Planning & Design for Construction of Bridges

PVS Sarma
Vice President / Railways
Aarvee Associates
architects engineers & consultants pvt. ltd
 Structure of Presentation
➢Bridges – Types

➢Planning for Construction

➢Designing for construction

➢Design Considerations & Codes

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 Bridges – Types
• Based on function
• Highway, Railway, Metro

• Based on Material
• Concrete, PSC, Steel, Composite, timber, Masonry

• Based on Form & Construction

• Arch, Deck type, Truss, Suspension Bridge, Balanced Cantilever Bridge,
Cable stayed, extradose

• Based on crossing level

• ROB, RUB, Flyover

• Culverts
• Box, Pipe
 Planning for Construction
Requirements of good planning:
- Design decisions effect:
- -Buildability
- Cost
- time
- Modern Methods of Construction to save time & cost of
construction.
➢ Knowledge of Construction process
➢ Knowledge of Equipment & construction Techniques
➢ Knowledge of Interface issues
➢ Planning should also address Health & Safety aspects
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 Planning for Construction
• Benefits of Good Planning
➢ Considerable saving in time and cost is feasible with proper planning

➢ Significant improvement in Quality is feasible due to controlled

environment

➢ Unnecessary traffic closures and traffic diversions for prolonged

durations can be avoided due to reduced on-site construction time

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 Planning for Construction
• Actions in Planning
➢ Carryout thorough investigation
➢ Levels, utilities, adjacent structures, space available for cranes, access, geotech
➢ Plan for essential site production requirements
➢ Site access requirement, material handling, construction programme
➢ Plan for a practical sequence
➢ Construction sequence to maintain stability of structure at all stages. Assumed Method of
erection to be indicated in Design basis.
➢ Plan for Simplicity of assembly
➢ Standard simplified connections should be used wherever possible. Repetitious, automated
procedures increase speed of construction and reduce cost.
➢ Recognise complexity of Design process
➢ Supercomputers are available for complex designs, however, qualitative feel of structural
behaviour is essential.
➢ Agree information and programme
➢ Manage Design development
Bridge components

SUPERSTRUCTURE

BEARING WING WALL

PIER ABUTMENT

DROP WALL
 Planning for River Bridges
➢ Linear Waterway
➢ Span arrangement
➢ Type of foundation
➢ Type of Superstructure
➢ Bearings
➢ River Protection – Guide bunds, toe walls, etc.
 Linear Waterway
➢ Depends on Estimated flood
discharge, bed profile,
presence/absence of rigid banks, etc.

• Estimating Flood Discharge

⚫ IMPROVED RATIONAL METHOD ( C.A < 25 sq km)

⚫ SUH METHOD ( C.A > 25 sq km and < 2500 sq km)

VELOCITY AREA METHOD

EMPIRICAL FORMULAE Synthetic Unit Hydrograph

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⚫ Model analysis 30

25

FOR C.A > 2500 sq km, available actual 20

observation records to be considered.

Discharge in Cumecs
15

10

0 1 2 3 4 5 6 7 8 9 10
Time in Hours
 Planning for River Bridges
• Span arrangement, foundation, Substructure & Superstructure types:
➢ Cost Economics
➢ Construction feasibility
➢ Construction time
➢ Foundations:
➢ Piles (vertical/Raker), Wells/Caissons, Open
➢ Based on Scour, water depth during construction
➢ Substructures:
➢ Solid Abutments, Spill through abutments, multiple columns for abutments & piers, wall type
piers, etc.
➢ Superstructures:
➢ Slab, Girder, voided slab, box, various forms and materials
➢ Bearings
➢ To transfer loads to substructures, allow rotations, movements
➢ Sliding, Roller/Rocker, Elastomer, Pot/PTFE, Spherical

➢ Protection works
➢ Toe walls, Guide bunds, curtain & drop walls
 Toe Wall
& Pitching

