METHOD OF CONSTRUCTION OF SEGMENTAL CONCRETE BRIDGE

By , P P AMBEDKAR

Objective Of Dissertation work

Construction of segmental bridge involves use of different machineries and requires huge amount of skilled manpower. Hence the intention of dissertation is to study the Methods & techniques used in Construction of Segmental Bridge by Under Slung Method which consist of following activities. 1. Construction of Sub-structure 2. Construction of super-structure

Development of precast segmental bridge construction

First segmental bridge Second segmental bridge Segmental bridges in India

What is segmental construction

PC segments Prestressing cables

Pier

Method of construction of segmental bridge

1.Cast-in-Place Segmental Construction (Balance Cantilever method)

Bridge across the Lahn River in Germany

2. Precast Segmental Construction

Flyover at Agriculture College Pune

General design consideration

Principal Dimension of Segment W = Top Slab width D = Construction depth B = Bottom slab width L = Segment length

Construction of substructure
Cast-in-situ Pile
Detailed breakdown of activities is mentioned below
1. 2. 3. 4. 5. 6. Setting Out Removal of Overburden Driving Permanent Liner Boring / Chiseling Reinforcement Cage Lowering Concreting

1. Setting Out

2. Removal of overburden 3. Driving permanent liner

Tripod

Driving monkey

Driving cap

Liner

4. Boring/ Chiseling

CHISEL

BAILER

Excavated mud

Bailer

Removing of excavated material with help of bailer

5. Reinforcement cage lowering 6.Concreting

Chute

Funnel Tremie pipe

Major Equipment Required

1) F 35d/d winch 2) 3) 4) 5) 6) 7) Pile driving tools & accessories Tripod Generator 70 KVA Welding machine Concreting equipments Batching Plant - 4 no - 4 set - 4 set - 2 no - 2 no - 2 set - 1 no

TIME CYCLE
Sr.No. 1 2 3 4 5 6 7 8 9 Activity Road breaking/removal of top overburden/ Identification of utility services. Positioning tripod / winch Survey & setting out Permanent liner driving/ boring Chiseling(6m @ 0.1m/hour) Cage lowering Tremie Pipe lowering/flushing Concreting Removal of tripod/winch Total time for pilling There fore total time for one pile @ 20hours per day working Duration 2 days 2 hours 2 hours 20 hours 60 hours 2 hours 2 hours 3 hours 2 hours 93 hours 4.5 days

Construction Of Pile Cap

Detailed breakdown of activities is mentioned below
1. Clear area for excavation and marking

2. Exaction up to pile cap bottom level i. Excavation in soft soil ii. Chiseling in hard strata 3. Simultaneously chipping of pile 4. Preparation of bed with PCC 5. Cutting and bending and preparation of reinforcement cage 6. Shuttering for pile cap 7. Concreting

1. Clear area for excavation and marking 2. Exaction up to pile cap bottom level i. Excavation in soft soil ii. Chiseling in hard strata 3. Chipping of pile

Bottom of Pile cap

Pile chipping by jack hammer

4. Preparation of bed with PCC

Bed preparation for pile cap by laying PCC

5. Cutting and bending and preparation of reinforcement cage

Pile reinforcement bar

Tying of reinforcement

6. Shuttering
7. Concreting of pile cap
Haizen cloth for curing

Shuttering

MAJOR EQUIPMENTS REQUIRED

1. 2. 3. 4. 5. 6. 7.

JCB Excavator Dumper Breaker (Jack hammer) Bar bending and cutting machine Concrete batching plant Transit Mixer Needle vibrators (60 mm)

1 No. 1 No. 2 Nos. 1 No. 1 No. 2 Nos. 2 Nos.

TIME CYCLE
Sr.No. 1 2 3 4 5 6 7 8 9 10 Activity Waiting period for curing of pile Clearing area, survey and marking for excavation Excavation in soft soil Chiseling in hard rock Cutting and removing liner Chipping piles up to pile cap bottom level PCB) Preparation of bed with PCC as leveling course Reinforcement cutting, bending and fabricating cage Placing and fixing shuttering Concreting
Total time =

Duration 7 Days 2 Hours 12 Hours 2 Days 4 Hours 4 Days 8 Hours 1 Day 3 Hours 1 Hour
8.5 days

