BRIDGE & STRUCTURES RESEARCH, DESIGN & DEVEPLOPMENT SOME RECENT ACHIEVEMENTS New Initiatives in Design and Fabrication Revision of Railway Codes for Seismic Design of Railway Bridges + The existing Design provisions of Bridge Rule for Seismic Design of Railway Bridge % Design of 91.44m span has been standardized. are Obsolete as these were based on “Bow string gitders for NHAI drawings of 42m 1S:1893-1984 which has been completely ‘span bow string ROBs have been issued for revised with new design philosophy in Year ‘one way twolane. 2002, The Seismic design methods have + Design of 60m Bow Arch Bridge for NHAI one ‘also advanced all over the world. way two lane isin progress. 4 Based upon new IS Codes and prevailing + Design of 72m Bow Arch girder has been latest international practices, IITK-RDSO completed. On-Going Research Projects ey i371 Review of Fi Railway Bridges 4 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. 4 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. ia for Design of Guideline were issued in Nov-2010. The New methodology suggested takes into account the Flexibility of the structures in calculating design Seismic Forces and it also takes into account the Duetilty factor of the bridge in absorbing and sustaining Earthquake forces by going into inelastic range + Certain issues were pointed out regarding these guidelines, especially related Response reduction factor and Live Load factors. This matter was discussed in 82nd BSC jin 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 ‘Most ofthe problems in the Railway bridges (RSW CaRaereNE SeeN once eM Unter have been found in the Fatigue failures of preparation Stringer! Rail Bearers where the increased _ section isjustited % The matter was discussed in 83° BSC + The reasons for this change has been es ee atoe ipa rer a identified as follows i. Use of complete stress cycle for members like diagonals. correction slips are to be proposed by B&S. dte. On-Going Important Design Projects ii. Use of full impact factor for fatigue = Design of 106.6 m Span Open Web Girder design (In Euro codes, 50% of impact + 106.6 m span open web girder is required factor is used). forimportant bridges. ili, Use of rivets which have low fatigue % Design work has been taken up in hand strength. (This problem has been + Steel proposed is E350 B0, with double- solved by using HSFG bolts). diamond type truss. ‘Matter was discussed in 83" BSC and as = Design of 30.5 m Span Ballasted Deck per discussions, the revision will be done by RDSO and presented during the next BSC meeting. Through Type Girders + The through girder drawings are all with steel channel sleepers. = a TRDS eS Aeli ele ee oy * + For better riding and for permitting laying of LWR on bridge, ballasted deckis preferred. Design of 30.5 m span with RCC deck over stringers has been taken in hand. Design of Bow-String Girders for Revised Lane width ROBs ° Design of Bow string girders for revised lane width is required as per IRC guidelines. The work is held up because there is no ‘AEN/XEN 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 forthese. Design work has been taken up and likely to be 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 > — Long term monitoring of bridges can be done. SALIENT FEATURES > Category ofproject — Artificial Inteligence > Sanctionedcost — Rs. 187.02 lakhs. > ExecutiveAgency - Centerfor Railway Research (IIT Kharagpur) > Exp. Upto Mar, 2016 — Rs. 181.02 lakhs > Budget Grant — Rs.2.09 lakhs > Exp. In Current Year — NIL OBJECTIVES/DELIVERABLES > Extensive literature survey to find out state of art system of Wireless Sensors suitable for Indian Railways. > Development of energy efficient and secure topology design to reduce battery consumption & pilferage. Developing numerical models for four Representative Standard Span for Railway Bridges, > Analysis of Superstructure & Sub- structure to find the locations for placing the sensors Design of Wireless Sensor Network for Bridge Health Monitoring, > Investigation for use of suitable Wireless Sensors for Flood Water Level monitoring, > Testing of Sensors on a model through simulation. > Training of25 Railway Engineers. STATUS > Literature Survey Completed. > Sensors and base stations procured for wireless network > Water level sensor procured and initial testing done on Bridge No 57 in SE Railway. 