REPORT ON

ZUARI BRIDGE
SITE VISIT

BY
ARUN K V & ARUN K S
(Bridge Engineer) BRIDGES DESIGN UNIT
CHIEF DESIGN OFFICE
DESIGN WING, PWD
CONTENTS

1. INTRODUCTION ON SITE VISIT

2. ZUARI BRIDGE
2.1 SALIENT FEATURES OF THE PROJECT
2.2. INTODUCTION
2.3. PROJECT CORRIDOR
2.4. PROJECT DETAILS
5.5. CONSTRUCTION SEQUENCE
3. MANDOVI BRIDGE
4. PRESENTATION ON SITE VISIT
5. WAY FORWARD
1. INTRODUCTION ON SITEVISIT
As per the approval from government two Bridge Engineers from this office (Arun
K V and Arun K S) has conducted site visit on the Zuari Bridge (India’s Second largest
bridge) in Goa which is under construction. Two days has been spend on the site to
witness various construction activities.
Day1. We have reached the site on 10/06/2022 (Friday) morning. We got an overview
about the project from Mr. Atul Joshi, vice-president of Dilip build con, the contractors of
this project. He has explained the hurdles they faced during execution of the project. Then
we have moved to the project location where we have witnessed ongoing activities like
joining operation of HDPE stay pipe, stay cable erection, stressing of stay cable, lifting
and placing of precast deck slab etc.
Day2. On day two 11/06/2022 (Saturday) we have got opportunity to visit the fabrication
yard where fabrication of segments are being done. The laser cutting machine and robotic
welding machine were already shifted to some other construction site because majority
of deck segment fabrication is over. In the fabrication yard we have witnessed manual
welding segment assembly and painting activities. After that we moved to the site office
were we got chance to see the construction drawing of the project. Then we moved the
Mandovi bridge (which is open to traffic) location to perceive the particulars of the bridge.
2. ZUARI BRIDGE
2.1 SALIENT FEATURES
1 TITLE OF THE PROJECT
2 DISTRICT
IMPLEMENTING AGENCY
DPR PREPARED BY
Zuari bridge package II (Bridge
proper) (Construction of bridge
including approaches across river
Zuari on NH17 (New NH-66) on
Panjim -Mangalore section in the
State of Goa (Pkg. II Km 530/850 to
km 531/934 on EPC mode)(Job no.
NH-17-Goa-2015-16-169))
TISWADI
Ministry for Road Transport and
Highways (MORTH)
S. N. Bhobe & Associates

DESIGN CONSULTANTS Groupe Ingerop and Infinite Civil

Solutions Pvt Ltd
PROJECT OUTLAY The project involves the construction
of a 640m long, 8-lane cable-stayed
bridge across the River Zuari and a
450m long elevated approach to it,
with only two pillars in Goa, India.
NATURE OF THE PROJECT EPC MODE
PRESENT STATUS OF EXISTING Existing 2 Lane Bridge does not cater
BRIDGES/ROADS to heavy vehicles

NEED FOR THE PROJECT This new bridge is essential as the

condition of the existing 2 Lane Bridge
does not cater to heavy vehicles which
currently use an alternate route 40
kms longer. This new bridge will
ensure a smoother vehicular traffic in
the area including that of heavy
vehicles.
TYPE OF BRIDGE STEEL CABLE STAYED
TOTAL SPAN LENGTH OF Span length of 640m (Central Span-
BRIDGE 360 m, End Span-140m on either side
of the central span)
OVERALL AND CARRIAGEWAY IT has eight lanes (4+4). It has
WIDTH’S dual carriageways of 27 m each and
has a center median of 10.7m.
PROVISION OF FOOTPATH 2.50 m

OTHER DETAILS OF PROPOSED NIl

BRIDGE
2.2 INTRODUCTION
Zuari cable stayed bridge is a high demand project as the existing bridge in Zuari
River connecting Panjim and Mangalore does not cater to heavy vehicle movements due
to its poor condition. Construction of the Zuari cable stayed bridge includes building a
bridge across the river Zuari on NH-17/ NH 66 on Panjim – Mangalore section in the State
of Goa. The Zuari cable stayed bridge is 640m long with central navigational span of
360m and end span on both sides of 140m. This makes the bridge the 2nd longest and
widest cable stay bridge in India. A tourist observatory and restaurant at the 110m high
tower is planned on the bridge.

