Annual|Reportt2015-20/16) BRIDGE & STRUCTURE RESEARCH, DESIGN & DEVELOPMENT Heavy Axle Load Operation Guidelines issued to zonal railways forinstrumentation and associated with Zonal Railways for Instrumentation of Bridges to assess the actual loadings on the bridges and to access the capacity of bridges to carry Heavy Axle Loading. In this connection, three consolidated reports forinstrumentation were issued. Development of Standard Designs Composite Girders Drawings for 12.2m and 18.3m span composite girders with HSFG bolts issued Plate Girder for DFC Loading (25tAxle Load) RDSO drawing No. BA-1006, BA-1056 & BA-1057of plate girder for BGML loading have been checked and found adequate for 25t axle load, Open Web Girder for 25tLoading Design and Drawing of 61.0m & 76.2m Open Web Girder for 25t loading with new fatigue criteria & HSFG. bolts has been completed Heavy Axle Load Operation Consultancy and Proof Checking Work "Checking of Design Document of Sone Bridge no. 531 of E.C. Railway for MBG loading from procedural point of view as per revised parameters decided by TAG = Scrutiny of Design Basis Report of Jaipur Metro Rail Corporation. = Scrutiny of Design Basis Report of Bangalore Metro Rall Corporation. = Scrutiny of Design Basis Report of Chennai Metro Rail Corporation. = Scrutiny of Design Basis Report of Mumbai Metro Rail Corporation. Guidelines forInstrumentation Guidelines issued to zonal railways for instrumentation and associated wilh Zonal Railways for Instrumentation of Bridges to assess the actual loadings on the bridges and to access the capacity of bridges to carry Heavy Axle Loading. In this connection, three consolidated reports forinstrumentation wereissued. Scrutiny of Design Basis Reports (DBR) of Viaducts of Metros Design basis Reports Scrutinized and sent to Railway Board Mumbai Metro One: (General Design Basis Report) Mumbai Metro One Load test(Approved) Bangalore Metro examined some issuesas per representation on approvalfrom RB Hyderabad Metro examined some issues as per representation on approval from RB Design Basis Reports Under Examination LMRC DMRC (Phase-tI!) Kochi Metro Rail Gandhinagar and Ahmedabad Metro (MEGA) Model DBR Model DBR (August’2014): Issued, Revised Model DBR (Ver 2.0) of February 2015: Issued Updation of Codes, Manual & Specifications as Per Current Development! Needs Indian Railway Bridge Manual (1998) A&C Slip No. 32 of Dated 12.03.2015 Regarding Roller Bearings (Replacing the existing para2222(f) A&C Slip No. 33 of Dated 21.03.2016 Regarding bearing (the existing Papa 107(1) (a) is amended and Para 107 (1)(f) is added and Para 222 (3) is amended by adding sub para 222(3) (c),(d) and (e) Fabrication and Erection of Steel Girder Bridges and Locomotive Tumtables Fabrication specifications) A&C Slip No. Dated 28-01-2015 Regarding load test (Replace existing clause 5.3.3) Consultancy / Proof Checking Works Inspection and Testing B&S Directorate is having a well furnished laboratory with following facilities. ‘Impact load and static load testing facility for full scale testing of newly developed FRP/ 6 OL —EComposite sleeper as required by nodal Concrete Core Cutting Machine. Directorate. NDT Testing of Concrete Bridges with Corrosion Analyser, Profometer, Rebound Hammer, CAPO Test & Lock Test, WINDSOR Probe etc. Testing of Steel Bridges by Acoustic Emission Technique Residual Life Assessment of Stee! Bridges. Testing of Brick & Stone Masonry by FLAT Jack Method Resistivity Meter, Profometer, Pull off Tester, Permeability Tester, Ultrasonic Pulse fArrangementaoratatie oad rest Velocity Meter and Corrosion Analyser ialCore Cutting Equipment Instrumentation Capabil RDSO RDSO has the following instruments which are used for testing of bridges as per reference received from zonal railways: + Complete Structural Testing System (On loan from Northern Railway) Can be used for measuring strains, accelerations, displacements and temperature on steel as well as concrete bridges. fies Available with \> ENS “Vibration Signature Instruments Can be used for determining the natural frequency of girders. 