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, PSC Box and PSC girders > Design of 12m Span Model Bridge for outdoor experiments finalized & same to be fabricated > Final Report on Flood Water Monitoring ‘System has been submitted to RDSO on 21-02-2016 > 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. > 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 advisedto IITIKGP on 19.05.2016. > On receipt of Second Draft Final Report on 14-07-2016, shortcomings again advised vide RDSO letter dated 19-07- v v vBRIDGE & STRUCTURES: 2016. Final report from lIT/KGP and validation of whole system on Bridge 168 Upisstill pending, > Request for expediting the project done 0n21.07,2016. Prof /Civil Engg. With SRA had meeting in RDSO on ist & 2nd August/2016 for detailed discussion and assured to ‘complete the project atthe earliest > Draft final Report on “Numerical Modeling of Railway Bridges” has been submitted by IITIKGP for scrutiny of RDSO on 30.4.16. After Scrutiny by RDSO the shortcomings in report has been advised to IIT/IKGP on 19.05.16, v ™ Development of Criteria for Dynamic Analysis of Steel Railway Bridges ° * ey i371 BENEFITS EXPECTED > 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 > Sanctionedcost - Rs. 43,22,640.00 > Yearofsanction - 2012-13, DF-3, PH-18 > Agency - IITRoorkee > MOUDate = 09.10.2012 > Expendituretill - Rs40.01 Lakhs. 31.03.2016 > BudgetGrant = Rs 1.12 Lakhs, 15-16 > Expenditurein = Nil currentyear 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. > Procedure (step by step) to conduct Dynamic analysis. > Draft Provisions for Bridge Rules/ Stee! Bridge Code along with design implications. ‘+ CURRENTSTATUS > Results of Dead Load and Free vibration analysis completed for all Plate Girder and Truss Bridges. > Dynamic analysis for all Plate Girder Bridges completed (including case with CDA). > Dynamic analysis of OWG completed. > IIT Roorkee has informed that all analysis work has been completed and report preparation work is 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. > Shear connectors will be tested to verity their strength in static and dynamic conditions. Methodology for design of continuous composite girders for high speed train operations will be finalized. > Existing steel bridge code will be converted to limits state to make itin tine with the concrete bridge code which is already inlimitstate % SALIENTFEATURES > Sanctionedcost - Rs. 118.95 lakhs > ExecutiveAgency— Centre for Railway v Research (IIT Kharagpur). > Exp.UptoMar,2016 — Rs. 78.55 lakhs. > BudgetGrant — Rs. 3.48 lakhs. 2015-16 > Expenditurein — Nil current year OBJECTIVESIDELIVERABLES > 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 (up to 350 kmph). The report will contain the design = a TRDS eS Aeli ele ee oy basis and the present analysis methodology followed in different ‘countries. > Report of test results for shear ‘connector, if required to be done during development of design provisions. » Design recommendations (with commentary on provisions) for existing railway loads and speed in phase-1 (up t0160kmph), > 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 160 kmph). > Design of 2-3 typical spans jointly selected by RDSO and IT, Kharagpur. CURRENT STATUS > Technology Appreciation and Literature Survey has been completed. > Preliminary report on design basis including analysis methodology for Phase-1 (up to 160 kmph) submitted. > A report has been submitted in July 2016. > Furtherworkis going on. = Evaluation and Management of Longitudinal Force on Substructure of Railway Bridges * * EXPECTED BENEFITS > Measurement of longitudinal forces on sub structure will be done forthe rolling stock and track structure currently in Use, The formula for longitudinal forces tobe taken in design will be rationalised Wverified > Actual dispersion of longitudinal forces will be verified through measurements > Methods for retrofitment of existing old bridges for the higher longitudinal forces like Shock Transmission Units (STUs) willbe suggested and tested in field. SALIENT FEATURES > Sanctionedcost. — Rs. 784.43 lakhs. > ExecutiveAgency- SERC, Chennai (under CSIR). > Exp. Upto Mar, — Nil 2016 > BudgetGrant — Rs, 126,00 lakhs. 