Post on 20-Feb-2017
Department Of Civil Engineering
Rajapeth ROB (Non railway portion … Dastur nagar side ...
Submitted by: Guided by:Mr. Akash S. Kolamkar (4CA44) Prof. A. R. Bijwe
Department Of Civil Engineering
Rajapeth ROB (Non railway portion … Dastur nagar side ...
Submitted by: Guided by:Mr. Akash S. Kolamkar (4CA44) Prof. A. R. Bijwe
Department Of Civil Engineering
“Rajapeth ROB”(Non railway portion)
… Dastur nagar side... Under the guidance of
Prof. A. R. Bijwe
Content’s Introduction When I joined…. Some important Specification’s Structural drawing’s Concrete work’s Curing Stressing Bearing’s Traffic operation’s Problems Faced at Site Safety measure’s When I Resigned…. References Animated Presentation of Rajapeth ROB.
Introduction
a) When gate is closed b) when gate is opened
Amravati railway station is placed just side of Rajapeth crossing hence daily
many trains are crossed over this section.
Therefore, every times need to closed it, hence traffic operation are completely
stopped , and possibility of accidents are increased.
After train will crossed over this section , then large traffic complication should be formed.
Some people are try to cross this section under
the gate, then possibility of accidents was not
ignored.
Sometimes , emergency services like
Ambulance , Fire services are also need to stop
there.
Possibility of accidents was increased between
traffic from ‘Ram mandir to Rajapeth’ and traffic
from ‘Rajapeth square to Shankar nagar’
Rate of accident should be high with in this
area, because of this project reduction of
accidents are possible.
a) People’s try to cross under section
b) Traffic after crossing this section
Current status of crossing
b) Important information about project
Name of project :- Design & Construction of Approaches (Non Railway portion) to
ROB in of level Crossing No.S-4 on BD-AMI Section, Near Rajapeth,Amravati.
Amount of Contract :- 4053.28 lakh’s
Date of work order :-01/10/2015
Period of Completion :- 24 Month’s (Upto 30-09-2017)
Defect Liability Period :- 60 Month’s
Name of Client :-
Amravati Muncipal Corporation (AMC).
Name of Contractor :-
M/S. Chaphekar and company, Nagpur.
Project Management Consultant (PMC):-
S.N. Bhobe and Associates Pvt. Ltd. Mumbai.
Designer and provider of Stressing Materials:-
Dynamic Prestress (I) Pvt.Ltd. Nashik.
c) Authorities
Designer of steel :-
Crescent Engineer’s Mumbai.
Material testing & designer:-
Geotech services Pvt. Ltd, Nagpur
Designer of bearing’s:-
Tefcon Bearing Pvt. Ltd Pune.
D ) General Arrangement Drawing of Project The G.A.D. plan whose
show arrangement of bridge
i.e name of arm, name of
pier , name of abutment
,type of bearing and there
location, slope , and general
instruction also.
This is the first drawing of
Rajapeth ROB.
‘C’ Arm
‘A’ Arm
‘B’ Arm‘D’ Arm
e ) Constructional Area’s
Area whose
highlighted with yellow
color this area was
construction by
another company. For
that work a separate
tender should be
invited by IRCTC.And remaining construction was done by
m/s Chaphekar and company Nagpur.
The whole work is
divide in two parts :-
1) railway portion
2) Non Railway portion.
f ) Some important Specification’s
All units is in:-
1)dimension – MM 2)Levels -M
Clear cover to R/f :-
for all type of concrete work use only 40 mm cover.
Grade of steel Fe 500
Laps :-
1)min . Lap length 50 X dia of bar.
2)Lapping shall be staggered suitably.
3)Not more than 25 % of bars shall be lapped at one section.
Slope for ‘C’ arm is designed as 1 : 25.64 ( 1 M = 39 MM )
When I joined…...
I will joined on this project as an designation of assistant site engineer on ‘C’ arm at Dastur
nagar side , when I join there then following work should be completed :-
The foundation of CA-02 , CP-10 , CP-11 , CP-09 should be done. At ‘C’ Arm of
Dastur nagar side.
The pier cap and pedestal of CA-02 , CP-11 , CP-10 are already casted.
The bearing at CA-02 , CP-11 , CP-10 are fixed.
Cable pipe’s are laid at there position .
The diaphragm of CA-02 and CP-10 are completely casted.
Bearing plate’s are fixed but clamp should not be opened.
Continuing the Process of inserting cable’s in pipe.
Continuing the work of fixing formwork and reinforcement of soffit & rib .
a) PSC Girder at Support
Pier 1800 dia.
