PROJECT WORK

Construction of Bridge no 352 (6 x 30.50M PSC Box Girder)

Of (Daitari – Keonjhar – Banspani) B.G. Rail link Project
By
K.K VERMA, XEN/C/S.E.C.Rly.
D.V.V.SATYANARAYANA, AXEN/C/E.Co.Rly.
Y.SUBBAYYA SASTRY, AXEN/C/S.C.Rly.
N.S.BUNDELA, ADEN/S.E.C.Rly.

(Of Session no 811 Integrated Course)

UNDER THE GUIDANCE OF

SRI VIVEK BUSHAN SOOD
COURSE DIRECTOR, IRICEN. 1

15-04-2008
 SALIENT FEATURES OF SUPER STRUCTURE
• LOCATION : Bet. Sagadapata – Tangariapal
of DKB Project.
• KM : 142/ 6 - 8
• SPAN : 6 X 30.50M
• SUPER STRUCTURE : PSC BOX GIRDER
• LOADING : HMLS
• LENGTH OF GIRDER : 33.00M
• WIDTH OF GIRDER : 3.00M
• HT.OF GIRDER : 3.00M
• CONCRETE QTY(Each) : 160 M3
• WEIGHT OF GIRDER : 400 MT.
• DETAILS OF PSC : 24 DUCTS of 12T/13
• HT. STEEL(Tendons) : 8.50 M.T
• REINF.STEEL : 15 M.T.
• BEARINGS : ELASTOMERIC(750 x 550 x95 mm) 2
 LAUNCHING SCHEME

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SEQUENCE OF CONSTRUCTION OF BRIDGE NO 352

SUB STRUCTURE EARTH WORK SUPER STRUCTURE

CASTI NG BEDS
FOUNDATIONS
ON A-2 SIDE

CASTI NG OF PSC
RCC SUBSTRUCTURE
BOX GIRDERS
FABRICATION AND
LEADI NG STRESSI NG AND
RCC BED BLOCK OF LAUNCHING GIRDER GROUTI NG

LAUNCHING OF PSC
BOX GIRDERS

COMPLETION OF BRIDGE IN ALL RESPECTS 5

 EARTHWORK ON APPROACHES

• The earthwork on both approaches to be done up to

formation level

• As it is decided to cast the PSC Girders on A2 side the

formation level is to be made ready for 300 m.

• The earthwork on both sides of A1 and A2 for a length

of 80 m should be made up to top of Bed Block level i.e
3 M below formation level.

• This arrangement is required for shifting the Launching

Girder over the spans and withdrawal of same after
completion of Launching of all PSC girders.
6
 EARTH WORK ON APPROACHES
PSC Box girder and girder casting area Layout

A2 P5 P4 P3 P2 P1 A1
CASTING BEDS AREA

G1 G2 G3 G4 G5 G6

P L A N
SPACE FOR FABRICATING
AND REMOVAL OF STEEL
G1 G2 G3 G4 G5 G6 LAUNCHING GIRDER

A2 P5 P4 P3 P2 P1 A1
E L E V A T I O N 7
 PREPARATION OF CASTING BED ON
APPROACH EMBANKMENT.
• The casting beds for the PSC girders are to be made on
one end of the bridge.
• RCC M 25 grade casting bed of size 33.00M x 3.00 M x
0.30 M is provided on completed formation on A2 side.
• RCC Lifting pads on four corners of the casting bed are
provided.
• For Fabrication of Launching girder, enough space
i.e 80 M is left bet. A2 and Girder no 1 casting bed.
• In this fabrication area earthwork is carried out up to
top of bed block level i.e 3.00 m below formation level.
• After fabrication, the top of steel launching girder of size
72.00 M x 3.00 M x3.00 M, should exactly coincide with
casting bed level.
• Independent Casting beds to be prepared for all the six
8
girders with a gap of 5m as working space.
 R.C.C.CASTING BEDS &PSC BOX LIFTED
WITH JACKS

X –SECTION OF
PSC BOX GIRDER

100t Jack 100t Jack

R.C.C Casting bed with base For lifting heads 9

 CASTING OF PSC BOX GIRDERS

• The PSC girders are to be cast without ballast walls on the

casting beds by placing plain G.I sheet.
• After binding reinforcement, placement and profiling of
cable sheathing, shuttering is completed and all girders
concreted with M 45 Grade concrete.
• After concrete attaining the required strength i.e 300
kg/cm2, first stage stressing is taken up.
• Girders are to be lifted to a ht. of 100 mm with the help of
jacks to facilitate 2nd stage stressing after concrete
attaining its full strength.
• After Grouting the ducts with cement slurry, all the
girders are ready for launching.
10
PSC GIRDER WITHOUT BALLAST WALLS
READY FOR LAUNCHING