2015-46 > Expendituretill — Nil OBJECTIVES/DELIVERABLES > Evaluation, analytically as well as experimentally, the longitudinal force ‘coming on the sub-structure of Railway Bridges. > Formulation of guidelines for design provisions regarding longitudinal loads on steel and pre stressed concrete bridges. > Review and evaluation of suitable methodologies/techniques for mitigation oflongitudinal forces. > Training of 30 nos RDSO/ Indian Railways Officials and Engineers for evaluation of longitudinal force on bridges sub-structure and its mitigation. CURRENT STATUS. > The agreement signed by SERC is under evaluation by Project Evaluation Committee > The proceedings are likely to be finalized in current week. > Thenthe PEC proceedings will be putup to DG RDSO and Railway Board for further approvals. Details of Training Conducted One week training of SSE(D)s as part of IRICEN course being conducted by B & S dte at RDSO regularly. One week training in MIDAS design software was conducted for RDSO's designers (Two Rounds). One week training in Complete Structural Testing System (CSTS) given to 41 engineers from 8 zonal railways. One week training in NDT was conducted through SERC, Chennai. RDSO's laboratory staffattended the same. For the first time, conducted one week training course at RDSO for 29 Bridge Design engineersas part of IRICEN's regular course. One Day interactive session with SSE/Bridges on “Practices adopted in Maintenance of Bridges Over indian Railways” was organized for improvement of bridge management system. Conducted 2 days familiarization training inBRIDGE & STRUCTURES: software "LUSAS BRIDGE PLUS" which was BOGIBEEL RAIL-CUM-ROAD BRIDGE attended by RDSO offcials in March, 2014. Conducted successfully 4 days training on Rail Structure Interaction using the software *LUSAS BRIDGE PLUS’ which was attended by 12 railway officials and 20 RDSO officals in May, 2014. Two days training to RDSO officials on Rail Structure Interaction conducted in July, 2014. = 4 Days training for officers & supervisors on bride girder fabrication and erection work including fabrication of ROBs and elastomeric bearing was organized in Aug & Sep, 2014. Details of Non-Destructive Testing Done = Non-destructive Testing done in four bridges (Bridge Nos 557, 17, 18 and 19) constructed by RVNL near Bhubaneswar in ECoR and reports submitted forfurtheraction = Report on Non-destructive testing of Bridge No.325 near Titlagarh, Sambalpur Division, East Coast Railway m= Non destructive testing of retaining wall of RUB at RDSO, Manak Nagar, Lucknow 1 __Reporton Non-destructive testing of Br, No, 332 near Balasore, Kharagpur Dvision, South Eastern Raitway. Details of Consultancy Assistance to Railways Consultancy rendered to N C Rly regarding Chambal bridge in Gwalior - Etawah section which had developed cracks in pier P6. Two rounds of ND testing and one round of instrumentation studies have been completed and reports given toNCR. Details of Other Recent Activities of Directorate Inspection of 23350 t of fabricated steel! work of triangulated and welded plate girder bridges has been completed in 2016-17 as against target of 180001. This is exclusive of the two national important bridges i.e, Bogibeel, and Chenab. Total no. of 15 speed certificates were vettedlissued from bridge point of view and 8 trial reports have been vetted = Four girders of 125m span Rail cum Road bridge over Brahmputra at Bogibeel (a national importance project) have been inspected and cleared for launching in 2016-17, making the cumulative total of 30 spans. ON RIVER BRAHMAPUTRA (FIRST FULLY WELDED BRIDGE OF RAILWAYS) Total length: 4.940m Spans: 39spans of 125m Location: Dibrugarh district, Assam, India Carries: Railway and Road vehicles Bridge Type: Truss Type, Rail Cum Road Bridge Materials: Steel, Concrete Bearings: Spherical Bearings It is a combined Rail-Cum-Road Truss Bridge in Dibrugarh district at Bogibeel of the north eastern Indian state of Assam over river Brahmaputra connecting Assam and Arunachal Pradesh border. ‘Superstructure of this bridge is composite Welded steel truss and reinforced