Anticrash Side Barrier
PSC GirderBearing
Deck SlabRib
Soffit RCC Pedestal
Pier Cap
RCC) Depth Foundation (7000X5500X2000
PCC 150 thick
Structural drawing’s (CA-02 to CP-10) 60 m only
Drawing of PSC Girder at Support
Actual Site Photograph of
PSC Girder at Support
Captured on 19 06 2016
a) Pier (CP-10) b) Abutment (CA-02)
Pier 1800 dia.
PSC Girder
Pier Cap
Diaphragm at support
abutment
bearing
End block
Abutment(CA -02)
Pier (CP-11)
Pier (CP-10)
b ) Showing Plan & C/S of PSC Girder C/C Bearing of 30 MT & 29 MT @ Arm “C” from CA-02 to CP-10
c ) Reinforcement detail in PSC Box Girder at center
d ) Reinforcement detail in PSC box Girder at Intermediate Support
e ) variation in width of Rib reinforcement
60 m span
End blockCA-02
End blockCP-10
f ) detail’s of Anticrash barrier
Barrier’s Rebar16 mm dia. bars
Drain water collector.
Anticrash barrier is designed to restrain vehicles
from crashing off the side of a bridge and falling onto
the roadway.
While barriers are normally designed to minimize
injury to vehicle occupants, injuries do occur in
collisions with traffic barriers.
It keep vehicles within their roadway and prevent
vehicles from colliding with dangerous obstacles such
as buildings, walls or large storm drains.
This bar provided for holding the formwork of
Anticrash barrier.
a ) Grade of Concrete to be used in Concreting
RCC Abutment - M-35
RCC Pier - M-35
RCC Anticrash Barrier - M-40
RCC Deck Slab - M-40
Pedestal - M-45
Foundation of
Abutment and pier - M-30
Pier cap - M-30
Leveling coarse - M-25
Concrete work’s
concrete
b ) Ready Mix Concrete Plant
RMC plant is located at Shankar nagar . Just 10
min. travelling Distance from Site.
This area say as “Camp”
All the worker’s are lived at
camp. b) Operating panel
Sand Aggregate
Supply of cement
Discharge ofconcrete
Ready-mix concrete is
concrete that is manufactured in
a factory or batching plant,
according to a set recipe, and
then delivered to a work site by
truck mounted in transit mixers.
a) RMC Plant
C ) Transportation of concrete Transportation of concrete
should done by Transit Mixer’s (TM)
The capacity of TM is 6 m3
Maximum rotation speed of TM is
up to 21 RPM.
TM Should be present on site within
10 min.
Company operate 4 transit mixer’s
Within four two mixer’s from “Tuli
Concrete movers”
And another two mixer’s are own by
Company .Transit Mixer
d ) Concrete testing
Slump cone test appratus
i ) Slump Cone test
The value of slump cone test
should not be less than 25 MM and
more than 75 MM.
Slump cone test should be perform
both at plant and site .
Tamping rod 16 mm dia.609.6 mm in length
Slump should be
recorded with time also .
This test should be perform
under the execution of
company’s engineer and PMC
engineer .
When transit mixer is present on
site . Then firstly slump cone test was
performed to check workability of
concrete .
ii ) Compressive Strength of concrete
b) Concrete cubes
After slump cone test . Iffound satisfied result then cubes should be filled.
For every TM six cubes to be filled. from this six cube , Three cube’s are sendto PMC and remaining cubes send toAMC Laboratory at Prashant nagar .
Both of slump cone test and filling of cube should be done under execution ofcompany’s engineer and PMC’s engineer.
A separate record should be maintain onsite which include’s 1) portion of construction2) grade of concrete3) time when slump perform4) value of slump (both plant and site)7) no. of cube’s filled and many more.
a) Universal testing Machine
Concreting on 09 06 2016 for PSC Girder’s
e ) Movement of concrete on site
After testing of concrete , if
slump is maintained, then concrete
will be allow to concreting work .
Otherwise TM will be returned.
Concrete pump.(56 m³/hr)
Pipe for transporting Concrete.
f ) Placing of concrete
Pipe should be directly placed on formwork where concrete is
required .
If the pipe is placed at there
position then concrete pump give
Stroke to Discharge the concrete
from pipe at there location .
Concrete coming out of the pipe line
g ) Compaction of concrete Compaction of concrete is the process
adopted for expelling the entrapped
air from the concrete.
Compaction of concrete is done by
using electric Vibrators .
This is a type of needle vibrator .
This vibrator is operated by
electrically .
Company have seven number of
vibrator’s .
In them five are electrically
operated and two are operated by
Diesel engine .
h ) finishing This is last process of concreting , it’s
need for slab , soffit. And not need for
web concreting. After vibrating the
surface should be make well leveled and
give necessary slope under execution of
engineer.