In addition to the road connectivity between North Goa and South Goa, this project
has high tourism potential. The project location got its own geographic beauty due to the
natural estuary. Hence the construction of high level bridge across the estuary will give a
panoramic view of the sea/river at an elevated level. Hence the Bridge is proposed as an
Iconic Bridge blended with local heritage. The estimated EPC cost of the project is 545.40
crores.
2.3 The Project Corridor
The project comprises of 3 sections – a 8.2 km highway from GMC Bambolim to Goa
Velha, a new 1.08 km Zuari Bridge (Cortalim – Tiswadi) and a 3.6 km highway to Verna.
Approximately 6.4 km of these highways will be elevated.

Zuari Bridge location

 Zuari Bridge (Artistic view)

Project Details

Zuari cable stayed bridge has 8 (4+4) lanes with 27m wide dual carriageways and a
centre median of 10.7m. Bridge deck is of composite structure (steel structure and
concrete) with a temporary steel walkway connecting both sides of embankments and
pylon foundation locations for construction logistics. The bridge deck is fabricated at site
using high tech robotic welding equipment. It is transported by barge into the river, where
it is lifted and erected by lifting frames. DBL has joined hands with a Ukraine based
company, Mostobudivelnyi Zahin Limited (MBZ) with a 74% and 26% stake respectively,
to construct the cable stay bridge. MBZ has experience in construction of bridges
including suspension bridge of 840 metres with a central span of 520 metres and is the
technical partner to Dilip Buildcon Limited for this project. MBZ’s involvement is to support
in design, technical matters and execution.

2.4 CONSTRUCTION SEQUENCE

Pre construction activities

 Soil Investigation will be carried out at Pylon, Pier locations

 On the Agassaim side a temporary steel walkway measuring to a length of 200m
will be constructed to connect the embankment and pylon location P72. On the
Cortalim side, the temporary steel walkway measuring to 270m connecting
embankment and Pylon P73 will be built for construction logistics.
Pile foundation

There will be 140 permanent piles of 2.0m dia at locations of pylons P72 and P73. To
allow work to be carried even in volatile tide and water conditions high capacity rotary
piling rigs erected over floating pontoons on river. Rotary rigs is an international practice
in building bridges and is considered economic and time – efficient technique. 2.0 m dia
piles are used for the first time in India. 8 mm thick permanent steel liner was used for
piles.

Pile foundation construction

Pile cap

The Pile cap construction at Pylons 72, 73 measures to 87.3 x 26.3m. This mega Pile
cap pour is planned in stages and the usage of Glass fibre reinforcement technology is
under review to mitigate potential corrosions of Construction joint. The concreting work
for Piles and Pile cap, Pylon will be done through Piping from embankments.
The pile caps are constructed on three stages and are stitched together by internal
prestressing strands. To reduce the heat of hydration cold water is been circulated
throughout using pvc pipes running on both directions.
 Pile cap construction

Pylon

100 m high Twin Pylons will be constructed with stay connectors at levels as per
design at both side of the bridge “ie’ P72 and 73 using Tower cranes.
 Pylon construction

Placing of Stay connectors inside pylons

Deck erection

Steel Girders of size 27m x 12m will be fabricated with advanced automated machineries
and equipment. Steel girders will be shifted by barges. The girders will be erected by
fabricated steel lifting frames. Girders fabricated using international technology of plasma
cutters and robotic welding machines near bridge site. The robotic arm takes a few hours
to prepare one steel segment as against a week it would have been taken if done by
manual welding.