86 —ELeee BRIDGE & STRUCTURE ON-GOING RESEARCH PROJECTS Review of Fatigue Criteria for Design of Railway Bridges “The Fatigue Criteria for design of Railway Brides was revised vide correction slip no in the June, 2012. “The Implication of the revised Fatigue criteria has been a large and somewhat unjustified increase in the sectional area in some members. This necessitates a Review of the Design Criteria for Fatigue The increase in the section from old to new fatigue criteria is up to 150% in the Diagonals etc resulting in large increase in Steel Weight. ‘Most of the problems in the Railway bridges have been found in the Fatigue failures of Stringer! Rail Bearers where the increased section is justified ‘ The reasons for this change has been identified as follows: > Use of complete strass cycle for members like diagonals. > Use of full impact factor for fatigue design (In Euro codes, 50% of impact factor is used). > Use of rivets which have low fatigue strength. (This problem has been solved byusing HSFG bolts) ¢ Matter was discussed in 83" BSC and as per discussions, the revision will be done by RDSO and presented during the next BSC meeting. Revision of Railway Codes for Seismic Design of Railway Bridges 4 The existing Design provisions of Bridge Rule for Seismic ¢ Design of Rallway Bridge are Obsolete as these were based on IS:1893-1984 which has been completely revised with new design philosophy in Year 2002. The Seismic design methods have also advanced all over the world “Based upon new IS Codes and prevailing latest Intemational practices, TK-RDSO Guideline Were issued in Nov-2010. The New methodology suggested takes into account the FlexibilityBRIDGE & STRUCTURE of the structures in calculating design Seismic Forces and it also takes into account the Ductility factor of the bridge in absorbing and sustaining Earthquake forces by going nto inelasticrange. ‘Certain issues were pointed out regarding these guidelines, especially related Response reduction factor and Live Load factors. This matter was discussed in 82nd BSC in 2014.The issues have been examined and revised RDSO guidelines for seismic design of bridges have been issued in January 2015. ‘The correction slips to Bridge Rules and IRS Concrete Bridge code are under preparation. ‘The matter was discussed in 83" BSC meeting and based on discussions, the correction slips are tobe proposed by B & S directorate. ON-GOING IMPORTANT DESIGN PROJECTS % Design of 91.44m Span Open Web irder > 91.44 m span open web girder is required forimportant bridges. > Design workis complete. > Steelusedis E350 B0, with K-type truss. > RDSOdrawingisunder preparation Design of 72m Span Bow String Arch Girder for ROBs 72 m span Bow String Arch girder is required for long span ROBs. Design work is complete. Steel used is £35080 > RDSO drawing is being developed to facilitate planning and execution of mega bridges. Design of 106.6m Span Open Web Girder > 106.6 m span open web girder s required for important bridges. > Design work has been taken up in hand > Steel proposed is E350 BO, with double- diamond type truss. Design of 30.5m Span Ballasted Deck Through Type Girders » The through girder drawings are all with steel channel sleepers > For better riding and for permitting laying Pa (Annual|Report/2015-2016) of LWR on bridge, ballasted deck is preferred. > Design of 30.5 m span with RCC deck ‘oversstringers has been taken in hand, % Design of Bow-String Girders for Revised Lane Width ROBs » Design of Bow string girders for revised lane widthisrequiredas perIRC guidelines. > The work is held up because there is no AENIXEN forthe same. Design of ROBs for Revised Lane Configurations > The lane widths have been revised by MOST for different locations of ridges. > All existing designs need to be checked and revised for these. > Design work has been taken up and likely