Construction of Pier
Job breakdown
1. Cutting, and bending of reinforcement 2. Preparation of reinforcement cage 3. Casting Pier starter 4. Erection of staging and simultaneously fixing shutters 5. Concreting of pier 6. De-shuttering and dismantling staging 7. Curing

1. Cutting, and bending of reinforcement & preparation of reinforcement cage 2.Casting Pier starter 3. Erection of staging and simultaneously fixing shutters

Pier shutter

Staging for supporting pier shutter & providing working platform at top for concreting

4. Concreting of pier 5. Curing

MAJOR EQUIPMENTS REQUIRED

1. 2. 3. 4. 5. 6. 7. 8. HM 101 Crane -1 No Bar bending and cutting machine-1 No. Concrete batching plant -1 No. Transit Mixer - 2 Nos. Concrete Pump -1 No. D.G. Set -1 No. Compressor - 2 Nos. Needle vibrators (60 mm) - 2 Nos.

TIME CYCLE
Sr. no. 1 2 3 4 5 6 7 8 Activity Cutting and Bending Reinforcement Tying and Cage Preparation Casting Starter and Curing Staging and Simultaneously Shuttering Concreting Waiting till achieving strength for deshuttering Deshuttering Curing Duration 2 Days 1 Day 2 Hrs. 1 Day 3 Hrs. 1 Day 12 Hrs. 28 Days

Total time required excluding curing =

3 days

CONSTRUCTION OF APPROCHES
Construction of approach involve two major activity that are as follows: i) Construction of Abutment wall. ii) Construction of Wing wall (Retaining wall)

Types of abutment:
Masonry abutments: RCC abutments:

R.C.C Abutments
In this case abutment wall is directly rest over raft /pile foundation. Whole abutment wall made of rich mix concrete. Abutment wall construction involves following activity:
1. Cutting, and bending of reinforcement 2. Preparation of reinforcement cage 3. Casting abutment starter 4. Erection of staging and simultaneously fixing shutters 5. Concreting of abutment. 6. De-shuttering and dismantling staging 7. Curing

RCC Abutment

Shuttering

Staging arrangement

Wing wall
The wings walls are of masonry or RCC masonry, now days wings wall are constructed with new technique that is Geosynthetic Soil Retaining wall in which precast RCC panel is used. The advantage of this construction system is given below.
1. It requires very limited construction space compared to the conventional wall systems. 2. The completed structure occupies less space compared to the conventional wall systems. 3. By using a facing of high rigidity, the stability of the wall system is increased while the deformation is minimized. 4. The geosynthetic layers are closely spaced so that a wide range of backfill can be used without affecting performance.

Component of part of GSR Wall

1.Concrete leveling Pad: 2.Precast concrete facing panels 3.Joint material 4.Geogrids 5.Backfill

Construction of Superstructure
Construction of Superstructure of segmental bridge involves two major activities that are as follows: 1) Segment Casting 2) Segment Erection

Different method of segment casting: 1)Long line casting 2)Short line casting

Long line casting

Short line casting

Segment casting involves following activities

1) Base mould preparation 2) Surveying and marking 3)Reinforcement cage leveling 4)Lowering and positioning stopend 5)Placing and fixing inner formwork 6)Concreting and finishing 7)Deshuttering of inner formwork and stopends 8)The segment used for match casting is then placed in the stacking yard and the newly casted segment is used for next match casting.

1) Pre-cast Bed Survey and Setting out of moulds as per the co-ordinates.

2) Changing/re-fixing of liner material where required and cleaning of beds.

RUBBER LINER

3) Surveying and marking

LIFTING FRAME

EOT CRANE

4) Reinforcement cage lowering:

REINFORCEMENT CAGE

5) Lowering and positioning stopend:

REINFORCEMENT CAGE

Stopend

False work

Turn buckels

Inner formwork

6. Placing and fixing innerformwork:

7. Concreting and finishing:

8. Deshuttering INF& Stopend: 9. Lifting and stacking of segments:

MAJOR EQUIPMENTS REQUIRED FOR SEGMENT CASTING

1) EOT 120T Capacity 2) Welding Machine 1 No. 2 No. 2 No. 2 Sets 1 No. 2 No.