11
 CASTING SCHEME
GIRDER CASTING AREA LAYOUT
A2 P5 P4 P3 P2 P1 A1

G6 G5 G4 G3 G2 G1

P L A N
STEEL LAUNCHING GIRDER

G6 G5 G4 G3 G2 G1

A2 P5 P4 P3 P2 P1 A1
E L E V A T I O N 12
 WORKS TO BE ENSURED BEFORE LAUNCHING

• Abutments and Piers to be completed including bed

blocks.
• Dirt wall and fly wings of A1 and A2 not to be concreted
to facilitate movement of steel Launching girder.
• Anchor hooks to be cast in bed blocks to provide
required anchorage to Gantry portals.
• Track materials for 450M long temporary track of gauge
2.5 M to be made ready. Released CST-9 sleepers with
welded tie bars are sufficient for this purpose.
• Ballast required for a cushion of 150mm(250 cum).
• The fabricated launching girder is assembled on A-2side
approach in the launching direction.
• Track is welded on steel launching girder to a gauge of
2.5M. 13
 LAUNCHING EQUIPMENTS
• Steel launching girder of 72 m. Length
( Wt.125 M.T)
• 5 M.T winch trolley for movement of steel
launching girder
• Counterweight trolley
• Trolleys for transporting of girders - 2 nos.
• 5 M.T winch trolley(for movement of girder
trolleys)
• Hydraulic jacks - 8 nos.
• Gantry Portals - 2 nos.
• Trolley for movement of gantry columns
14
 STEEL LAUNCHING GIRDER OF 72M LONG

DIRECTION

1. Launching Girder Fabricated in Pieces of 12m long to

facilitate transportation.

2. 1st 36m length designed to bear the weight of PSC box

Girder and hence steel sections used in this portion are
heavier than remaining 36m length which is meant for
supporting and counter weight.

3. Approximate Weight of launching truss is 125 MT.

15
 5MT WINCH TROLLEY
FOR MOVEMENT OF
STEEL LAUNCHING GIRDER

16
COUNTER WEIGHT TROLLEY

During movement of launching

to next span, counter Weight trolley
should move in opposite direction
17
WINCH 5 MT CAPACITY
FOR LEADING PSC GIRDER

TROLLEYS FOR SHIFTING

OF PSC GIRDER

18
HYDRAULIC JACK
100 MT CAPACITY

19
 GANTRY PORTAL
TRACK OVER THE
LAUNCHING GIRDER

20
GANTRY TROLLEY FOR
PORTAL MOVEMENT
OF GANTRY

21
 SHIFTING OF LAUNCHING GIRDER
OVER 6TH AND 5TH SPAN
• The steel girder is pulled with the help of
power operated winch and is placed on
first two spans i.e. on abutment and
adjacent two piers.
• Rollers are placed on bank and on the
bed blocks for shifting.
• After proper position of launching
girder, remove the rollers and ensure
firm sitting of launching girder on the
bed blocks of A-2,P-5,P-4
• Gantry portals on bed blocks of A-2,P-5
are kept in expand position with the help
of gantry trolley.
• Construct dirt wall , fly wings of A-2.
• Raise the earthen bank up to the
formation level. After raising the level of
the approach bank, the track is laid on
the approach up to casting bed.
• Now the launching girder is ready for 22
launching of PSC girder.
 LIFTING OF PRECAST GIRDER
USING JACKS FOR LOADING ON TROLLEY
• The PSC Girder(G-1) is to be
lifted over the casting bed
with the help of four hydraulic
jacks of 100 T capacity each.
• Each lift is to be in stages of
100mm.
• Wooden blocks supports to be
placed underneath PSC girder.
• Supports to be provided at the
bearing location areas only.
• Jacks to be placed below the
lifting pads only.
• In successive increments PSC
girder is to be lifted to a ht.of
2.00 m over the casting beds.
• Now the PSC Girder is ready
for placement of track and
trolleys below it to facilitate 23
leading.
 LIFTING OF
PRECAST
GIRDER USING
100T JACKS FOR
LOADING
ON TROLLEY
24
 GIRDER PLACED ON TROLLEY AND SHIFTING TO THE SPAN
• Keep the PSC girder over the
hydraulic jacks placed below
the lifting heads.
• Remove the wooden blocks in
the bearing area for linking
purpose.
• Link the track below the PSC
girder .
• Place two trolleys below the
PSC girder in the bearing area.
• Rest the PSC girder over the
trolley by lowering hydraulic
jacks.
• Remove the wooden blocks and
hydraulic jacks.
• Now the trolleys are ready to
shift to the first span.
• Shift the PSC girder loaded on
trolley to the first span location
using power operated winch.
25
SHIFTING OF PSC GIRDER PLACED
OVER THE TROLLEYS TO THE
26
SPAN
 GIRDER SHIFTING TO POSITION FOR PLACEMENT

• Once the girder placed

on trolleys reaches at
proper launching
location,(Exactly over
the bearing area)lock
the trolleys.