FLOORING

Spurs
 Planning for Bridges in Urban
environment
• Issues:
➢Traffic congestion / traffic diversions
➢Underground Utilities (Sewer, Gas pipe lines, cables,
etc.,)
➢Safety of adjacent buildings/structures
• Solutions:
➢Precast & Prestressed concrete
➢Steel / Composite
➢RE walls
Interchange — Existing Structures
Proposed Improvement
Completed Interchange
Elevated Metro structures- Precast elements
 Planning for Bridges in Hilly regions
Construction feasibility –
Deep Gorges, rivers with
boulder beds, accessibility
for plant & equipment
Slip form construction for
tall piers
Key technical data of
Chenab Bridge:
Bridge length: 1,315 m
including the 650 m long
viaduct on the northern
side Chenab Bridge
Arch span: 467 m
 Planning for Road Over Bridges
• Railway Requirements
• SOD
• Future expansion plans of Railway
• Railway ROW
• Train movement during construction
• Construction feasibility
SCHEDULE of DIMENSIONS
 Kukatpally ROB
• Provision for future
track

• Steel composite
Girder for easy
erection

• Erection with
minimum blocking
of trains
movement
 Road Over Bridge to cross 5 tracks
• ROBs in DFC Project:

Sasaram ROB: 3 x 36 (PSC)+ 1 x

60m Bow String + 3 x 33.5m PSC
spans

• Bhabhua ROB: 1 x 60m Bow

String Bridge
 Planning for Road Under Bridges
• Issues to be addressed:
• Clearance available for Highway structure
• Drainage & Maintenance
• Steep approaches
• Train movement for RUB below running lines

Method for construction under running tracks

• Box Pushing Method with block of train movement

• Precast box segments placed with cranes in traffic block.
 Planning for facilitating Inspection &
Maintenance.
➢ Inspections:
➢ To assess structural soundness and fitness for use
➢ To identify trouble at the earliest stage
➢ To keep a systematic record of condition and behaviour (data
bank)
➢ To plan repair and rehabilitation strategy and programme

➢ Maintenance:
➢ Bearings replacement
➢ Painting of Steel Bridges
 Inspection Facilities
Ladders,
Cradles &
platforms

Sliding Platform
Inspection Arrangements
Inspection using crane in progress
 Planning for Interfacing with other other
Departments
Viaduct design & construction Considering future flyover & future subway

4 Level crossing-Rapid Metro- Gurgaon

 Planning for Fast Construction
Saving Construction time is essential.
–Issues need to be addressed in the planning stage:

• Land availability:
• Land for sufficient working access and space to simplify and speed up
construction, with required use of large lifting equipment
• Utilities:
• Significant influence on the construction programme, but their impact
can be minimised by avoiding the need for diversion.
• Traffic Management:
• Road closures, lane closures, rail or waterway possessions can affect the
speed of bridge construction.
• Off-site fabrication:
• Erection time on site can often be reduced through the prefabrication of
elements in a workshop or alongside the bridge.
• Repetition:
• Standardisation of details and dimensions within and between different
bridges will reduce construction time.
 Planning for Fast Construction
• Permanent formwork.
• Precast Concrete
• Use of Couplers
• Travelling Falsework
• Reinforce Earth Walls
• Precast concrete Box Sections
• Precast arches
• Precast Concrete Beams
• Precast Segmental Bridges
• In situ Balanced Cantilever Bridges
• Incrementally launched Bridges
• Transversely slid or rolled bridges
• Jacked boxes

• Use of steel instead of concrete will definitely reduce construction time, but will be
costly.
 Construction of RUB- Pendurthi - Kothavalasa

• East Coast Railway Level crossing No. 484

• Installation of 20 segments 1.5m width each
• Construction Process:
• Track Removal
• Earthwork excavation
• Shifting of Base slabs and Boxes
• After completion of excavation, preparing surface, placing of base slabs and prefabricated
boxes.
• Linking the track.
• Planning:
• Earthwork excavation from both sides.
• Shifting of Boxes and base slabs as a parallel activity.
• Boxes lifted from both sides and placed at requisite location
• 16 Nos. Heavy duty Excavators, 3 nos. Heavy duty cranes, 5 Tippers, 4 Hydra Machines,
Heavy Weight Jacks, 300 Work force.

