situation before Sealink :
Distance from Lovegrove Jn toMahim Junction = 7.7 km
Traffic Signals = 23 Nos
Travel time:
Morning peak hour = 35 min
Evening peak hour = 38 min
Average Journey Speed = 13 kmph
Savings due to Sea Link
Direct Cost savings = Rs 14.11 per car
(fuel, tyre,wear & tear, lubricants,etc)
Travel time savings = 29 min per car
Time value @ Rs 100/ hr = Rs 48.43 / car
Hence, total savings = Rs 62.59 / car
Benefits
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Fuel savings worth Rs. 100 Crs per Annum
Savings in travel time up to 20 - 30 minutes
Reduction in Air, Noise & Sound Pollution
Reduction of Nox by 43% & CO by more than 75%
No adverse effect on Tides, Fisheries and livelihood ofFishermen
Ease in driving with reduced mental tension and overallimprovement in the quality of life
Reduced Accidents
Proper Landscaping Measures along the Approaches andPromenade along Waterfront to enhance Environment of theArea
Other Socio Economic Benefits
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Project Overview
The entire project was originally conceived as one large
project comprising, different components
In order to accelerate the overall construction schedule, the
project has been divided into five construction packages.
Package I: Construction of flyover over Love Grove junction at
Worli
Packag e II: Construction of cloverleaf interchange at Mahim
intersection
Pack age III: Construction of solid approach road from the
Mahim intersection up to the start
of the Toll Plaza on the Bandra side and a public promenade
Packag e IV: Construction of Cable-Stayed Bridges togetherwith viaduct approaches extending from Worli up to the Toll
Plaza at Bandra end, Intelligent Bridge System (IBS).
Package V: Improvement to Khan Abdul Gaffar Khan Road
HCC built Package IV, which is the
largest phase of Bandra - Worli
Sea Link.
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MAHIM BAY
APPROACH ROAD& TOLL PLAZA
BANDRAAPPROACH
600 m BANDRACABLE STAYED
350M WORLICABLE STAYED
WORLI APPROACH
KAGK LINKBRIDGE
WORLI
BANDRA
LAYOUT OF BANDRA WORLI SEALINK PROJECT
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Salient Features of the Project
An 8-lane bridge with 2 lanes dedicated for buses.
Unique bridge design for the Link Bridge
Single tower supported 500 meters long Cable Stayed Bridge at Bandra
Channel and Twin tower supported 350m Cable Stayed Bridge at Worli
Channel for each carriageway.
Modern toll plaza of 16 lanes with automated toll collection system.
An intelligent bridge with state - of - art systems for traffic monitoring,surveillance, information and guidance, instrumentation, emergency support
Development of promenade and landscaping to enhance the environment.
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Project Implementation Entities
Project Owner : Maharashtra State Road Development Corporation
Main Contractor : Hindustan Construction Co. Ltd [HCC]
Design Consultants : Sverdrup Asia Ltd. (India)Stup Consultants India Pvt. LtdDar Consultants UK in JV with Dar Consultants India
Proof Consultants : Construma ConsultancyMott Mc DonaldSchlaich BergermanTY Lin International
Consultants to Main Contractor : VSL, Singapore
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Scope of Work in Package IV executed by HCC
449m long embankment with 20m wide promenades for 16-lane toll plaza
800m long Precast Segmental Approach Bridge on Bandra side
600m long Cable Stayed Bridge with 125m high Towers including transition spans
200m long Precast Segmental Approach Bridge between Bandra & Worli Cable
Stayed Bridge
350m long Cable Stayed Bridge on Worli Side with Pylons including transition spans
1400m long Precast Segmental Approach Bridge on Worli Side
811 m long link bridge to KAGK road comprising 510m Precast Segmental Bridge and301m Cast-in-Situ Bridge
Setting up Traffic Monitoring, Surveillance, Information & Control Systems, Drainage, Street
Lighting, Signage Marking, Landscaping & Arboriculture
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P t Y d
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Precast Yard
Located on Reclaimed Land
Total storage requirement 2342 Nos Original storage 470 Nos Precast Segments.
As the area available is limited, the segments are to be stored in stacks of threelayers.
The bearing capacity of existing ground was very poor and found to be less than2 T/Sqm.
Limitation to storage capacity requirement of 2342 nos.
Detailed Ground Stabilization was done to improve Bearing Capacityof Soil
Excavation of the ground to a depth of ~ 2.5Mtrs.
Strengthening the ground using rubble soling and filling the voids with sand The soling thus done was compacted layer by layer using vibratory rollers
Total area of the Pre-cast Yard was covered with a layer of PCC
RCC Footing done to facilitate storing of segments
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Precast Yard
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Super Structure Construction
Precast Segmental Construction for
the Prestressed girder :
Superstructure construction in thisproject is very complex due tofollowing reasons :
Construction across deep sea.
The deck girder in this project is one
amongst the heaviest.
Deck girder cross section - Triple cell
precast box girder
Girder
width
M
No. of
spans
Span
lengths
MBandra
Approach
Bridge
18.10 17 50
Cable stayed
bridge 1
22.70 1 500
2nd approach
bridge
18.10 4 50
Worli cable
stayed bridge
22.70 1 250
Worli
approach
bridge
18.10 28 50
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Segment ProductionCasting Yard
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Segment casting activities
Method: - Short line match castMajor activities involved in the casting ofsegments
Rebar cage tying.
Alignment of cell.
Concreting
TPT stressing
Lifting & Storage
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Rebar Cage tying in the Jig
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Rebar cage lifting from the Jig
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Lif i f R b
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Lifting of Rebar cage
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Rebar cage Lowering in the Cell
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Concreting Pour Sequence
CONCRETE PLACING SEQUENCE
1
5.33M
22a
3.17M 3.17M
3a 3
1.26M 1.26M
44a
1.66M1.66M
5a 5
1.26M 1.26M
66a
1.66M1.66M
7a 7
4.39M 2.52M
8a 8
2.69M 2.69M
9a 9
2.19M 2.19M
10
4.28M
TOTAL CONCRETE QUANTITY = 44.30 CUM
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Match casting
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SITE PHOTOGRAPH SEGMENT LIFTING
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SEGMENT : TRANSPORTATION
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LAUNCHING TRUSS
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Relocation of Launching Trusses using 1600 MT
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Relocation of Launching Trusses using 1600 MT
capacity Barge Mounted Crane Asian Hercules
Various options examined :
1. Dismantling of the trusses at present locations & reassembling them at new locations
2. Lowering the trusses on a suitable floating craft & shift erect them.
3. Shifting the total truss using a floating crane.
Factors considered to decide on solution :
i. Limited working period available to executed the work in sea,
ii. Effect of open sea on dismantling & re-erection, etc
iii. Relocation of the trusses in one piece using a floating crane was selected as the best
option.
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Relocation of Launching Trusses using 1600 MT
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g gcapacity Barge Mounted Crane Asian Hercules
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Project Implementation is a collective responsibility
Owner
Developer
Consultant
RegulatoryEntities
Contractors
Vendors
Value Engineering
Meticulous planning
ModernConstructionManagementTechniques
Cutting EdgeTechnologies
Risk Management
World ClassProjectManagementpractices
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December 14, 201247 Precast Segmental Construction in Mega Bridges