ING-IABSE Webinar series in Association with ICE

Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

BRIDGE DECK ERECTION EQUIPMENTS

Rakesh Kumar Choubey
AGM- Engineering Structure, Dilip Buildcon Limited
A Post Graduate Civil Engineer from Dr. A.P.J. Abdul Kalam Technical University, Lucknow and Post
Graduate in Project Management (PGPM) from NICMAR with 12+ years of vast construction experience
in infrastructure like Bridges and Metro Rail viaduct structures, Long span bridges, Cable stay & Extra-
dosed bridges, Precast Segmental bridges and Pre-Stressed girder bridges. Having Sound knowledge of
engineering software’s like MIDAS, STAAD Pro and AutoCad etc. . . . Well familiar with Indian Road
congress (IRC) and Indian Standard Codes (IS).
Currently holds following Professional Membership-

• Chartered Engineer (India)- CEng(I), • Professional Engineer of Engineering Council of India

• E-Life Member of Indian Road Congress (LMIRC) (PE-ECI),
• Member of The Institution of Engineers (India)-MIE, • Life Member of Indian institution of Bridge Engineers –
LMIIBE.
• Member of International Association of Engineer-MIAE
Currently heading the Division of Enabling/Temporary structure design and involved in smooth
execution of special projects at Dilip Buildcon Limited.
 TOTAL ORDER BOOK (FY14-FY21)
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
 ORDER BOOK- GEOGRAPHY & CONTRACT WISEWISE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
 BUSINESS DIVISIONS
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
 BRIDGE DECK ERECTION EQUIPMENTS (BDE)
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

BRIDGE DECK ERECTION EQUIPMENTS

(BDE):-
THE EQUIPMENTS USED FOR ERECTION
OF SUPERSTRUCTURE (BRIDGE DECK) TO
ITS POSITION ARE CALLED BDE.

EXAMPLE-

1. LAUNCHING GIRDER
2. LIFTING FRAME
3. BRIDGE BUILDER
4. MOVABLE SCAFFOLDING SYSTEM
5. FULL SPAN LAUNCHER
6. WING LAUNCHER
ETC.
 SELECTION OF BDE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

TYPE OF BRIDGE

BALANCE SIMPLY SUPPORTED/ CAST IN SITU (SIMPLY

CANTILEVER/EX CABLESTAY CONTINUOUS SPAN SUPPORTED/
TRADOSED PRECAST SEGMENTAL CONTINUOUS SPAN)

SPINE WING SEGMENTAL MOVABLE

LAUNCHING UNDER SLUNG
LIFTING FRAME LIFTING FRAME SUPER SUPER SCAFFOLDING
GIRDER (STAGING)
STRUCTURE STRUCTURE SYSTEM (MSS)

UNDER SLUNG LAUNCHING WING LAUNCHING

OVER SLUNG LG
LG GIRDER LAUNCHER GIRDER

UNDER SLUNG
UNDER SLUNG LG
OVER SLUNG LG OVER SLUNG LG
LG
 INTERFACE OF STRUCTURAL DESIGNER AND
BDE MANUFACTURER/DESIGNERS
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

1. THERE SHALL BE CLEAR TWO-WAY COMMUNICATION BETWEEN

STRUCTURAL DESIGNER AND BDE MANUFACTURER/DESIGNER.
2. DESIGNER SHALL PROVIDE GAD & ACTUAL WEIGHT OF EACH
SEGMENTS.
3. BDE SHALL BE DESIGNED AFTER CONSIDERING ABOVE WEIGHTS.
4. REACTION VALUE AT EACH CONSTRUCTION STAGES SHALL BE PROVIDED
TO STRUCTURAL DESIGNER.
5. TIE DOWN HOLES ARRANGEMENT SHALL BE PROVIDED TO DESIGNER
FOR CHECKING LOCAL STRESSES.
 CHECKLIST DURING MANUFACTURING OF BDE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

• GRADE OF MATERIAL IS USED AS PER DRAWING AND

DESIGN.
• WELDING THICKNESS IS MAINTAINED AS PER DRAWING.
• MTC REPORT SHALL BE DOCUMENTED.
• THIRD PARTY TEST REPORTS OF STRUCTURAL STEEL SHALL
BE DOCUMENTED.
• DPT AND ULTRASONIC TESTS ARE CONDUCTED TO CHECK
THE WELDING QUALITY.
 CHECKLIST DURING EXECUTION
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

• DEFLECTION
• DEFLECTION CHECKING OF LG AND BDE SHALL BE CARRIED OUT DURIING EACH SPAN ERECTION.
• DEFLECTION DURING ERECTION OF SPAN SHALL BE LIMITED TO L/400.
• DEFLECTION DURING AUTOLAUNCHING SHALL BE LIMITED TO L/250.

