HCC's Construction of Mega Bridges using Precast Segmental Methodology

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
December 14, 2012
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December 14, 2012
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
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Precast Segmental construction provides solutions to these challenges and exceeds Project Requirements
December 14, 2012
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
10 December 14, 2012 Precast Segmental Construction in Mega Bridges
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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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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December 14, 2012
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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December 14, 2012
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
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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December 14, 2012
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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December 14, 2012
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
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.
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

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

27
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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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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December 14, 2012
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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December 14, 2012
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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December 14, 2012
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.
Relocation of Launching Trusses using 1600 MT capacity Barge Mounted Crane Asian Hercules
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December 14, 2012
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
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December 14, 2012

HCC's Construction of Mega Bridges using Precast Segmental Methodology

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Hindustan Construction Co Ltd

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

December 14, 2012

Precast Segmental Construction in Mega Bridges

December 14, 2012

Precast Segmental Construction in Mega Bridges

Reduces Intermediate Piers & thus Obstructions to flow

Avoid system of staging from river bed level

Faster & economical technique as it saves time.

December 14, 2012

Precast Segmental Construction in Mega Bridges

Construction Planning has to be Meticulous and needs lot of Care

Proper Sequencing of Key Construction Operations should be clearly established.

December 14, 2012

Precast Segmental Construction in Mega Bridges

HCC A brief profile

Nuclear & Special Projects

Shafts & Penstocks

December 14, 2012

Precast Segmental Construction in Mega Bridges

Our track record in Bridge Construction

Indias leading Mega Bridge Constructor

December 14, 2012

Precast Segmental Construction in Mega Bridges

Signature Bridges Built by HCC

Godavari Rail Bridge

Cable Stayed Bridge across Naini, Allahabad, UP

Kaliabhomora Road Bridge

Badarpur Elevated Road

December 14, 2012

Precast Segmental Construction in Mega Bridges

Construction of Mega Bridges with Precast Segmental Construction HCCs experience

Bandra Worli Sealink Indias Engineering marvel

December 14, 2012

Precast Segmental Construction in Mega Bridges

To connect 2 suburbs of Mumbai Worli & Bandra

Reduction in travel time between the two suburbs

Reduction in traffic congestion

December 14, 2012

Precast Segmental Construction in Mega Bridges

Savings due to Sea Link

Other Socio Economic Benefits

Reduction in Air, Noise & Sound Pollution

December 14, 2012

Precast Segmental Construction in Mega Bridges

December 14, 2012

Precast Segmental Construction in Mega Bridges

LAYOUT OF BANDRA WORLI SEALINK PROJECT

600 m BANDRA CABLE STAYED

350M WORLI CABLE STAYED