Actual Photograph .Captured on 09 06 2016
Concreting of rib
Concrete is
fill in rib up to
this level only .
and remaining
concreting
should be done
at the time of
concreting of
deck .
Diaphragm
End block must be cast beforecasting the rest of the
bridge girder.
Curing Method of Curing is select
as per situation , but try to
make a better curing for
newly casted member.
Curing by Gunny bags should
be preference For pier ,
abutments & soffit also .
Ponding method are select
for curing the deck slab.
And when both
of these curing
method are not
applicable then
manually curing
should be
preferred.
a) Manual curing
c) Ponding method
Stressing Stressing of all cables should be done after 10 days of concreting.
But not before the concrete has attained a works cube strength of 28 Mpa.
Follow the sequence of cable stressing cable no:- 1,5 then 3,7 and 2,6
Cable shall be stressed from both ends simultaneously.
The values of extensions given in the cable extension chart are applicable at
each end.
Initial slack should be eliminated while measuring the extension.
Stressing should be continued till the desired extension is reached.
The cables shall be grouted immediately after all the cable’s are
stressed.
The grouting shall be done according to I.R.C.18
Cable’s nos. 4 & 8 are dummy cable’s
The slip at each end shall not Exceed 6mm.Stressing
Abutment (CA-02)at Dastur nagar
This Cable’s should be open for Stressing.
The hole provided for filling pipe by cement Slurry ,After Stressing.
Situation on 09th June 2016
a ) One side for stressing
Grout tube
Prestressing has two types:-1. Pre-tensioning. 2. Post tensioning
On Rajapeth ROB the post-tensioning method useas method of stressing.
1 cable orDummy
Abutment (CA -02) Dastur nagar side Situated on 09th June 2016
b ) No. of stressing cable’s
If incase some problem was standingat time of stressing then dummy cable should
be used.
19 cable’sNO. 02
1 cableor
Dummy. NO. 04
14 cable’s NO . 03
19 cable’sNO. 06
14 cable’sNo. 07
1 cableor
DummyNO. 08
19 cable’sNO. 01
19 cable’sNO. 05
The Cable’s should be Covered by this pipes , for protection of cable
from concrete and easy movement of cable’s at time of stressing.
After stressing this pipes are completely fill by cement slurry .
Total 8 pipes are provided at both sides.
In case of interference of rebar & the cable duct ,the rebar shall be
adjusted or kinked away to clear the interference.
c ) Protection of cable’s
Pipe’s in rib
d ) Components of Stressingi ) Wedges & Anchor Head’s
wedges Anchor head
Cables are locked using the wedges and barrels. These wedges and barrels provide such arrangement that cable can come out of it, but can’t go back.
a) Sheet for components of stressing & its location By Dynamic prestress Pvt.Ltd
b) Arrangement’s
ii ) jack
Jack are use for stressing the cable’s
from one end and same jack should be
placed at another end.
Jack’s are lift by using cranes.
This steel pipe’s are provided for
easily Inserting the cable’s in anchor
head.
a) Specification of jack used.Specification’s by manufacturer.
b)steel pipe’s c) Jack
iii ) location of cable’s
Pipes Grout tube
Bearing plateCables
a) Anchor head
Wedge’s
Stressing block
trumpet
Wedge’s
b) Prestressing system conewith recess Dimension c) Arrangement's
iv ) Prestressing pump
Monostrand hydraulic jack
Cables
Wedges and barrels
Prestressing pump
Prestressing pump are displaying that how many
pressure is applying to cables for stressing.
Pressure is given at same time form both sides of bridge.
Pressure is applying after interval of every 50 kg/cm2
points and also measure the elongation of both
side cable’s.
Elongation at both end should
be restrictly same.
Least count of the
prestressing pump : 5 kg/cm².
e ) Cable Profiling in PSC girder’s
Normally in post-tensioning one
side should be fix and another side
will be stressed, but on Rajapeth
ROB “cable profiling” should be
provided hence both side stressing
should be needed.
Cable Profiling in girder
f ) Location of cable’s in center of span
Cable Profiling in girder
g ) after stressing work
After stressing wedges are lock the cable’s at anchor head.
Removed the jack from cable’s.
And remaining cables are cut except 50 mm distance
from anchor head.
Whole block are packed by concrete, only grout tube having
25 mm pipe are carried out from this concreting for filling
slurry in pipe.
h ) Grouting work
Grout is a particularly fluid form of concrete.
Grout is generally a mixture of water, cement, sand,
Grouting can be defined as the filling of duct, with a material that that provides an
anti-corrosive alkaline environment to the prestressing steel and also a strong bond
between the tendon and the surrounding concrete.