3) Gas-cutting Equipment 3) Concreting Equipments 4) Batching Plant 5) Transit Mixer -

TIME CYCLE
Sr. No. Activity Description Time Required in Hrs. 6 1 1/2 1 8 3 24 2 46 1 Total time= 92 Hrs

1 2 3 4 5 6 7 8 9 10

Base mold cleaning, rectification of rubber liner and applying POP Survey and marking Lowering reinforcement cage Lowering and aligning stopend with jacks and knuckle bolts Placing and fixing inner-formwork Concerting and finishing Curing till deshuttering stopend Deshuttring stopend Curing till deshuttering inner-formwork Lifting and stacking segment

Segment Erection
Probably the most significant classification of segmental bridges is by method of construction. Although construction methods may be varied as ingenuity of the designers and the contractor they fall into two basic categories: 1) Cast-in-Place segmental construction. (Balance Cantilever method) 2) Precast segmental construction.

Cast-in-Place segmental construction

Segment Casting Cycle

Precast segmental construction

1)Segment erection by Crane

2) Segment erection by Winch and Beam

3)Launching Gantry (Over head method)

4)Segment erection by Under-slung method

Segment erection by Under Slung Method

Segment erection involves following activities

1. Survey and Barricading 2. Erection of EOT 3. Fabrication and erection of staging 4. Erect sliding trolley with jack arrangement 5. Launch precast segments 6. Temporary pre stressing of segments 7. Permanent pre stressing

1. Survey and Barricading 2. Erection of EOT

EOT crane of 125 tone capacity

Rail track alignment

3. Fabrication and Erection of Staging

Main girder Cribs Seating girder

Bracing
Concrete block

4. Erect Sliding Trolley with Jack Arrangement

Screw jacks arrangement with pot bearing

Main girder Tie box

5. Transportation of precast segment 6. Launch Precast Segments 7. Temporary Prestressing of Segments

Hydraulic pipe Hydraulic machine

Lifter

Mac-alloy bar

Outside temporary prestressing

Inside temporary prestressing

8. Bearing Installation

8. Permanent Prestressing

TIME CYCLE
Sr. No. 1 2 3 4 5 6 7 Activity Staging Arrangement Placing of segments Dry Matching Glue and temporary stressing Install Bearing/ grouting and waiting till attain strength Permanent pre stressing Dismantle staging Duration 1 Day 1.5 Days 0.5 Days 1.0 Day 2.0 Days 0.5 Days 2 Days Average Progress: 6 Days per span

Case Study
NAME OF PROJECT: PUNE FLYOVER AT UNIVERSITY CIRCLE & AGRICULTURE COLLAGE . SITE ADDRESS: GANESHKHIND ROAD, UNIVERSITY CIRCLE, PUNE 411 007 NAME OF CONTRACTOR: AFCONS INFRASTRUCTURE LIMITED NAME EMPLOYER: MAHARASTRA STATE ROAD DEVELOPMENT CORPORATION NAME CONSULTANT: DAR CONSULTANTS (U.K) LTD. in association with DAR CONSULTANTS (I) PVT. LTD

UNIVERSITY CIRCLE JUNCTION:

GENERAL FEATURES OF UNIVERSITY CIRCLE FLYOVER 1) Length 2) Carriageway 3) Foundation 4) Substructure = = = = 700 M between abutments Single three lane carriageway Bored cast-in situ piles resting on rock RCC Piers Segmental, Deck width 12 M

5) Superstructure =

AGRICULTURE COLLEGE JUNCTION

GENERAL FEATURES OF AGRICULTURE COLLEGE FLYOVER 1) Length 2) Carriageway 3) Foundation 4) Substructure = = = = 210 M between abutments Dual two lane carriageway Bored cast-in situ piles resting on rock RCC Piers Segmental, Deck width 16.4 M

5) Superstructure =

The pre-casting Yard includes the following:

Casting Bay Curing Yard Stacking Yard : For casting deck segments. : For curing deck segments. : For stacking deck segments.

