MUNGER RAIL CUM ROAD BRIDGE

PROJECT

PRESENTATION

17.01.2014

INTRODUCTION

Project Name Construction of Steel Superstructure for Rail-cum-Road Bridge Across River Ganga at Munger in Bihar

Job code No. 8802

Location Between Munger & Khagaria in

Bihar Similar Bridge Across river Brahmaputra in Assam

Importance To provide a long awaited

connectivity Description Two lane Road & single Railway track Bridge Length 3.690 Km

Superstructure Welded Steel Truss (riveted joints)

LOCATION MAP

Munger Bridge

SALIENT FEATURES Employer East Central Railway, Patna

Client BBJ Construction Co Ltd, Kolkata

Contract Value Rs 375.19 Crores

Completion Period 30 months

Span Arrangement 1 x 32.6 + 29 x 125 + 1 x 32.6

Type of Superstructure THROUGH TYPE WELDED STEEL TRUSS

Weight of 125m Span 1885 MT/Span

Width/Depth of 125m Span 13.35m/18.5m

Gammon Scope 12 x 125

Quantity of Structural Steel 24770

Site Joints Riveted Ancillary Works RCC Deck, Bearing Pedestals, Exp

Joints

ERECTED SPANS

Khagaria end

Munger End

P 29

P28

ERECTION IN PROGRESS

Typical 125m Span elevation

Top Chord Members

Bottom Chord Members

Diagonals

Verticals

End Raker

Road Deck

Rail Track

Matching point of North and Sounth End

Key Technical Features

Item Features

Type of span Welded girder with riveted connection at joints

Height / Width of span 19.68m / 13.0m outside dimension

No of members in one span 417 members

No load & Dead Load camber 181.35 mm & 112.5 mm at center

Weight of one span 1885 MT

Max weight of single lift 25 MT (1st Bottom Chord after assembly)

Type of welding in members Submerged Arc Welding / MIG Welding

Type of steel being used E 250B, E 350Cu, E 450Cu (Normalized, Fully Killed)

Key Specifications

Item Code no. Item covered Steel supply IS :2062: 2006 Steel plates / Rolled section

Fabrication IRS:B1 - 2001 Fabrication

Welding IRC: WBC Metal arc welding in steel

  IRS: M-39/M-46/M-28 SAW welding /MIG welding/MMAW

  IS:9595 Metal arc welding in carbon steel

  IS:7307 (Pt-1) Approval test for welding procedures

  IS: 7310 (Pt-1) Approval test for welders

Ultrasonic Testing ASTM (SA 578/ 578M)/ IS:4225 UT of plates

  IS:4260 UT of butt welds

Riveting IS:1148 /IS:1149 Steel rivet bars / HT Steel rivet bars

  IS: 1929 Hot forged steel rivets

Painting IS:9954 Surface preparation (Sand Blasting)

  IS: 5666 Etch primer

  IS:104 / IS:2074 Zinc chrome Primer (Yellow) /(Red Oxide)

  IS:2339/IS:2590 Aluminum paints /Aluminum for metalizing

Erection IRS- B1 :2001 Erection of steel members

SCOPE OF WORK - STEELWORK

A SUPPLY, FABRICATION

Supply Steel of Grade Fe 410W & Fe 490 Unloading, Stacking Fabrication of Members at Site Workshop Trial Assembly & Dismantling Shop Riveting, where necessary Sandblasting & Metalizing/Painting Span wise Stacking

WORKSHOP

SCOPE OF WORK - STEELWORK

B ERECTION

Transportation & Pre-Assembly Erection of Truss by Cantilever

Method Field Riveting Alignment & Lowering on Bearings Grouting of Bearings Final Painting

SCOPE OF WORK – CIVIL WORK

For Entire Bridge Length Concreting of Bearing Pedestals Concreting of RCC Deck of Bridge Installation of Crash Barriers Installation of Expansion Joints Road Surfacing Road Marking

