VOCATIONAL TRAINING REPORTSTUDY ON CONSTRUCTION OF FLYOVER

OF BRPNNL, PATNA

COSTRUCTION OF FLYOVER FROM

MITHAPUR TO CHIRIYATAND

Submitted by- Under guidance of:Vishal Prakash Er. Arvind Kumar

Enrol no.-CIV/93/13 Project engineer

Reference no.- NIT/T&P/15/159 Dt.01.10.15 BRPNNL, Patna

National institute of technology, Srinagar

ACKNOWLEDGEMENT

I would like to express my deepest appreciation to all those who provided me the possibility to complete this report . A special gratitude I give to project manager Er. Arvind Kumar,( BRPNNL) , whose contribution in stimulating suggestions & encouragement, helped me to coordinate my project especially in writing this report. Furthermore I would also like to acknowledge with much appreciation the crucial role of Er. Tanweer siddique(Bridge), Er. Rishu Singh(Q.S), Er. Ashish Kumar (Survey) and S.P. Singla construction Pvt. Ltd. Staffs for best possible guidance regarding the Project.Lastly, I would like to appreciate the efforts made by BRPNNL, Patna for providing the professional experience to the us.

Date: 22/01/2016 VISHAL PRAKASH Place: Patna

BIHAR RAJYA PUL NIRMAN NIGAM LIMITED, PATNA

CERTIFICATEThis is to certify that the project named “Study on construction of Flyover from Mithapur to chiriyantand” submitted by Mr. VISHAL PRAKASH Enrol no.- CIV/93/13 in partial fulfilment of the requirement for Bachelor of Technology Degree in Civil Engineering at National institute of technology, Srinagar And this work has not Plagiarized from elsewhere to best of my knowledge.

Date: 22/01/2016 Er. Arvind KumarProject Engineer

CONTENTS.NO TOPIC PAGE NO.

01. INTRODUCTION 05

02. CONSTRUCTION DETAIL

06

03. EXECUTION OF PROJECT

07

04. SURVEYING 08-09

05. FOUNDATION 10-13

06. SUBSTRUCTURE 14-26

07. SUPERSTRUCTURE 27-34

08. SPECIFICATIONS 35-36

09. CONCLUSION 37

10. REFERENCES 38

INTRODUCTIONBIHAR RAJYA PUL NIRMAN NIGAM LIMITED, PATNA(BRPNNL) was established on 11th June 1975 as Govt. Company.

The recent project , flyover from “mithapur to chriyantand” is also in construction under BRPNNL .

It will reduce the Traffic problems . In Patna due to excess vehicles and poor traffic system and poor road space i is necessary to construct flyovers.

The Flyover is 2x2 lane of carriage way 5.5m from Mithapur R.O.B to chiriyantand via station road (854m. Elevated +207m ramp) in Patna.

CONSTRUCTION DETAILSProject title Construction of flyover (2 lane and

1 lane) carriage way (5.5m) from G.P.O golembur to Chiriyatand flyover via station road

Project estimated cost 150 crores

Contractor S.P. Singla constructions Pvt.Ltd.

Consultant Stup Association with treetek

Client BRPNNL, Patna

Site Location Station Road

EXECUTION OF PROJECT

Sequence of construction:1. Surveying2. Analysis and design of the structure3. Piling

a. Drillingb. Pile cap Construction

4. Construction of Pier shaft and Pier cap5. Construction of Pedestal and seismic stopper6. Construction of segments and/or girders7. Launching and gluing of segments8. Construction of road over bridge

SURVEYING

TOPOGRAPHICAL SURVEY:

Topography is used to determine the position or any point in both the horizontal and vertical coordinates( Latitudes, Longitudes, Altitudes).

Survey includes Reconnaissance. Then

various maps are studied and then detailed

is done by Total station and layouts are

given on AutoCAD.

With the help of this total space for the

construction of the flyover ,no. Of lanes and

total carriage are decided.

TRAFFIC SURVEY:Is done carry out design improvement traffic system and management. Traffic forecasts predicts the future traffic levels on the road. In this flyover design is so made to meet for next 25 yrs.

TRAFFIC MONITORING:Traffic control includes CCTV and other means for monitoring traffic by local and state roadways to manage traffic flow and providing advice concerning traffic congestion.