Reinforcement Yard : For fabrication of reinforcement of all structural elements like pile, pile cap, pier, precast segment, etc. Casting, Curing & : For casting, curing & stacking of Parapet, Retaining Stacking Bay wall & Kerbs. Fabrication workshop: For fabrication of structural steel for shuttering, supportive elements & temporary works. Mechanical workshop : For fabrication of tie rod

CLASSIFICATION OF SEGMENTS
No Type End Diaphragm (ED) 1 Segment width 1.45 Location & Function ED rest on Abutment. It also has a downstand that enables it to sit on bearings. It has a wall ... It houses coupler cones for pre- stressing cables which are locked here. It is located adjacent to ED segment. ID segment rest on all the piers except expansion piers. 2.725 2.917 There are 3 nos. SS in the middle of every span. CSS segment last segment of intermediate span which has stressing CSC Segment is starting segment of next span

Adjacent to End Diaphragm (EDA) Internal Diaphragm (ID) Standard Segment(SS) Coupling segment stressing end (CSS) Coupling segment coupling end (CSC)

2.095 2

4 5 6

2.917

SEGMENT ERECTION
There are 3 types of spans to be erected i.e.:
Type A-Beginning span of each bridge unit, Type B-Internal spans, Type C- End of each unit. Type A has 13 segments to be erected with an End diaphragm at the span. And a CSS segment at the end of the span. Type B Span start with CSC segment & end with CSS segment. Type C Span start with CSC segment & end with ED segment. the start of

PLAN SHOWING DIFFERENT TYPES OF SEGMENT WITH THERE LOCATION IN SPAN A TYPE.

For erection of 16.4 m wide segment involves following activities

1. Survey and Barricading 2. Erection of EOT 3. Fabrication and erection of staging 4. Erect sliding trolley with jack arrangement 5. Launch precast segments 6. Temporary pre stressing of segments 7. Permanent pre stressing

MAJOR EQUIPMENTS DEPLOYED

1) EOT 60T Capacity 2) EOT 120 T capacity 3) Service crane PH 320 4) JCB Excavator 2 Nos. 5) Trailer of 40 T capacity 6) Trailer of 100 T capacity -1 No. 3 No. 1 No. 1 No. 2 No -

Labour required for segment erection including staging& gluing :

Welder Grinder Gas cutter Skilled labour Unskilled labour TOTAL NO. 30 = 01 = 01 = 01 = 17 = 10 =

Capacity of horizontal hydraulic jacks = 50T Capacity of screw jacks = 100T Capacity of one HT strands = 25T Stress induced in each strands = 25.26 Kg/cm2 Total stress induced in nineteen strands = 480 Kg/cm2 Total elongation of HT cables = 265mm Diameter of one stand = 15.7mm Diameter of one duct = 110mm Gluing material used = Sikadur (Component A & B) Quantity of gluing material required per joint = 70 kg Wastage of gluing material per joint = 7 kg Load carrying capacity of Bearing plate = 800T Grouting pressure = 5 Kg/cm2 Properties of gluing material given below
Gluing details Setting time Strength Mfg. by Segment Gluing Bearing Gluing 45 Min. 100 Mpa 24hrs. 1hr. in 45 Mpa 24hrs. in

Technical details

SIKA (Goa) Ltd.

SIKA (Goa) Ltd.

 Following were the main reasons to delay in the completion of project

Land acquisition problem Improper matching of segment Delay in decision making Labour strike Delay in approval of drawings from consultant Delay in diversion of utilities

CONCLUSION
After studying detail procedure segmental construction that segmental bridges posses following advantages Rapid erection of superstructure. High quality & high strength of concrete can be achieved. Whenever we need to allow traffic underneath even during construction. The structural geometry may be adopted to any horizontal or vertical curvature or any roadway super-elevation. Concrete shrinkage & creep substantially reduced. Segmental construction relatively insensitive to weather condition. Enhanced durability of bridge.

Segmental bridge reveals following disadvantages

Need for higher level of technology in design

Necessity for a high degree of dimensional control.

The possible solution to the problems discussed in the case study can be enlisted as follows:
Perfect matching of segment at site can be achieved by considering vertical & horizontal alignment of bridge profile at the time of segment casting. Whenever the segments are not matched properly considerable time is lost in chipping out the segment faces. Hence the segment casting should be done accurately in accordance with drawings.

Thank You