• OVERTURNING MOMENT-
• FACTOR OF SAFETY AGAINST OVER TURNING SHALL BE TAKEN AS 1.33.

• TIE DOWN ARRANEGMENT-

• IT SHALL BE ENSURED THAT TIE DOWN IS PROPERLY DONE AND SHALL BE CHECKED AT LEAST TWO TIME IN A DAY.

• HYDRAULIC JACKS AND ACCESSORIES-

VISUAL INSPECTION OF HYDRAULIC JACKS SHALL BE DONE ON DAILY BASIS. CALIBRATION OF JACKS NEED TO BE DONE
ON REGULAR BASIS.

• STRUCTURAL BEHAVIOUR-
• STRUCTURAL BEHAVIOUR OF LG AND ITS SUPPORTS SHALL BE DOCUMENTED ON REGULAR BASIS.
 CHECKLIST DURING EXECUTION
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

• DIFFERENT SPAN LENGTH-

• IT SHALL BE ENSURED THAT CONSTRUCTION SEQUENCE IS PROVIDED FOR EACH TYPE OF SPAN AND THE SAME SEQUENCE
IS FOLLOWED DURING EXECUTION. IT IS NECESSARY AS THE LOCATION OF SUPPORTS CHANGES, THE SHEAR FORCES
BEHAVIOUR IMPACTS THE LG DESIGN.

• DIFFERENT CURVATURE RADIUS-

• IT SHALL BE ENSURED THAT CONSTRUCTION SEQUENCE IS PROVIDED FOR EACH TYPE OF CURVE SPANS AND THE SAME
SEQUENCE IS FOLLOWED DURING EXECUTION. IT IS NECESSARY AS THE LOCATION OF SUPPORTS CHANGES TO COUNTER
THE AUTOLAUNCHING PROCESS.
 PROJECTS
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

PROJECTS

BALANCE
SIMPLY
CANTILEVER/EXTR CABLESTAY
SUPPORTED/CONTINUO
ADOSED
US SPAN PRECAST
SEGMENTAL
SHARAVATHI SAHIBGANJ ZUARI CABLE STAY
EXTRADOSED- EXTRA-DOSED BRIDGE
BC BRIDGE BRIDGE

LIFTING LAUNCHING LIFTING LAUNCHING LIFTING

FRAME GIRDER FRAME GIRDER FRAME SPINE WING
SUPER
STRUCTURE

BANGALORE- NIDIGATTA-
ZUARI PKG 1 ZUARI PKG 2 ZUARI PKG 3
NIDIGATTA (PKG 1) MYSORE (PKG-2)

WING WING LAUNCHING WING LAUNCHING WING

LAUNCHING LAUNCHING LAUNCHING WING
LAUNCHER LAUNCHER GIRDER LAUNCHER GIRDER LAUNCHER
GIRDER GIRDER GIRDER LAUNCHER

OVER UNDER OVER UNDER

OVER UNDER OVER UNDER OVER UNDER
SLUNG LG SLUNG LG SLUNG LG SLUNG LG
SLUNG SLUNG SLUNG SLUNG SLUNG LG SLUNG LG
 PROJECTS
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

PROJECTS

CAST IN SITU (SIMPLY

SUPPORTED/
CONTINUOUS SPAN)

