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Hindustan Construction Co Ltd

Construction of Mega Bridges using Precast Segmental Methodology Mr S.K.Dharmadhikari Group Technical Officer HCC Group of Companies December 14, 2012

Mega Bridges Current Scenario

Mega Bridges by nature have significant Design & Construction Challenges

December 14, 2012

Precast Segmental Construction in Mega Bridges

Mega Bridges by nature have significant Design & Construction Challenges

December 14, 2012

Precast Segmental Construction in Mega Bridges

Mega Bridges by nature have significant Design & Construction Challenges

December 14, 2012

Precast Segmental Construction in Mega Bridges

Mega Bridges by nature have significant Design & Construction Challenges

December 14, 2012

Precast Segmental Construction in Mega Bridges

Requirements of Mega Bridge Projects


Aesthetics
Most Mega Bridges are Signature structures The Bridges dominate the local landscape The layout to be in harmony with Environment Innovative Design

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

December 14, 2012

Precast Segmental Construction in Mega Bridges

Precast Segmental construction provides solutions to these challenges and exceeds Project Requirements

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Precast Segmental Construction in Mega Bridges

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

Reduces Intermediate Piers & thus Obstructions to flow

Avoid system of staging from river bed level

Faster & economical technique as it saves time.

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Construction Planning has to be Meticulous and needs lot of Care


Delicate process and needs fine balance.

Careful and Systematic Approach needed for Segment Casting as any Imbalance can cause severe damages

Proper Sequencing of Key Construction Operations should be clearly established.

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Precast Segmental Construction in Mega Bridges

HCC A brief profile

Business Lines

Hydro
Dams & Barrages

Water Solution
Storage Dams Barrages Bulk water transmission canals

Transportation
Roads Bridges Tunnels MRTS

Nuclear & Special Projects


Nuclear Power Plants Ports

EPC
Lump sum turnkey EPC Design Build Engineering Center

Tunnels
Powerhouses

Shafts & Penstocks

Tunnels
Pipelines Pumping Stations Treatment Plants

Underground Caverns
Utility buildings & industrial structures

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Precast Segmental Construction in Mega Bridges

Our track record in Bridge Construction

Indias leading Mega Bridge Constructor


More than 5 decades 300 bridges 34 bridges in Iraq 43 bridges in Nepal Over 50 km of bridge length

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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Signature Bridges Built by HCC


Mokameh Bridge [1959]
Indias first road cum rail bridge

Varanasi Bridge
Prestressed Concrete Road bridge across River ganga Length 1296.5 M

Length - 1854 M

Godavari Rail Bridge


Indias first and only bow string arch bridge

Cable Stayed Bridge across Naini, Allahabad, UP


Length 1510 M

Length 2745 M

Kaliabhomora Road Bridge


3 km long bridge over majestic river Brahmaputra, one of the largest river in Asia

Badarpur Elevated Road


Large scale elevated highway project built in congested urban environment
Length 4.4 Km

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Construction of Mega Bridges with Precast Segmental Construction HCCs experience

Bandra Worli Sealink Indias Engineering marvel

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

To connect 2 suburbs of Mumbai Worli & Bandra

Reduction in travel time between the two suburbs

New Route

Reduction in traffic congestion

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

Savings due to Sea Link


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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Other Socio Economic Benefits


Fuel savings worth Rs. 100 Crs per Annum Savings in travel time up to 20 - 30 minutes

Reduction in Air, Noise & Sound Pollution

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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LAYOUT OF BANDRA WORLI SEALINK PROJECT


WORLI
KAGK LINK BRIDGE WORLI APPROACH

600 m BANDRA CABLE STAYED

350M WORLI CABLE STAYED

BANDRA APPROACH

APPROACH ROAD & TOLL PLAZA

MAHIM BAY
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BANDRA

Salient Features of the Project


An 8-lane bridge with 2 lanes dedicated for buses.

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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Project Implementation Entities


Project Owner : Maharashtra State Road Development Corporation Main Contractor : Hindustan Construction Co. Ltd [HCC]

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 :

Consultants to Main Contractor : VSL, Singapore


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Scope of Work in Package IV executed by HCC


449m long embankment with 20m wide promenades for 16-lane toll plaza 800m long Precast Segmental Approach Bridge on Bandra side 600m long Cable Stayed Bridge with 125m high Towers including transition spans 200m long Precast Segmental Approach Bridge between Bandra & Worli Cable Stayed Bridge

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.

Detailed Ground Stabilization was done to improve Bearing Capacity of Soil



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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
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Precast Yard

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Super Structure Construction


Girder width M Bandra Approach Bridge Cable stayed bridge 1 2nd approach bridge 18.10 No. of spans 17 Span lengths M 50

Precast Segmental Construction for the Prestressed girder :


Superstructure construction in this project is very complex due to following reasons :
Construction across deep sea. The deck girder in this project is one
amongst the heaviest.

22.70

500

18.10

50

Deck girder cross section - Triple cell


precast box girder

Worli cable stayed bridge


Worli approach bridge

22.70

250

18.10

28

50

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Segment Production Casting Yard

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Segment casting activities

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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Rebar Cage tying in the Jig

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Rebar cage lifting from the Jig

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Lifting of Rebar cage

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Rebar cage Lowering in the Cell

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Concreting Pour Sequence

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

6
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

CONCRETE PLACING SEQUENCE


TOTAL CONCRETE QUANTITY = 44.30 CUM

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Match casting

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SITE PHOTOGRAPH SEGMENT LIFTING

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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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Project Implementation is a collective responsibility

Value Engineering

Owner

Cutting Edge Technologies


Developer

Vendors

Meticulous planning

Risk Management

Contractors

Consultant

Modern Construction Management Techniques


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Regulatory Entities

World Class Project Management practices

Precast Segmental Construction in Mega Bridges

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