• The gantry columns are

shifted inside to the
contracted position.

• The PSC Girders four

lifting heads are inside
the gantries but load is
still on the trolleys. 27
THE EXTENDED AND CONTRACTED POSITION OF GANTRY LEGS

Expanded Position
(before girder entry)
Contracted Position
(After girder entry)

28
 PLACEMENT OF PLATFORMS AND JACKS
ON GANTRY COLUMNS

• The PSC girder is

slowly lifted from the
trolleys and supported
on the specially
designed platforms
using 4 Nos. 100 Ton
jacks supported on
gantry columns.
• Once the girder is
loaded on the platforms
and jacks, the trolleys
are removed and sent
back to casting bed for
shifting of another PSC
girder. 29
LIFTING AND SUPPORTING OF PSC GIRDERS ON JACKS
AND REMOVING TROLLEYS

P-5 P–4 P–3

30
 FORWARD SHIFTING OF STEEL TRUSS TO NEXT SPAN
• Lower the PSC girder up to top of steel launching girder with the help
of jacks provided in the portal gantries.
• This is to increase the stability of gantry during the shifting of steel
launching girder.
• The steel launching girder is pushed forward to the next span with the
help of winch and rollers.
• Remove the rollers and ensure resting of launching girder over the bed
blocks of piers.

31
FORWARD SHIFTING OF STEEL TRUSS TO NEXT SPAN

P-5 P–4 P–3

32
LOWERING OF PSC GIRDER TO TOP OF BED BLOCK BY
350MM IN STAGE WISE

33
 LOWERING OF BOTTOM PLATEFORMS BY 350 MM
(GIRDER WILL BE SUPPORTED ON UPPER PLATEFORM)

P-5 P–4 P–3

STAGE-I 34
EXTENDING THE JACK RAM TO TRANSFER THE LOAD OF PSC
GIRDER (BY OFFLOADING THE PINS OF UPPER PLATEFORMS )
TO PINS OF LOWER PLATEFORMS THROUGH JACKS

P-5 P–4 P–3

STAGE-II 35
 LOWERING THE GIRDER BY 350 MM (BY LOWERING THE JACK RAM)
AND SUPPORTING THE UPPER PLATEFORMS ON PINS AND OFFLOADING
THE JACKS AND LOWER PLATEFORMS

P-5 P–4 P–3

STAGE-III 36
THE STAGE-I,II & III WILL BE REPEATED 1O TIMES TO
LOWER THE GIRDER IN POSITION

P-5 P–4 P–3

37
 LOWERING OF PSC GIRDER OVER THE BEARINGS
AND LINKING OF TRACK

• When PSC Girder is 500mm

above the bed block,clean the
bearing portion.
• Place Elastomeric bearings at
required position.
• Lower the jacks till PSC Girder
rests on bearings.
• Track linking is carried out on
top of PSC box girder and this
track is connected to the
approach track and track on
steel launching girder.
• Shift the gantry columns to the
next span with the help of
gantry trolley.
38
LOADING OF GANTRY COLUMNS ON GANTRY MOVING TROLLEY

P-5 P–4 P–3

39
SHIFTING OF GANTRY COLUMNS TO NEXT SPAN

P-5 P–4 P–3

40
 SHIFTING OF PSC GIRDER FOR NEXT SPAN
• Repeat the same procedure.
• Lifting PSC Girder at casting bed
• Placement on trolley
• Leading to steel launching girder
• Placement over steel launching
girder over exact bearing area
• Contraction of gantry
portals,removing trolleys
• lowering of PSC Girder upto top
of launching girder
• shifting of steel launching girder
to the next span,
• Lowering of PSC Girder and
placement over elastomeric
bearings
• linking of track over the PSC
Girder,
• shifting of gantry columns to next 41
span for balance spans.
 EXTRACTION OF LAUNCHING GIRDER
• After launching of final PSC Girder, steel launching
girder is to be led over the approach embankment of A-1
side.
• The dirt wall and fly wings on A-1 to be completed.
• The launching girder on approach embankment to be
dismantled and removed from the site.
• Balance earth work to be completed up to formation
level.
• Dismantle the temporary track .
• Ballast walls, hand railing, foot paths, trolley refuges and
wearing course, expansion joints to be completed.
• Now the bridge is ready for linking the track.
42
15-04-2008
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15-04-2008 44