Girders fabricated at site

 Erection first segment at pier table

Placing and stressing of first stay cables

 Erection second segment after stressing first segment by lifting frame

Steel Girders will have a precast concrete slab installed over them.

Precast slab lifting

Stay cable

The project includes the installation of stay pipes, stay cables and anchorages. 45,614
km length of high tensile steel wires used to hold the deck which is more than earth’s
circumference (40,075 km). The live end of stay cable are located inside the pylons. All
the stressing operations are done inside the pylon. All the stressing operations are
automated.

Cable Anchorage at deck slab

Damper for Stay cable

 End Anchorage of stay cable

Joining operation of outer pipe of stay cable

Stressing operation of stay cable at pylon

After stressing of stay cables (with Deputy GM and OVM Stay cable Installation
Supervisor)

Details of observatory tower at pylon locations

3.0 MANDOVI BRIDGE
The Mandovi Bridge at Goa is 620m in length crossing the river Mandovi . The span
arrangement consists of three main spans of span 150 m and two end spans of 85m
span. The bridge superstructure consists of 21m wide externally strutted PSC segmental
box girder, with dual carriageway of 2 x 8.5m with 3.0m wide median at centre. The depth
of proposed box girder is 3.0m supported by stay cables which is anchored in the pylon
and stressed from the box girder. Prestressing was done to establish connection between
the segments and also to resist bending moments. Balanced cantilever method of
construction is adopted for construction.

The cable stayed bridge is constructed using balanced cantilever method. The first stage
is the erection of towers and segments. After that the cables are erected. Finally the link
segments are erected and the bridge construction is completed. Figure 6 shows the
different construction stages in the construction of the bridge. In this method, firstly the
tower is erected and a segment of the deck is erected starting from the tower on either
side. Then the cables are erected symmetrically on either side. Finally the link segment
is used to connect different spans. The wind tunnel sudy for the project is done at CSIR-
SERC Chennai.
Setup of wind tunnel study at CSIR- SERC Chennai.
4. PRESENTATION ON SITE VISIT
A detailed in house Presentation has been done for the Engineers of Bridges
Design Unit to share the information that we gained on various construction activities and
construction details of these projects. 9 Assistant Bridge Engineers and 2 Bridge
Engineers from this office attended the session.
5. FEASIBILITY OF SUCH LONG SPAN BRIDGES IN KERALA.
Such long span iconic bridges can be planned in locations where there is mandatory
vertical and horizontal clearances are required and also in locations having tourism
potential. Design of such long span bridge will require collaborations with experts from
the industry who had done similar projects. The Deck of Zuari bridge is made of Structural
Steel which will increase overall lifespan. As the desire for eco-friendly construction
increases, steel will become more convenient for construction projects. It can easily be
recycled and doesn’t need to be permanently disposed of. The use of structural steel in
bridge projects should be encouraged.
6. WAY FORWARD
Bridges design unit has already completed medium span visually attractive bridges in
some locations and some of the projects are ongoing some of them are follows
1. Naluchira Bridge – Extradosed Bridge (central span 70m)
2. Padaharam Bridge – Boxgirder Bridge resembling Kerala architecture (45 m span)
3. Malampuzha ring road bridge – Steel Network tied arch bridge (Central span 60
m)
Locations should be identified where we can go for such long span iconic bridges. The
General Arrangement Drawings for DPR of such projects will be prepared in-house. For
the Detailed Engineering and for preparation of Construction Drawing collaborations with
experts from the industry, who had done similar projects, will be required. Facility for proof
checking of the design and special studies like wind tunnel experiment is mandatory.
Total length of Zuari bridge is 1040 m (including 640 m cable stay part), The total cost
of the project is 545.4 Crores. For a conventional type of bridge for this length the cost
will be one third. Budget allocation for such iconic bridges should also be planned in view
of that.