First Name: Gopalji Roll No.

: CE21M112 Lecture date:05/10/2021

Mr. V. Sadasivam gave a presentation on 5th of October,2021 on ‘Construction of 8-

Lane Dwarka Expressway’ which bypasses Gurugram and provides facility of an alternative
to NH 8 to reduce congestion and pollution providing better connectivity with the IGI airport,
Delhi. He also emphasized on construction of bridges during the presentation as 34m wide
and the major project component along with other elevated road networks is 8 lane elevated
road carriageway. Elevated service road connections, cloverleaf and trumpet intersections are
part of this project. Out of total 4 packages, III and IV are explained which were executed by
L&T.
The main carriageway has used Elastomeric Bearing of 1100 mm dia. with 415 mm
height, which were introduced for first time in the country. The typical 40m spans is divided
in 14 pre-cast segments 28 wing segments. The segments are of different types depending on
its location in the span which are Diaphragm Segment, End Segment, Tapering Segment,
Running Segments. These segments are moulded as per the actual profile of the carriageway
which takes care of the turn and lean of the span.
This process is end to end and is initiated by placing a launching girder (LG) and
proceeds in one direction. LG has a length 86m is required to erect spine segments, which is
balanced and progressed at 3 points on piers. Multiple LG can be used to from both ends or
middle to expediate the work depending on the supply of the spine segments. In case of this
project 14 segment trolleys which can move along the line of the bridge are hanged from LG.
A well-choreographed sequence is method is in place to put the segment in its location, first
of all the LG is prepared for the new span. 18 precise steps are followed to erect a single
span. The segments are brought from the casting yard by heavy trailers and the segment
trolley lifts up the segment. All segments (14) are hanged in the dry fir sequence from
respective segment trolleys in orderly manner. After checking for the perfect alignment and
matching, epoxy glue is applied between the segment before pre-stressing for using 16 main
cables and 6 blister cables. Transverse Prestressing Jack is used for pre-stressing of wing
Segments. Epoxy glue is necessary to arrest water percolation inside the hollow segment, also
it ensures perfect joint. A wing erection trolly places wing segments after the span is erected,
this increased the width of the carriageway.
Following 9 steps are involved for auto-launching of LG in the next span, where
carefully synchronised front support, middle support, rear support, the rear trolley, counter
weights are moved keeping the centre of gravity within the support avoiding overturning.
The pre-casting yard is suitably located from where logistics can be handled with
ease. The load carrying capacity of existing roads limits the size of each segment along with
CE5060 – 2021 Technical Report on Industrial Seminar Lectures Page 1 of 2
First Name: Gopalji Roll No.: CE21M112 Lecture date:05/10/2021

the trailer size. The casting yard layout is interesting to note that how casting, curing and
storage is placed in a sequence bringing efficiency and the proper hierarchy to the SOPs.
Longline Mould for spine segments casting is used. Generally, two-tier storage for segments
with suitable packing and stacking pedestal is preferred for easy retrieval of required
segments. 125 MT segment handling and 40 MT shutter handling gantries are installed in the
yard, this helps in efficient handling of the mould, reinforcement cage, casted segments.
Specialised apparatus is placed for curing arrangements for precast segments. A unit
for period of 48 hrs for a 4-blister segment, 43 hours for a 2-blister segment, 39 hours for
running segments is calculated by estimating the of end to end process duration, which
includes shuttering, placement of reinforcement, concreting, strengthening, and then de-
shuttering. The sequence in which the segments are cast facilitate perfect joint as the
subsequent segment is casted against the previous segment. A key and depression is
introduced to ensure a perfect match.
The QAQC is maintained in broadly 3 stages; casting of segments, Pre-Dispatch
segment inspection and erection. The segments are inspected and tested before dispatching to
the site for erection this includes visual inspection, Re-Bound Hammer testing, UPV testing,
Cover meter testing before Dispatching and other tests as required to maintain quality. Safety
is another aspect of the project of this nature, for every stage of the construction SOPs are
devised in consultation with authority engineers, NHAI & MORTH team, for every activity
involved like transportation and placing of segments, lifting of segments, launching
operations, stressing operations.
Segmental Construction technique is useful for fast construction of elevated
carriageways or bridges. This method has benefitted by reducing the working space required
on the project site (here highway) keeping more way free for traffic. The logistics for such
project is crucial as the synchronised coordination between casting yard and sequencing of
onsite erection determines the progress of the project.

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