TRAFFIC CONTROL:Traffic controllers(T.C) usually known as Lollipop men shows the their Stop/Slow sign known as STOP. A camera is also installed to detect the traffic rule violations, including speeding of vehicles.

FOUNDATIONS:

Foundations are the structures which are constructed below existing ground level. It sustains the loads coming from the sub structures and superstructures.

Bridges had to carry a big load so PILE FOUNDATION are preferred.

It is a type of foundation which where good soil are at the depth of 10-15m or soil having low bearing capacity.

In this flyover Group of piles drilled for piling:

for P1 to P14- 10 Piles (140 nos.), for P21, P23, P24, P26, P27, P29, P30, P32,33& P21A- 4 Piles(40 nos.), for P22, P25, P28, P31, P22A- 6 Piles(30 nos.), P16 to P19 – 8 Piles(32 nos.)

Total nos. Of piles =242 piles

PILE FOUNDATION

All piles have Dia. =1200mm

Depth =25m (except for P1A, P1B, P1D which have 30m piling)

M35 Grade of concrete

Piles are structure that are made up of steel, concrete, timber. They are used to build pile foundation, and use of piles is necessary to ensure safety.

• PILES are divided

in given category:

Steel piles

Concrete piles

Wooden( Timber)

piles

CONCRETE PILES

In this flyover ,Piles used are Concrete cast in-situ piles.

Types of Concrete Piles:

Pre

cast

Pile

s

These are prepared by using ordinary Reinforcements & they can be octagonal

These Piles are casted to any Length& cured.

Pre

cise

pile

s

These are Prestressed by use of high strength steel cables. Ultimate Strength= 260ksi.

After curing ,the cables are cut, thus producing high compressive force on piles.

Cas

t in

-sit

u p

iles

Piles are built by making hole in the ground and then filling it with concrete.

Two types – a) Cased, b) Uncased

PILE BORING:Digging in ground for strong foundation is Pile Boring. For excavation on top soil 2-3 m an instrument named AGAR is Placed on the top of the digging machine.

Liner is used to maintain the stability of the soil.

SOFT GROUND DIGGING HEAD:It is being made for digging clay and it is made of heavy duty high carbon. It is being is done in 3 phases:

A) EXCAVATION- Digging is done by Auger Machine( MAT) up to 28m. After digging flushed Bentonite to prevent the bore hole from collapse and installing the bottom section of temporary casing in ground by oscillating and jacking.

B)CONCRETE PLACEMENT:

Concreting is done by transit Mix Truck and it has got ability

to take 7 cubic m of concrete which are casted in foundation and settled by TREMIE Pipe.

The pile shaft will be concreted by underwater Tremie technique the pipe is inserted to the bottom of pile leaving cover of “500mm”. Concrete will be poured by tremie pipe by using concrete skip.

C) INSTALLATION OF REINFORCEMENT:

After completion of concreting, dowel bars of required length and nos. Will be installed to pile shaft and down to the predetermined level before extraction of bottom steel casing.

Reinforcements is done by steel, cage and Liner.

SUBSTRUCTURE

Sub

stru

ctu

re

Pier cap

Pier shaft

Pile cap

Pile cap:

• Formation of pile-pile cap= R.L of existing ground level-cut off

level

Pile cap is formed by combination of pile and then binding the steel followed by shuttering

• Dimension of pile caps-

for P1 to P15:

length= 16m, breadth=5.2m, height=1.8m

for P16 to P19:

length= 12.4m, breadth= 5.2m, height= 1.8m

for P21, P23, P24, P26, P27, P29, P30, P32, P33, P21A, P20A, P23A, P20

length=breadth= 5.2m, height=1.8m

for P22,P25, P28, P28, P31, P22A

length= 8.8m, breadth= 5.2m, height= 1.8m

After piling completion, soil is excavated for construction of pile cap.

For proper pile cap P.C.C. Is provided for separation from mud. At site 75mm thick PCC is carried out for control over seepage.

• Reinforcement steel in Pile cap

• Grade of concrete used

M35

S.no. BARS

1. 20mm @140mm c/c

2. 16mm @140mm c/c

3. 32mm @90mm c/c

4. 32mm @180mm c/c

5. 16mm @180mm c/c

PIER SHAFTA pier shaft is a raised structure provided mostly at the centre of the pile cap which supports the structure and transfer the several types of load to the foundation.