SPINE WING SUPER SEGMENTAL SUPER

STRUCTURE STRUCTURE

SAHIBGANJ APPROACHES

BHOPAL METRO INDORE METRO

ZUARI PKG 1

LAUNCHING WING
GIRDER LAUNCHER
LAUNCHING LAUNCHING
GIRDER GIRDER

MOVABLE
OVER SLUNG UNDER SLUNG UNDER SLUNG SCAFFOLDING
LG LG OVER SLUNG LG (STAGING) SYSTEM (MSS)- NOT
OVER SLUNG LG USED
 SHARAVATHI EXTRADOSED-BC BRIDGE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

BRIDGE LENGTH - 2.125 KM

Extra-Dosed Span - 3*177 + 2*104.5 = 740M
Balance Cantilever - 6*135 + 6*90 +1*35 = 1385M
SUPER STRUCTURE TYPE - PRECAST SEGMENT
 SHARAVATHI EXTRADOSED-BC BRIDGE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

TYPE OF BDE USED -

1. LIFTING FRAME
2. LAUNCHING GIRDER
 SAHIBGANJ EXTRADOSED BRIDGE OVER GANGA RIVER
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

EXTRA-DOSED BRIDGE LENGTH - 6KM

EXTRA-DOSED SPAN - (1*180 + 2*110)*15 = 6KM
SUPER STRUCTURE TYPE - PRECAST SEGMENT WITH STRUT
TYPE OF BDE USED -
1. LIFTING FRAME
2. LAUNCHING GIRDER
 ZUARI CABLE STAY BRIDGE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

CABLE STAY SPAN - 1*360 + 2*140 = 640M (LHS + RHS)

DECK WIDTH - 27M LHS + 27M RHS
HEIGHT OF PYLON - 100M
TYPE OF BDE USED-
1. LIFTING FRAME
2. UNDER SLUNG FOR ERECTION OF ANCHOR SEGMENT
 ZUARI CABLE STAY BRIDGE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
 PRECAST SPINE AND WING SUPER STRUCTURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

ZUARI APPROACHES – LENGTH -

6.146KM
MAX SPAN LENGTH - 50M
DECK WIDTH – 28M & 36M
SUPER STRUCTURE TYPE -
PRECAST SPINE WING
TYPE OF BDE USED-
1. OVER SLUNG LAUNCHING
GIRDER
2. UNDER SLUNG
3. WING LAUNCHER
 PRECAST SPINE AND WING SUPER STRUCTURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

WING LAUNCHER
 PRECAST SPINE AND WING SUPER STRUCTURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

UNDER SLUNG
 PRECAST SPINE AND WING SUPER STRUCTURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

BANGALORE – NIDIGATTA (PKG

1)
FLYOVER LENGTH-4.42KM
MAX SPAN LENGTH-36.5M
DECK WIDTH – 28M
SUPER STRUCTURE TYPE -
PRECAST SPINE WING
TYPE OF BDE USED-
1. LAUNCHING GIRDER
2. WING LAUNCHER
 PRECAST SPINE AND WING SUPER STRUCTURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

NIDIGATTA – MYSORE (PKG 2)

FLYOVER LENGTH-3.37KM
MAX SPAN LENGTH-35M
DECK WIDTH – 28M
SUPER STRUCTURE TYPE -
PRECAST SPINE WING
TYPE OF BDE USED-
1. LAUNCHING GIRDER
2. WING LAUNCHER
 PRECAST SPINE AND WING SUPER STRUCTURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

SAHIBGANJ APPROACHES-
LENGTH-1.96KM
MAX SPAN LENGTH-45M
DECK WIDTH – 28M
SUPER STRUCTURE TYPE -
PRECAST SPINE WING
TYPE OF BDE USED-
1. OVER SLUNG LAUNCHING
GIRDER
2. WING LAUNCHER
 PRECAST SEGMENT SUPER STRUCTURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

BHOPAL METRO + INDORE

METRO
LENGTH-6.225KM + 5.29KM
MAX SPAN LENGTH-34M
DECK WIDTH – 8.5M
SUPER STRUCTURE TYPE -
PRECAST SEGMENT
TYPE OF BDE USED-
1. LAUNCHING GIRDER
2. PARAPET LAUNCHER
 ANIMATION VIDEO OF LG & WING
LAUNCHER FOR ZUARI PROJECT
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
 ANIMATION VIDEO OF SAHIBGANJ
PROJECT
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021