• Completed in 4.5 Hrs of block.

Construction of RUB- Film
 Designing for Construction

• Design of Permanent Structures

• Design of Temporary Structures
• Design Considerations & Codes
 Design of Bridge Structures
➢ Structure elements dimensioning based on logistics
available and limitations, if any.

➢ Detailing to include all necessary information for

integration of individual elements.

➢ Provisions for holding / lifting of precast elements during

handling / transportation / lifting and erection.

➢ Structural elements to be designed for erection stage

loading and conditions
 Design of Bridge Structures
• Common Types

• Concrete Bridges (RCC/PSC)

• Steel Bridges
• Composite Bridges
• Cable Stayed / Extradosed
 Codes for Designing of Bridges
➢ Highway Bridges -IRC Codes
– IRC 112, IRC-6, IRC-78, etc.,

➢ Railway Bridges - IRS Codes

– Bridge Rules, IRS Conc. Bridge Code, IRS Steel Bridge Code, etc.,

➢ International Codes
-Euro, AASHTO, UIC, etc.,

➢ IS codes
- IS 456, IS 800, IS 2911, etc.,
 Concrete Bridges

• Concrete has been an increasing popular choice for bridge

construction.
• Wide range of different substructure & Superstructure forms.
• Advantages of Concrete: Durability, Strength, Precast construction

Concrete Bridges: RCC, PSC

PSC: Pre tensioning & Post tensioning,
Segmental Construction
Balanced Cantilever Construction
Modular precast concrete Bridges
Concrete Bridges
Concrete Bridges
Concrete Bridges
Concrete Bridges
Concrete Bridges
Flyover structures in Hyderabad Outer ring road
Pre-tensioning or Post-tensioning
Pre-tensioning Post-tensioning
1. If plant is accessible, this is If plant is too far away or the
cheaper quantum of job at a place is less
(a)Saving in anchorages then this is better
(b)Saving in conduits and
grouting
(c)Centralized production

2. Tendons are to be straight Advantage of curving can be

taken
3. Better quality control mostly More efforts for quality control

4. Cannot be used for very large Can be used for longer spans
spans
 CASTING OF SEGMENTS

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 ERECTION OF SEGMENTS

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Durga flyover- spine segment erection &
attachment of wings.
 Lucknow Metro Viaduct required to cross 12
tracks
➢ Crossing 12 Indian Railway tracks In
Charbagh yard of Lucknow Railway
Station (9 tracks of NR & 3 tracks of NER)

➢ Alignment route modified to suit railway

expansion plans.

➢ RUB over NH-25 adjacent to Metro

crossing as per new alignment

➢ Not feasible to provide pier between

tracks

➢ Stopping of trains during construction

not feasible.
 Viaduct after completion of construction

Length: 255m (75+105+75)

 Front frame Rear bogie Mainframe work
Rear frame

Main rail Main rail

- After traveler L & R to final position and lock

- Check all level of formwork

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 Casting segment

- To follow step rebar work and cast next segment (R)

- And post stressing step

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Casting segment

- To follow step rebar work and cast next segment (L)

- And post stressing steps

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 Top levels
136.740 136.740
136.740 136.740 136.740 136.740

- CLC – check Top & Bottom Levels of segment before

Move to next step
-

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 Design Aspects

➢ Prestressing:

➢ 4 Phases:
Phase 1 After casting of each segment
(Two numbers for each
segment : 64 nos)

Phase 2 After casting of 16 segments

(through top blisters : 5 x 2 x 2
= 20 nos)

Phase 3 After completion of end

stitching (trough bottom
blisters: 8 x 2 x 2 = 32 nos)
Total No of Cables: 140.
Phase 4 After Mid stitching (Through
Total No ofbottom blisters
Cables: 140.– 12 x 2 = 24 Longest Cable: 102m
Nos). 102m
Longest Cable:
 Design Aspects

➢ Design Criteria:

Approved DBR

IRS, UIC & AASHTO Codes

➢ Analysis & Design:

Longitudinal analysis: MIDAS

Transverse analysis- STAAD-Pro
Design: OASYS

➢ Rail Structure Interaction

 Construction Methodology

➢ Balanced Cantilever construction

Method.
➢ Pier head with 1st segment on
either side cast-in situ.