DIMENSION OF THE SHAFT:

length= 2m, breadth= 2m, height=

and length= 1.5m, breadth= 1.5m, height=

REINFORCEMENTS IN SHAFT:

S.no. BARS

1. 4 sides 17 NOS. 32mm

2. 4 sides 10mm @100 c/c

3. 4 sides 10mm @200 c/c

4. 16mm @100 c/c

5. 12mm @200 c/c

6. Links 10mm @200 c/c

PIER CAP-

Pier caps are the topmost structure of the substructure. Above these the superstructures (segments & girders) are placed.

DIMENSIONS OF PIER CAPS:For P1 to P14: Length= 6m, Breadth= 3.3m

For P23, P26, P29, P32, P33, P20A : Length= 5.4m, Breadth= 2.8m

For P21, P24, P27, P30, P31, P21A : Length= 5.4m, Breadth= 1.9m

For P15, P19 : Length= 11.4m, Breadth= 2.8m

For P16 to P18 : Length= 11.4m, Breadth= 2.4m

GRADE OF CONCRETE FOR CASTING

M 35 Except pier 17 ,where M 40 is used.

REINFORCEMENT USED IN PIER CAP

S.no. BARS

1. 12mm @150 c/c

2. 25 nos. 32mm ,top bar

3. 2*5 16mm

4. 12mm @150mm c/c, LV bar

5. 17 nos. 20mm, hunch bar

6. 25mm @125 c/c, Loop

7. 5 nos. 16mm @125mm c/c, Ring

8. 3 nos. 16mm @200mm c/c, Ring

9. 12mm @150mm c/c, bottom bar

10. 24 nos. 20mm @435 c/c in four layers, 6 in each layer

BEARINGS, PEDESTALS, SEISMIC STOPPERS

After the accumulation of all the reinforcements in pier cap a

surface is formed over which Bearings, Pedestals and Seismic stoppers are provided as per the design.

Seismic stopper: The current designs of seismically designs

as a second line of defence. These structures allow development of in-service moments of the deck, without transmitting loads on pier and foundation, while during earthquake they resist the entire seismic action.

Height of stopper= 1.2m

LV bars are used of 400mm

& 700mm ,16mm dia.

PEDESTALS AND BEARINGS

DIMENSIONS :

• Pedestal: Length= 700mm, Breadth= 700mm, Height= 500mm

• Bearing: Height= 137mm

A bearing is an element of superstructure which provides an interface between superstructure and sub structure. This is important because of the deformations and dimensional changes in superstructure due to Thermal expansion, seismic forces, wind loads etc. & here use POT PTFE bearing

REINFORCEMENTS :A mesh of dimension 750mm*850mm is used inside pedestal at

20mm and 100 mm from the top.

8mm @75mm c/c and12mm @100 c/c

MAKING OF PILE AND PIER CAP

PROCESS-

Messing of Pile caps, pier shafts & pier caps by different reinforced steel bars.

Welding by Arc welding method.

Shuttering and then casting(concreting).

CONCRETING OF STRUCTURES

Concrete is a composite material made up of mainly cement,

water and aggregates in definite proportion as per the grade of the concrete to achieve the desired physical properties.

After casting of the structures curing is done.

CURING OF THE STRUCTURE:-

For attaining the full strength of the concrete i.e. Compressive strength curing with water is properly done on the casted structure. It takes almost 28 to 30 days for a concrete structure to attain its strength and durability.

DIA. AND DEPTH OF THE BORE HOLES: • Diameter of the pile =1200mm

• Depth =25m (foundation level)

• Lap length =50D

• Reinforcements : 18 nos. 20mm dia.

& 18mm @150c/c

The 25m of depth consists of following

4 layers:

clay(7m)

Gravel & clay mixes(6m)

Clay(3m)

Sand gravel mix

SUPERSTRUCTURE

Structures which are above the pier cap and placed on the bearings are superstructure. Roads are further constructed over it.

SEGMENTS

• TWO TYPES: A) PIER SEGMENT, B) NORMAL SEGMENT

GIRDERS

• Used I –girder in this project

SEGMENTS:

Placed on the bearing plate. These are used to make a span of the flyover. Segments are precast made up of M45 GRADEconcrete and FE 500. These structures are posses both Tension and Compression members, so designs are made by taking in account both forces on it.

TYPES OF SEGMENT USED:• Pier segment(P.S)- These are placed at the end of the span on

the pier cap. Length of P.S is smaller than the normal segment and the anchor hole are inclined. Two P.S are used in making of the span.