ENABLING WORKSA FOR FABRICATION Camp Establishment at Khagaria End Fabrication Workshop – 3 nos Layout Platform Establishment at Munger End (BBJ

Yard) Trial Assembly & Stacking Yard Sand Blasting & Metalizing Enclosure Feeding track

ENABLING WORKSB FOR ERECTION Fabrication of Heavy Duty Trestles Piling for Anchor Span Supports Erection Cranes Design/Manufacture Fabrication of Links/Pins Fabrication of Strengthening Members Staging for Erection/Site Joints Scaffolding for Riveting/Painting Access Ladders/Platforms/Walkways

SALIENT CONTRACTUAL FEATURES

MOBILISATION ADVANCE STAGE I

5 % of CV against BGB - 18 % interest

MOBILISATION ADVANCE STAGE II

5 % of CV against BGB - 18 % interest

PLANT ADVANCE 10 % of CV. Max 75 % of Plant cost. Hypothecation/BGB for full value of plant.

SECURITY DEPOSIT 10 % of each Bill. Max 5 % of CV.

LIQUIDATED DAMAGES

Entire amount levied by Railways if contractor is solely responsible. OR proportionate to their value of work to total value.

FAILURE IN EXECUTION OF THE CONTRACT

Performance guarantee will be encashed & SD will be forfeited.

SITE FACILITIES TO BE PROVIDED TO RAILWAY

Furnished Office, Codes, manuals, 2 vehicles, 6 computers, software, 2 printers, maintenance personnel, motor boat, walkie talkies etc.

SALIENT CONTRACTUAL FEATURES

MAJOR QUANTITIES

Mild Steel (Fe 410W) Supply – 8249 MT

HT Steel (Fe 490) Supply - 16521 MT

Mild Steel Fabrication/Erection - 7420 MT

HT Steel Fabrication/Erection - 15162 MT

Load Test of 125m Span - 3 nos

RCC M30/M35 - 12900 m3

Reinforcement - 2100 MT Supply of cement - 5779 MT Supply of Reinf Steel Fe 500 - 2205 MT Design, Supply of Exp Joints

Modular Strip Seal 125m Span - 29 nos Modular Strip Seal 32.6m Span - 2 nos

BBJ’S SCOPE OF SUPPLY

AS PER CONTRACT AGREEMENT

APPROVED FABRICATION DRAWINGS WILL BE ISSUED BY BBJ AFTER APPROVAL BY RLYS

MASTER JIGS WILL BE PREPARED AND GOT APPROVED BY BBJ. GAMMON MAY BE ALLOWED TO MAKE WORKING JIGS FROM THEM

BBJ WILL PREPARE AND GET ERECTION SCHEME APPROVED. GAMMON MAY FOLLOW

ESCALATION/STAR RATE PAYMENTSESCALATION FORMULA BASED ON BASE DATES

/INDICES

1. LABOUR R*(l-lo)/lo*0.3 Consumer price index(RBI) 15.07.2008. 143

2. MATERIAL R*(w-wo)*0.25 Wholesaleprice index-All commodities(RBI)

15.07.2008. 240

3. FUEL COMPONENT

R*(F-Fo)*0.15 Wholesaleprice index-Fuel,Power,Light & Lubricants RBI)

15.07.2008. 377.2

4. STEEL Ex works price at SAIL+ ED 01.07.2008

a. Reinforcement bars

Q*(Bs-Bso) 8 mm dia.

b. M.S.Angles Q*(Bs-Bso) 65x65x6 MM IS 2062.E250A SK

c. Plates Q*(Bs-Bso) PM plates 10 – 20 mm IS 2062 E 250A SK

d. Plates Q*(Bs-Bso) PM plates 10 – 20 mm IS 2062 E 350 cu

Not known.

e. Channels Q*(Bs-Bso) ISMC 200x75 IS 2062 E 250A SK

5. CEMENT R1*(Wc-Wco)/Wco)

Wholesaleprice index-Cement (RBI)

15.07.2008 – 222.