➢ 12m length to accommodate both

Form travelers.

➢ Form traveler erection and

fixing to pier head after pier
head attained required
strength.

➢ Erection of inner & outer

shuttering supported on form
travelers
 Construction Methodology (contd..)

➢ Concreting of box segment

of 3m length on each side of
central pier.

➢ Concreting of each box

segment done in single pour.

➢ Prestressing of segment after

attaining 0.8 fck or 5 days age
whichever is later.

➢ Movement of form traveler

under speed restriction of 30
Kmph for trains.

➢ The construction process

repeated up to 51m length on
each side of central piers.
 Construction Methodology (contd..)

➢ End spans – cast in situ for 21m

length

➢ Made continuous by End

stitching & Mid stitching.

➢ Form traveler Design to cast

Complete box segment in single
pour.

➢ No traffic block of railways

during construction.

➢ Curing compound used due to

presence of electrified track
below segments.
➢ Steel fibre reinforced concrete
used in blister blocks
➢ Anti Carbonation paint for
durability
➢ Construction methodology and
sequence finalised based on
discussions with Railways and
approval by CRS
Construction pictures
Construction pictures
 Safety measures during construction
➢ Providing sheet (GI/fiber sheets) below
Form Traveler.

➢ Covering whole Form Traveler with

Safety Net and providing Toe boards for
arresting falling of materials.

➢ Earthing of Form Traveler while working

over the OHE.

➢ Barricading of area around piers.

➢ Additional holding down hydraulic jacks

(pull back cylinders) fixed with Form
Traveler for extra safety against
overturning of Form Traveler.

➢ Checking Form traveler condition and

connections of members prior to every
movement of form traveler
➢ Using double nuts in all high tensile
steels Macalloy bars for extra safety.
Construction over busy road
 SEGMENTAL CONSTRUCTION
OVER RAILWAY TRACK
Cast in place balanced cantilever
SEGMENTAL CONSTRUCTION IN PROGRESS
OVER A RIVER/ SEA
Prestress- Anchorage Zone

Anchorage Zone
•Maximum stresses
during stressing
operation
Structure on MONO PILE Piers
 Steel Bridges
• For Railways
• Plate Girders for small spans & Truss Bridges for Long spans
• Less weight compared to concrete Bridges
• Issues - Corrosion & Fatigue
• Checking of Quality of field weld
• Cost Vs Concrete to be checked.
• Maintenance cost is more
 Traditional Steel Superstructures

Through truss Fish belly type

Deck type Plate Girder

Underslung truss Semi-through truss

 Steel Bridges- Change in Technology

• Riveting to Welding & HSFG Bolts

• Design for durability- Fatigue Design,
Paintings
• Corrosion Resistance Steel
Welded and Rivetted Steel Bridge
 BOLTS AND BOLTING

Bolt Grade: Grade 4.6 :- fu = 40 kgf/mm2 and fy = 0.6*40 = 24 kgf/mm2

Bolt Types: Black, High Strength Friction Grip

Black Bolts:
usually Gr.4.6,
made snug tight,
ductile and cheap,
only static loads
HSFG Bolts:
Gr.8.8 to 10.9,
less ductile,
excellent under dynamic/fatigue loads

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 TIGHTENING OF HSFG BOLTS

¾ turn
1) Turn-of-nut Tightening position
2) Calibrated Wrench Tightening snug-tight
3) Alternate Design Bolt Installation position
4) Direct Tension Indicator Method

Tightening of HSFG bolts

(a) Standard (b) Oversized

(c )Short Slot (d) Long slot

Feeler gauge
Hole types for HSFG bolts

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Corrosion Resistance Steel Bridge
 Camber of Steel truss Bridges

➢ Camber: To provide designed level

under live load and avoid secondary
stresses.

