Mega Bridges Using Precast Technology SKD
Mega Bridges Using Precast Technology SKD
Construction of Mega Bridges using Precast Segmental Methodology Mr S.K.Dharmadhikari Group Technical Officer HCC Group of Companies December 14, 2012
Constructability
Durability
High Construction Investments. High Quality & High precision Low maintenance cost Should be strong & durable during its life time.
Faster Construction Ease & flexibility in Construction Cutting Edge Technologies Value Engineering Specialised skills & resources
Security
High value projects - potential terror targets Design to mitigate the security risks
Precast Segmental construction provides solutions to these challenges and exceeds Project Requirements
Precast Segmental Bridges are highly durable structures for a number of reasons
Superstructure is Post-tensioned in both the Transverse and Longitudinal directions, placing the bridge deck in compression at all times
This eliminates the possibility of cracking of the bridge deck and intrusion of corrosive agents that would damage the mild steel reinforcement and the post-tensioning in the deck
These factors combined with low-maintenance detailing of the bearings and expansion joints enable the structure to easily achieve its design life with minimal maintenance by the owner
When building over water, efficiency is achieved through the simplification of operation. Allows off-site casting that removes complicated casting procedures and unpredictable weather from the critical path. Once the segments are cast, they can easily be barged to the erection site, lifted onto the erection truss using a barge-mounted crane, and assembled
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This is the most suitable method for Long Span Bridges across River / Sea / Creeks
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Careful and Systematic Approach needed for Segment Casting as any Imbalance can cause severe damages
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Business Lines
Hydro
Dams & Barrages
Water Solution
Storage Dams Barrages Bulk water transmission canals
Transportation
Roads Bridges Tunnels MRTS
EPC
Lump sum turnkey EPC Design Build Engineering Center
Tunnels
Powerhouses
Tunnels
Pipelines Pumping Stations Treatment Plants
Underground Caverns
Utility buildings & industrial structures
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Experience
Expertise
Design & Construction Complex projects involving difficult logistics Speedy construction Construction in urban environment
Diverse Capability
Precast Segmental techniques Cable stayed / conventional bridges Pile / Well foundations River / Land bridges PSC / RCC / Steel / Composite bridges
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Varanasi Bridge
Prestressed Concrete Road bridge across River ganga Length 1296.5 M
Length - 1854 M
Length 2745 M
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First bridge in India built on open sea Developed completely by Indian Engineers
One of the most complex and advanced construction projects ever to have been undertaken in India.
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Purpose
New Route
Existing Route
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Benefits
Situation before Sealink :
Distance from Lovegrove Jn to Mahim Junction = 7.7 km Traffic Signals = 23 Nos Travel time: Morning peak hour = 35 min Evening peak hour = 38 min Average Journey Speed = 13 kmph
Direct Cost savings = Rs 14.11 per car (fuel, tyre,wear & tear, lubricants,etc) Travel time savings = 29 min per car Time value @ Rs 100/ hr = Rs 48.43 / car Hence, total savings = Rs 62.59 / car
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Reduction of Nox by 43% & CO by more than 75% No adverse effect on Tides, Fisheries and livelihood of Fishermen Ease in driving with reduced mental tension and overall improvement in the quality of life
Reduced Accidents
Proper Landscaping Measures along the Approaches and Promenade along Waterfront to enhance Environment of the Area
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Project Overview
The entire project was originally conceived as one large project comprising, different components
In order to accelerate the overall construction schedule, the project has been divided into five construction packages.
Package I: Construction of flyover over Love Grove junction at Worli Package II: Construction of cloverleaf interchange at Mahim intersection HCC built Package IV, which is the largest phase of Bandra - Worli Sea Link.
Package III: Construction of solid approach road from the Mahim intersection up to the start of the Toll Plaza on the Bandra side and a public promenade Package IV: Construction of Cable-Stayed Bridges together with viaduct approaches extending from Worli up to the Toll Plaza at Bandra end, Intelligent Bridge System (IBS).
Package V: Improvement to Khan Abdul Gaffar Khan Road
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BANDRA APPROACH
MAHIM BAY
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BANDRA
Unique bridge design for the Link Bridge Single tower supported 500 meters long Cable Stayed Bridge at Bandra Channel and Twin tower supported 350m Cable Stayed Bridge at Worli Channel for each carriageway.
Modern toll plaza of 16 lanes with automated toll collection system. An intelligent bridge with state - of - art systems for traffic monitoring, surveillance, information and guidance, instrumentation, emergency support Development of promenade and landscaping to enhance the environment.
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Design Consultants :
Sverdrup Asia Ltd. (India) Stup Consultants India Pvt. Ltd Dar Consultants UK in JV with Dar Consultants India
Construma Consultancy Mott Mc Donald Schlaich Bergerman TY Lin International
Proof Consultants :
350m long Cable Stayed Bridge on Worli Side with Pylons including transition spans 1400m long Precast Segmental Approach Bridge on Worli Side 811 m long link bridge to KAGK road comprising 510m Precast Segmental Bridge and 301m Cast-in-Situ Bridge
Setting up Traffic Monitoring, Surveillance, Information & Control Systems, Drainage, Street Lighting, Signage Marking, Landscaping & Arboriculture
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Precast Yard
Located on Reclaimed Land
Total storage requirement 2342 Nos Original storage 470 Nos Precast Segments. As the area available is limited, the segments are to be stored in stacks of three layers. The bearing capacity of existing ground was very poor and found to be less than 2 T/Sqm. Limitation to storage capacity requirement of 2342 nos.
Excavation of the ground to a depth of ~ 2.5Mtrs. Strengthening the ground using rubble soling and filling the voids with sand The soling thus done was compacted layer by layer using vibratory rollers Total area of the Pre-cast Yard was covered with a layer of PCC RCC Footing done to facilitate storing of segments
December 14, 2012 Precast Segmental Construction in Mega Bridges
Precast Yard
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22.70
500
18.10
50
22.70
250
18.10
28
50
30
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Method: - Short line match cast Major activities involved in the casting of segments
Rebar cage tying. Alignment of cell. Concreting TPT stressing Lifting & Storage
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4.39M
2.19M
2.69M
4.28M
2.69M
2.19M
2.52M
7a
9a
8a
10
6a
1.66M 1.66M 1.66M
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1.66M
5a
1.26M
4a 3a
1.26M
4 3
1.26M
5
1.26M
2a
3.17M
1
5.33M
2
3.17M
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Match casting
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SEGMENT : TRANSPORTATION
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LAUNCHING TRUSS
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Relocation of Launching Trusses using 1600 MT capacity Barge Mounted Crane Asian Hercules
Various options examined :
1. 2.
3.
Dismantling of the trusses at present locations & reassembling them at new locations Lowering the trusses on a suitable floating craft & shift erect them.
Shifting the total truss using a floating crane.
Factors considered to decide on solution : i. ii. iii. Limited working period available to executed the work in sea, Effect of open sea on dismantling & re-erection, etc Relocation of the trusses in one piece using a floating crane was selected as the best
option.
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Relocation of Launching Trusses using 1600 MT capacity Barge Mounted Crane Asian Hercules
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Value Engineering
Owner
Vendors
Meticulous planning
Risk Management
Contractors
Consultant
Regulatory Entities
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