For grouting work a separate grout tube
should be provided.
Grouting instrument
h ) diff. between before and after stressing .
Grout tube
b) After stressing worka) Before stressing work
Open for Grout tube
Surface filled by concrete
Bearing’s The bearing whose use in Rajapeth ROB these are
designed and provided by Tefcon Bearing Pvt. Ltd Pune.
Bearing’s are designed for 1)Design load :- 1860 KN , 2)Dead load :- 857 KN , 3) Hori. load :- 186 KN
PTFE Bearing are very sensitive for sliding due to very low coe. Of friction between PTFE and SS surfaces. Hence it is very essential to insert Wooden blocks between the girders and pedestals after installation of bearing . These wooden blocks should be removed when the bridge is open to traffic.
When bearing was send from manufacturer then the both top and bottom surface of join by weld ,this says as clamp. This clamp was removed after installation of bearing at there position.
Once when this bearing are received at plant, and company engineer are try open this ,then it’s opened but its not possible to again closed it , then finally send it to the manufacturer for repairing.
Material in contact with bearing :-1)top (soffit) – M40 2) bottom (pedestal) – M45
Clamp
a ) Sheet of free bearing
Sheet of bearing By Crescent engineer’s Mumbai
b ) type’s of bearing
Clamp
POT plate
Bearing’s are divide into two type’s1) fix end bearing 2) free end bearing
This is a type of fix bearing.
POT plate
This is a type of free bearing. Free in longitudinal direction. PTFE means Poly tetra fluro ethylene.
PTFE Base
A ) Fix end bearing B) Free end bearing
c ) Location of bearing’s in bridges
Pedestal
Free Bearing
PSC Girder
Free bearing’s in CA-02
Traffic operation’s Diversion plan when gate will closed during period of construction
Diversion plan of traffic during construction period .
This fig. shows
traffic diversion plan
during period of
construction , when
gate will closed.
This plan give’s
diversion option for
traffic without
crossing gate , with
safe traffic movement.
Problems Faced at Site… Due to construction site is in main area of Amravati . Hence large traffic problem
should be faced.
Very small space are remaining for movement of traffic , then traffic should be
congested at just side of site, Hence main problem stand as safely movement of
traffic .
One accidental moment I would like to share with you :-
at the time of concreting of rib , work is going to complete but because of TM will
empty and some minute’s are remaining for new TM , within this period concrete will jammed in pipe ,
and concrete pump give stroke of concrete , but concrete will jammed, then accidentally last pipe
whose completely filled with concrete this is forcely throw on main traffic road , luckily at that time
intensity of rainfall is very high , hence there have no traffic on road , and no anyone get injured.
Safety measure’s Providing the first aid.
Banners.
Providing the vehicle.
Using the safety equipments.
Minimum access for public in inside of project.
Training the workers.
All safety measure under execution of PMC officer.
Watchman’s are appointed to operate movement of traffic in construction
area, on the day of concreting.
Service road whose nearby site was repaired by company.
When I Resigned….
The whole work are stopped for one month between 11 July to 16 august.
Casting of all diaphragm’s should be done , within the span between CA-02 to CP-10.
Concreting of soffit are complete for 60 m span.
Concreting of rib should be done.
Pier of CP-09 & CP-08 are casted upto the level of pier cap.
Deck slab from CA-02 to CP-10 are casted with cantilever portion.
Stressing of all eight pipe cable’s are completed with grouting.
Clamp of all bearing’s are opened & wooden block are removed .
Cutting of cable’s except 50 mm and concreting of block should be done.
Reinforcement are placed for casting of anticrash barrier’s , it’s base are already fix to
concrete of deck with it’s reinforcement.
Conclusion Construction of the project link will provide an additional fast
and Safe moving outlet from the Dastur nagar & Shankar nagar to
the badnera road and thereby providing much needed relief to the
congested traffic. The entire project was executed by Amravati
municipal corporation .
Because of these project traffic movement of traffic will flow
without any Disturbances.
The rate of accident’s are reduced up to lowest amount.
References
I will work on Rajapeth ROB during period of 10th of June to 10th of July as
assistant site engineer.
Structural drawings submitted by Crescent Engineer’s Mumbai.
Official photograph’s of project.
www. Wikipedia. Com
A Textbook of Concrete Technology by M. S. Shetty.
A Textbook of Pre-stressed Concrete by N. Krishna Raju.
Animated Presentation of Rajapeth ROB
Rajapeth project.mp4
Thank you…Quarries ???
ASeminar Presented
by Mr. Akash Surendra Kolamkar
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