➢ Designed Camber shall be indicated

in the drawings and shall be checked
after fabrication and during
maintenance

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 Steel Bridges- Erection Methods
➢ Erection by Incremental lunching method

➢ Erection on ground by cranes

➢ Erection by Cantilever Method

➢ Erection using Launching gantry

 Steel Bridges- Erection Methods
• Erection by Launching nose method : Adapted for small waterways & above Railway tracks
• Launching Nose and Assembled Truss will be rolled over rail arrangement
• Supported by jacking arrangement on the pier.
• Launching nose is connected by a winch, which is connected on the opposite side of bridge
pulling the launching nose and correcting and guiding the alignment
60m steel span – Push launching
Launching of Bridge in Bridge 20 - JURL
 Steel Bridges- Erection Methods
Erection on ground by cranes: (Dry river beds, approach spans)
• For the spans on ground erection will be done by temporary supports from ground, and elements
will be placed using crane travelling on ground.
 Steel Bridges- Erection Methods
Erection by Cantilever Method: Adapted for Large Waterways
• Initially partial length of the bridge will be erected with the trusses using truck mounted crane
from ground wherever the dry ground is available.
• Later, truss erection will be done by cantilever method using travelling crane mounted on the top
chord of the completed trusses
• The top chord of the trusses of adjacent spans is connected with temporary members for
facilitating movement of travelling crane and material carrier
 ERECTION IN PROGRESS
MAHANADI BRIDGE PROJECT

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Erection by Launching Gantry
 Composite Bridges

Steel Beam – Easy erection

Connected to Concrete Deck by Shear
studs

Rapid Metro-Gurgaon
48m Span Composite Girder under
construction
Cable Stayed Bridges
 VIDYASAGAR SETU

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Extradosed bridges
Arch Bridges
 Bow String Arch Bridge ROBs
• ROBs in DFC Project:

Sasaram ROB: 3 x 36 (PSC)+ 1 x

60m Bow String + 3 x 33.5m PSC
spans

• Bhabhua ROB: 1 x 60m Bow

String Bridge
 CONSTRUCTION METHODOLOGY

Salient Features of the Bridge

❖ It is a Three Span Continuous Bow String Girder Bridge.
❖ With two numbers of 132.65 m span at its ends &
❖ One 150 m span at its middle portion.
❖ Total length of Bridge is 415.3 m.
❖ The height of bridge varies with a maximum height of 37 m at its
middle portion.

Naihati Bandel

132.65 m 150 m 132.65 m

Span - 1 Span - 2 Span - 3

 CONSTRUCTION METHODOLOGY

FINAL POSITION OF BRIDGE

SPAN - 2
SPAN - 1 SPAN - 3

FIRST ASSEMBLY OF SPAN – 1 IS PERFORMED

3RD GODAWARI BRIDGE NEAR
RAJMUNDRY (BS-81)
 Rajahmundry Godavari Bridge
• Span 94 m
• Twin Bow string RCC arch connected by precast
RC struts in lateral direction
• 12 pairs of vertical Dina Hangers comprising 49
wires of 7mm dia
• PSC box tie girder – 16 cables each comprising of
61 wires of 7 mm dia
• 12 cross tie beams in the girder connecting the
columns hanging from Dina hangers
Chenab Bridge Construction-animation
Integral Bridge- Rapid Metro
Integral structure