• NORMAL SEGMENT- These are placed in between two P.S for making the span and anchor hole are straight. Total 9 segments are used in between two pier. Total length of span= 2*2.35+9*3.25=33.95m

S.NO. SEGMENTS LENGTH

1. PIER SEGMENT 2.35m

2. NORMAL SEGMENT 3.25m

GIRDERS:

Individual beam like structure which are separately placed on the bearings. These structures are shorter in length than segment and stressing are done precast by using cables certain in nos. Depends on the design.

In this project I-girder of 3 and 6 span are used.

LAUNCHING OF SEGMENT:

The segments are launched by launching girder or gantry girder. Beam are connected both end of the segment and pressure are applied in segments. All the segments are joined to each other by gluing.

LAUNCHING OF DECK BY LAUNCHING MACHINE:Launching machine is used to uplift the segment of the bridge all the segments are lifted at once by the use of lifter.

Number of segment between two pier:

no. Of segment= 11

weight of one segment =600T

After placing of the segments Stressing is done by use of high tensile cables, so that loads came to the cable & bridge should be stable.

JOINTING OF SEGMENT:

Mixing of both type of chemical (Nitobond Pc base thixotropic epoxy adhesive& Nitobond Pc 30 harder) is done and every time two segments are compressed(glued) to each other. After 24 hours the process checked by flushing water and leakage in anchor hole.

ANCHOR HOLE-These are present in entire segment to for stressing of it. 6 nos. Of hole are present at one side of segment. Parabolic shape.

TENSILE WIRE-It is a high tensile steel wire inserted in all 11 segment for stressing. No. Of wire depend on the design(12, 19,25etc.).

Grade of the wire is 19T15.

PRESTRESSING:

Pre-stressing means creating a permanent stress in the structure. In this process dead end are fixed with life wedge to hold the tensile wire. And the free end is fixed with hydraulic jack and force are applied approximately 369 T.

GROUTING:Grouting involves injection of cemented material in a certain ratio of cement and water for isolated pore or void space is often called Simple grouting.

Quantity of material:

o Cement :1 bag

o Water: 22 litres

o Admixtures: cibex 100

SPAN:The distance between two span is 500mm.

Total span length between two pier varies in this project

P1-P5 =34m, P6-P19=37m and rest have distance= 20m

PRECAUSTION TO BE TAKEN DURING PLACING CONCRETE

o Water should not be added to concrete during its passage from mixer to form work.

o The form work(surface) which has to receive the fresh concrete should be properly watered(cured).

o Concrete should be placed in single thickness.

o Concrete should be tapped in such a way that no honeycomb surface appear on the surface.

TECHNICAL SPECIFICATION1) Chiriyatand to Gandhi maidan:

OTHER SPECIFICATION:o Pile group -4 and 6

o A1-P1- 33.25m, P1-P17- 34m, P17-A2- 33.25m

o Length of flyover= 612 m elevated , approach(RE Panel)= 147m fill.

Diameter of pile 1200mm

Vertical & horizontal loads 250T & 30T

Depth of pile cap 1800mm

Number of Piles 110

Number of pile cap 19

Number of segment 198

2) Station to Mithapur

DIAMETER OF PILES 1800MM

VETICAL& HORIZONTAL LOADS 230T& 20T

CONCRETE USED M35(EXCEPT P17: M40)

DEPTH OF PILE CAP 1.8m

NUMBER OF PILES 267

NUMBER OF PILE CAP 38

NUMBER OF SEGMENT 182

NUMBER OF SHAFT 40

NUMBER OF HAMMER HEAD 37

CONCLUSIONThe project report involves construction of flyover and shows concern over every written word.

Bridges break down separation and foster connectedness across gulfs and rivers, between people and countries. As far back as we can see in history, human beings have used new technology to solve problem and ease their physical burdens. The distinctiveness of humans as a species is defined by their use of tools, and bridge are technological tools that aims to solve the problem of crossing and obstacle in such a way as to cut down the efforts and time needed to do so.

As the traffic problem arises in the cities due to more vehicles in the cities because of big population. This flyover change the face of the city Patna and Paved the way to progress.

REFERENCES:

• Indian bureau of standard and meteorology.

• IS Indian standards.

• IRS Indian road congress( i.e. Recommended code of practise by IRS)

• ASTM American society of testing and materials.