R – Gross value Q – cost of steel supplied during month

R1 – cost of cement consumed during month

PENALTY FOR MISSING MILESTONES

MILESTONES KEY DATES REMARKS PENALTY

Submission and approval of erection scheme for 125 M span

D + 90 days

Railways to issue GAD & Stress sheet 15 days from LOIRailways require 30 days for approval

Rs 2 Lakh per day. If contractor makes up the progress within next two key dates, then the penalty shall be reimbursed. Maximum cumulative penalty is @ 3% of CV.

Submission of fabrication drawings for 125 M span with complete Design.

D + 150 days

Railways require 30 days for approval. 50% Drawings shall be submitted from D+60 days and balance 50% drawings within D + 150 days.

Completion of Trial assembly of one 125M span & Pass by Railways.

D + 270 days.

Railways require 21 days for approval. Trial assembly to be offered with all test reports, measurements & relevant doc.

Launching of First span except placement on bearings.

D + 300 days.

Launching of Second span except placement on bearings.

D + 330 days.

Launching of Fifth span except placement on bearings.

D + 390 days.

“D” is issue Date of LOA

MOBILISATION – KEY DATES

Award of Contract by BBJ 09.04.2009 Site Mobilization started on 07.07.2009 Receipt of Shop Drawings 26.02.2010 onwards

Receipt of Steel from SAIL 04.03.2010 onwards Fabrication Agency Finalized 04.03.2010 2 no Fabrication Shops Comp 31.03.2010 Mobilization for Jigs/Fixtures 31.03.2010 Full Mobilization of Agency 31.05.2010 Completion of Piers by Rlys 30.06.2010 Scheduled Completion Date 07.11.2011 1st EOT granted till Date 31.12.2013 2nd EOT applied up to 15.06.2015

PLANTS & EQUIPMENTSEquipment No's

Hydra (8 T to 14 T Cap) 9 nos.Handling cranes 2 nos. (45 MT & 50 MT capacity)EOT cranes 5 nos. (20 MT capacity)Goliath crane 2 no. (50 MT & 20 MT capacity)Generators 7 nos. (40 KVA to 500 KVA)Jacks 10 nos. (100 to 250 MT capacity)

Plate straightening Arrangement 1 nos. (with 2 x 350 MT Jack)Distortion correction Frame 2 nos.Compressors 7 nos.Radial drill machine 15 nos. Magnetic drill machine 37 nos.Pug machine 15 nos. SAW machine for outside welding 13 nos.SAW machine for inside welding 2 nos.MIG welding sets 12nos.MMAW sets 23 nos.Flux baking furnace 4 nos. USFD machine 1 no.Angle Grinding machines 60 nos. Riveting equipment's 3 setsAutomated I-girder Assembler 1 nos. Automated I-girder Straightener 1 nos. CNC Gas Cutting Machine 1 nos. End Milling Machine 1 nos. Calibrated Inver Tape 1 nos.

Measuring Instruments/Gauges As required

Safety equipment's As required

SUPPLY OF STRUCTURAL STEEL

Study shop drawings & make cutting plan

Prepare Steel Indent/obtain from BBJ Send Requisition to HO for P.O. Pursue SAIL for supply of steel Coordinate with SAIL Patna & Fatuha

Yard Authorized Agency to lift steel from

Yard Unloading & Stacking at Yard

Contd….

SUPPLY OF STRUCTURAL STEEL

Identification & Correlation with MTC Visual Inspection & Dimension check Verification of product analysis in MTC Joint Sampling for Testing at NABL lab Verification of Physical & chemical

properties Verification of Charpy V Notch Impact Test Review of Test Results by Railways Acceptance by BBJ/Railways.