Before
After
 Bridge Aesthetics
• Bridges are seen on the move.
• Overall proportions when seen from large distance.
• Shape and integration when seen from medium
distance
• Surface finish, texture & weathering when seen from
close
• Harmony of the bridge with surroundings is
important.
• Joints & Bearings effect aesthetics. Integral &
continuous bridges are generally aesthetic & also
durable.
Bridge Aesthetics
 Design for safety
• Designer shall foresee safety measures required during construction,
maintenance and repair works. (Lifting of heavy girders, space for
inspection, replacement of bearings, etc).
• Risk assessment to be carried. Risks shall be avoided, reduced or
controlled.
• To avoid working at Height, Prefabrication may be considered.
• Site cutting & welding – Provision of access platforms.
• Risk of Fire – Use of alternative product / Protective coatings.
 Sustainable Bridge Design
• Less carbon print. Has become increasingly popular.
Sustainable Bridge Design
 Development of Concrete Technology

• High Strength Concrete

• Self compacting Concrete
• High Performance concrete

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 High Strength Concrete

• Different definitions in different countries. Generally concrete with

cube strength above 60 Mpa.
• Section sizes and element weight can be reduced. Longer span can
be achieved.
• Ease out transportation and handling issues.
• Increase in speed of construction
• Additions - Microsilica, flyash, ground granulated blastfurnca slag,
admixtures, superplasticisers.
• Mix Design – ACI 363R
• Quality for concrete production and curing shall be as per
specifications.
 Self compacting Concrete
• Ability to flow under its own weight and fill the formwork completely.
• Posses high workability. Does not require vibration. Cohesive.
• Can be from low to high strength.
• Underwater structures, remedial works, complex reinforced concrete
shapes.
• Use of SCC in huge anchorage blocks of Akashi-Kaikyo Suspension
bridge, Japan saved construction period by 3 - 4 months.
• Additions (Powders & fillers)- Particle size below 80 micron, 200 to
300 kg/m3, produces stable cement paste.
• Adequate filling ability and segregation/bleeding resistance
• Admixtures- Superplasticisers, viscosity modifying admixtures
 High Performance Concrete
• The bridge design or specific construction challenges may dictate
enhancements to the characteristics of the concrete:
• Placement and compaction without segregation, long-term mechanical
properties, early-age strength, toughness, volume stability, or service
life in severe environments.
• Fibre reinforced Concrete: Steel/synthetic fibres to enhance toughness,
ductility & energy absorption capacity under impact. Reduce the
formation and development of cracks in the bridge form due to early-
age plastic settlement and drying shrinkage.
• Foamed concrete: Highly workable, low density- Used for filling voids
in bridges where access is difficult.
• High workability concrete
• Light Weight concrete
• Water resistant Concrete
 Load testing

➢ Test on Piles:

➢ Tests on Bearings

➢ Load test on completed

bridge for Design live
load including dynamic
Augment
 Design of Temporary Structures
• Staging Design for cast-in-situ construction & for launching of
bridges

• Design of Structures in casting yard:

• Bulkhead for pre-tensioning
• Gantry foundations

• Form traveller Design in balanced Cantilever Bridge

construction

• Design of Launching nose & connection to main bridge

superstructure.

• Use of Profiled deck for Superstructure

 Temporary Structures

• Dubai Metro – Precast shuttering forPier

cap & Precast Superstructure
PSC BOX - CYCLE OF ACTIVITIES
▪ Fixing Side shutters
 Arial view of pre-cast bed for 40 m long pre-
tensioned girders (2 lines each with 3 girders)
 Precast construction for Metro
• Why precast construction?
• Very long viaduct required rapid construction
• Construction through urban area and over congested highways required
minimal disruption
• High quality required factory controlled tolerances and finishing
 Precast construction for Metro
• Casting of segments
• Short-line casting used for curved spans
 Precast construction for Metro
• Deck erection
• Span-by-span erection
• Segments delivered at ground level or along completed deck
• Maximum segment weight = 72 Tonnes
• Maximum span weight = 700 Tonnes
 Precast construction for Metro
• Deck erection
• Installation of permanent tendons
• Gantry launched forward
 Conclusion

• Bridge design and construction is a challenging field,

calling for creativity to deliver beautiful, robust and
durable structures that will stand the test of time, allowing
people, vehicle and trains to cross streets, roads, railways,
rivers, valleys and estuaries.
Thank You
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