concrete. It is designed to carry a double line broad gauge railway and a 3-lane road on the lower and upper decks with spherical bearings. Out of 39 spans 30 spans have been inspected and cleared by RDSO and launched. CHENAB RAILWAY BRIDGE, J & K, INDIA Location: Chenab River between Bakkal and Kauri, J&K State, India Design: Arch Bridge Material: Steel and Concrete Total Length: 1,315 (4,314 ft) Height: 359m (1,178 f) Longest Span: 467m (1,532ft) No. of Spans: 17 The Chenab Bridge is a railway steel arch bridge under construction between Bakkal and Kauri in the Reasi district of J&K in HTS SS AIndia. This Iconic Bridge is of National Importance connecting Udhampur- Srinagar-Baramula Rail Link Project being constructed by KRCL under the supervision of Northern Railway. The bridge consist of main arch 467m span with approach span of 650m (13 spans) at end and 185m (4spans) at Bakkal end. Itis world's highest railway bridge with the widest span in the Indian broad gauge railway network RDSO is carrying out fabrication inspection of the Chenab Bridge and has done the prefabrication requirement like approval of QAP, scrutiny of WPSS and then qualifying the welders to take up the welding works. Till now 650 welding qualification records have been approved and 30 segments of Kauri end viaduct have been inspected by MBC directorate of RDSO. RDSO Designs of Steel Bridges Available Plate Girders for 25t Loading Drawings of 12.2m, 18.3m & 24.4m steel plate girder welded type for New Fatigue Criteria and HSFG bolts are available. m= Plate Girder for DFC Loading (32.5t Axle Load) Drawings of 12.2m, 18.3m & 24.4m steel plate girder welded type for 10 million cyclesissued Open Web & Open Web Underslung for25tLoading ler Drawings of welded type open web girder for 30.5m, 45.7m, 61.0m & 76.2m, 91.44m and Underslung Girder of 30.5 m for New Fatigue Criteria and HSFG bolts are available. eli ele ee oy Open Web Girder for DFC Loading (32.5t Axle Load) Drawings of welded type open web girder for 30.5m, 45.7m , 61.0m & 76.2m for 10 million cycles for DFC loading issued. RDSO Design of Composite Girders = Composite Girderfor25tLoading: Drawings of composite plate girder for 12.2m, 183m, 24.4m and 30.5m spans for New Faligue Criteria and HSFG bolts are available. = Composite girder for DFC loading (32.5taxle load) Design and drawings of composite plate girder for 12.2m, 18.3m, 24.4m and 30.5m spans as per NEW fatigue criteria issued (except for slab) Standard Design OF Road Over Bridges = RDSO Design of Composite Girders for ROBs Drawings of 18m, 24m, 30m & 36m span ‘composite girders for ROBs have been issued including for skew spans upto 20°, The drawings are for 6 different road width configurations (The drawings have been taken up for revision with revised deck configurations decided by IRC.) 1 Bow-String Girders for ROBs Drawings of 30m, 36m, 42m, 48m, 54m and 60m & 72mspan Bow string ROBs have been issued for two-lane road width Important Guidelines Issued B & S Die issues guidelines for various bridge related activities. Important guidelines issued are % NDTofbridges : BS103 ¢ Instrumentation of Bridges : BS 106 Inspection and Testing Facilities at RDSO's B&S Lab. B&S Directorate is having a well furnished laboratory with following facilities 4 Impact load and static load testing facility for full scale testing of newly developed FRP/Composite sleeper as required by nodal DirectorateAnnual Report 2016-17) BRIDGE & STRUCTURES Concrete Core Cutting Machine, 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 Corrosion Analysing Equipment (CANIN) i J br Residual Life Assessment of Stee! Bridges. Arrangement for Static Load Test UNTRS eS‘Annual Report 2016-17 4 ERs Instrument: with RDSO RDSO has the following instruments which are used {or testing of bridges as per reference received from zonalrrailways = Complete Structural Testing System (On loan from Northern Railway) Can be used for measuring strains, accelerations, displacements and temperature onsteel as well as concrete bridges. Vibration Signature instruments coeceanel Eetetreal Can be used for determining the natural frequency of girders. ion Capabilities Available ‘Testing of Brick & Stone Masonry by FLAT ppinde Jack Method.