tobe completed by 30.09.2016. » Drawings will then be required to be prepared for different spans. Progress of On going Research Projects (External) = Development of Railway Bridge Health Monitoring System with Wireless Sensor Network * Benefits Expected |. The use of wireless sensors reduces the losses associated with the wires such as thermal effects, drop in voltage etc, Setting up of test is very fast and ‘convenient. iii, Long term monitoring of bridges can be done * Salient Features Category ofproject — Artificial Intelligence Sanctionedcost_ — Rs. 187.02lakhs. ExecutiveAgency — CenterforRailway Research (UIT Kharagpur) Exp. Upto Mar, 2016— Rs. 181.02takhs BudgetGrant — —_ Rs. 2.09lakhs Exp. InCurrentYear— NIL % Objectives/Deliverables Extensive literature survey to find out aAnnual|Reportt2015-20/16) state of art system of Wireless Sensors suitable for indian Railways. fi, Development of energy efficient and secure topology design to reduce battery ‘consumption & pilferage. lil, Developing numerical models for four Representative Standard Span for Railway Bridges. ‘Analysis of Superstructure & Sub-structure tofind the locations for placing the sensors. ¥. Design of Wireless Sensor Network for Bridge Health Monitoring, Vi. Investigation for use of suitable Wireless ‘Sensors for Flood Water Level monitoring, vii, Testing of Sensors on a model through simulation, viii. Training of 25 Railway Engineers. Status Literature Survey Completed. ‘Sensors and base stations procured for wireless network iil, Water level sensor procured and initia testing done on Bridge No$7 in SE Railway. iv. Instrumentation testing completed on one bridge in SE Railway to check the arrangement proposed ¥. Numerical models prepared for four types of girders, viz Plate girder, open web girder, PSCBoxand PSC Igirders. vi, Design of 12m Span Model Bridge for ‘outdoor experiments finalized & same to be fabricated. vii, Final Report on Flood Water Monitoring System has been submitted to RDSO on 21-02-2016. vill. Some sensors and wireless data collection system is being tested. Testing of sensors also done on Br No, 168 UP. Validation of Numerical Model, fine tuning of system under progress. ix. Draft final Report on ‘Numerical Modeling of Railway Bridges’ has been submitted by IITIKGP for scrutiny of RDSO on 30-4- 2016 After Scrutiny by RDSO the shortcomings in report has been advised to IIT/KGP on 19.05.2016. x. On receipt of Seoond Draft Final Report fon 14-07-2016, shortcomings again advised vide RDSO letter dated 19-07- 5 BRIDGE & STRUCTURE 2016. Final report from IITIKGP and Validation of whole system on Bridge 168 Upis still pending, xi, Request for expediting the project done 0n 21.07.2016 xii, Prof/Civil Engg. With SRA had meeting in RDSO on 1" & 2" August2016 for detailed discussion and assured to complete the project at he earliest. = Development of Criteria for Dynamic Analysis of Steel Railway Bridges * * Benefits Expected i, Optimization and extension of impact values to be considered in bridge design for speeds upto which dynamic analysis is not required (~ 200 KMPH). The existing codal values are for 125/160 KMPH only. Criteria for dynamic analysis of bridges for higher speeds (Upto 350 KMPH) where CDAvalues cannotbe used Salient Features Sanctioned cost Year - €43,22,640.00 of sanction - 2012-13, DF-3, PH-18 Agency = lITRoorkee MoUDate - 09.10.2012 Expendituretill = 40.01 Lakhs. 