FABRICATION Commissioning of plants/equipments Transport steel from GIL Yard to BBJ Yard Make copy of Master Jigs/Fixtures Transport Jigs/Fixtures back to GIL Yard Prepare Lay Out & check with Jigs Issue steel to P&R based on cutting plan Prepare Templates for cutting of Plates Proceed with fabrication as per flowchart

FABRICATION

Broad Classification of Fabricated items

Built-up Sections Requiring Welding (62%) Top Chord, Bottom Chord, End Raker : Box Section Diagonals & Verticals : Channel Type Box; I-

Section Cross Girders, Stringers, Hangers : I-Section

Not Requiring Welding (38%) Gusset/Splice/Pack Plates – Plates Bracings, cleat angle & other Misc items – Angles Bent Gusset/Splice Plates – Plates + Bending

FABRICATION FLOWCHART FOR GUSSET/SPLICE PLATES

Issue of

Steel

Cutting Plan

Marking

Grinding

Cutting

Check for Straightness

Straightening

Tack with Jig

Finishing

Grinding

Remove JigDrilling

Sandblasting/Metalizing/Paint

APPROVAL BY RDSO

FABRICATIONFLOWCHART FOR BUILT-UP SECTIONS

Issue of Steel

Cutting Plan

Marking

Grinding

Cutting

Check for Straightness

Straightening

Fit Up & Tack Weld

Finishing

Grinding

Remove JigPlace Job on Fixture

Sandblasting/Metalizing/Paint

APPROVAL BY RDSO

Tack with Jig

Drilling

End Milling

SAW Welding

Straightness check

Straightening

LAYOUT PLATFORM

FABRICATION

FABRICATION Challenges

Avoid distortion during cutting/welding

Grinding of cut edges of thick HT Plates

Straightening during Fit up & welding SAW Welding inside box sections End Milling of Chord members Accuracy of drilling holes Achieve Camber

FABRICATION

FABRICATION

ERECTION

Cantilever erection as per Scheme by BBJ Involves two customized derrick cranes – 1st

for forward erection and 2nd for follow up work

Some members are strengthened to cater for the erection stresses.

First span (between P30 – P29) will be erected conventionally on trestle supports at all nodes

Once the camber & alignment is accepted, cantilevering of further spans starts.

Feeding of fabricated components will be by trolley at rail level

ERECTION SCHEME

Contd…..

ERECTION SCHEME

CANTILEVER ERECTION SCHEME

RIVETING High Tensile Rivets 24mm dia used at Site Joints Rivets replace temporary fasteners (bolts/drifts) A typical Riveting gang consists of five men All holes in the joint to be made fair Rivets comprise about 1.5% of the Span weight Equipments used

Compressor – Operates the forge, hammer, dolley Forge – Used to heat the rivet by pearl hard coke Tongue – Used to handle red hot rivets Hammer – Used to hammer and prepare rivet head Dolley – Used to hold rivet in position

ALIGNMENT Important to control cantilever erection To start after erection of 3 - 4 spans Involves

Jacking of entire span on Traversing base

Ensure Vertical & Horizontal Alignment

Lowering on Bearings Followed by grouting of Bearings Equipments used

Hydraulic Jacks – 500 T Cap – 9 nos Hydraulic Traversing Base – 9 nos Pack plates – As required

SAFETY CONCERN

Repeated handling of long heavy structural

Sandblasting area close to residential area

Access, staging & walkways on bridge Riveting platforms on bridge Jacking of spans Weather Condition during

cantilevering 1st Span erection on river bed

SAFETY

FINANCIAL STATUS (FORM F3)

DESCRIPTION AS PER TENDER AS PER LATEST CE

CONTRACT VALUE

a) WORK DONE 375.18 376.29

b) ESCALATION - 74.31

c) OTHERS - 0.97

d) TOTAL 375.18 451.57

B. S. EXPENDITURE 269.55 290.50

Y.S. EXPENDITURE 47.20 48.72

B.S. + Y.S. 316.75 339.22

PLANT HIRE CHARGES 6.80 6.93

B.S. + Y.S. + PLANT HIRE CHARGES 323.55 346.15

H.O. OVERHEADS 6.06 9.57

FINANCE CHARGES FOR –VE CASHFLOW 11.26

CONTINGENCIES 3.40 1.61

TOTAL EXPENDITURE 344.27 357.33

MARGINS 30.91 94.24

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