31.03.2016 BudgetGrant 15-16 | - @4.12Lakhs, Expenditurein current - Nil year Objective/Deliverables Dynamic Analysis of all types of Girder and Truss bridges including Comparisons of Dynamic analysis with CDA based normal analysis, for Passenger speeds 160 Kmph to 300 Kmph and Freight 125 Kmph to 150 Kmph for MBG, HM, 25 t and 32.5 t loading li, Procedure (step by step) to conduct Dynamic analysis. lil, Draft Provisions for Bridge Rules/Stee! Bridge Code alongwith design implications. Current Status i. Results of Dead Load and Free vibration analysis completed for all Plate Girder and Truss Bridges.BRIDGE & STRUCTURE i. Dynamic analysis for all Plate Girder Bridges completed (including case with DA), Dynamicanalysis of WG completed. IIT Roorkee has informed that all analysis work has been completed and report preparation workis going on. "Development of Provision for Design of Steel Concrete Composite Railway Bridges for Normal Speed ad Special Provisions for High Speed Passenger Traffic. + Expected Benefits |. Code for design of steel-concrete composite girders will be developed, benchmarking the same with other international codes. ji, Shear connectors will be tested to verify their strength in static and dynamic conditions. iii, Methodology for design of continuous composite girders for high speed train operations willbe finalized iv. Existing stee! bridge code will be converted to limits state to make it in line with the ‘concrete bridge code which is already in limit state. SalientFeatures Sanctioned cost Executive Agency — €118.95lakhs, ~ Centre for Railway Research (IIT Kharagpur), Exp. Upto Mar, 2016 - 878.55 lakhs. Budget Grant 2015-16 — © 3.48 lakhs. Expenditure in current — Nil. year Objectives/Deliverables i, Report on analysis and design of Composite Bridge girders for normal speed (up to 160 kmph)in phase-1 and special provisions for high speed Passenger Traffic in phase-2 (upto 350 kmph), The report will contain the design basis and the present analysis methodology followedindifferentcountries. li, Report of test results for shear connector, if required to be done during development of ign provisions. i (Annual|Report/2015-2016) iii Design recommendations (with commentary ‘on provisions) for existing railway loads and speed in phase-1 (upto 160 kmph). iv. Design recommendations (with commentary ‘on provisions) for high speed (up to 350 kmph) including continuous spans. ¥. Assessment of existing composite bridge girders for high speed passenger trains (beyond 160kmph) vi. Design of2-3typical spans oir by RDSO and IIT, Kharagpur. Current Status 1. Technology Appreciation and Literature Surveyhas been completed. li, Preliminary report on design basis including analysis methodology for Phase-1 (up to 160kmph) submitted. ili, Areporthas been submitted in July 2016 iv. Furtherworkis going on lyselected Evaluation and Management of Longitudinal Force on Substructure of Railway Bridges + Expected Benefits i. Measurement of longitudinal forces on sub structure will be done for the rolling stock and track structure currently in use. The formula for longitudinal forces to be taken in design will be rationalised Nerified li, Actual dispersion of longitudinal forces willbe verified through measurements. Methods for retrofitment of existing old bridges for the higher longitudinal forces like Shock Transmission Units (STUs) willbe suggested and ested infield. SalientFeatures Sanctioned cost ExecutiveAgency — %784.43 lakhs. — SERC, Chennai (under CSIR). Exp, UptoMar,2016 — Nil. Budget Grant2015-16 —% 126.00 lakhs. Expendituretilldate ——Nil Objectives /Deliverables 1 Evaluation, analytically as well as experimentally, the longitudinal force coming on the sub-structure of Railwayi, Formulation of guidelines for design provisions regarding longitudinal loads on steel and pre stressed concrete bridges. Review and evaluation of suitable methodologiesitechniques for mitigation of longitudinal forces. Iv. Training of 30n0s. RDSO/ Indian Railways Officials and Engineers for evaluation of longitudinal force on bridges sub-structure andits mitigation. CurrentStatus i. The agreement signed by SERC is BRIDGE & STRUCTURE under evaluation by Project Evaluation Committee. ‘The proceedings are likely to be finalized incurrentweek. Then the PEC proceedings will be put up to DG RDSO and Railway Board for further approvals. Inspection of Fabrication of Steel Girders RDSO has done inspection of 25690t triangulated girder and 4747t welded plate gitder were inspected during this 2015-16 a>nke