Abstract

The main objective of this study is to assess the new and different and one of the major Railway bridge
of the " CITY OF THE BRIDGES : SURAT "

And to perceive knowledge about methods involved in the bridge construction , Management , safety.
To this end , the study is divided in to the different chapters :

Chapter 1 : First chapter is about general introduction about bridge it's components , planning
phase .In which there is general discussion about components in foundation , substructure and
Superstructure also about planning of project and project consultants

Chapter 2 : This chapter is of to know about the actual scenario of the study area including problem
statements and objectives of study. It gives detailed idea about location and adjoining locations which
will connect through this project.

Chapter 3 : This chapter of study shows the details about the bridge. It's economical length , type of
bridge , foundation , materials , resources and also project consultants and total tender amount.

Chapter 4 : Fourth chaper is about the methodology of the project and construction process of different
components like abutment ,pier, pier cap , pile , foundation etc.

Chapter 5 : This chapter cover the pivot aspects of Management and Saftey during construction phase
and safe traffic control .oundation in detail. It will clear all concepts of construction processes and its
phases.

Chapter 6 : This chapter is about conclusion of the project how it's gonna be helpful to the road user
and also as infrastructure development. And also light up the sight , that every little thing is important
during working progress for a civil engineer.

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Acknowledgment
In the present world of competition there is a race of existence in which those who are having will to
come forward succeed. Project is like a bridge between theoretical and practical knowledge working.
With this willing I joined this particular project.

First of all , I would like to thank my supportive parents and family, whom I greatly indebted for me for
bringing up with love and encouragement to this stage.

I am highly obliged in taking the opportunity to sincerely thank The Bridge Cell of Surat Municipal
Corporation. And my utmost thanks for giving me this inestimable opportunity to learn through
observation and out of a textbook. I have gained invaluable insight into how construction of any
superstructure is handled and how any difficulty which comes in between is tackled. Apart from
technical knowledge , I have gained insight into management of construction , efficient manpower and
lots of other things.

I am deeply indebted to our site manager at site office Mr. Maheshbhai Patel and Dr. H S Bhavsar
( Asst. nodal officer - SMC ) whose help, stimulating suggestions and encouragement helped me all
the time. Also i am beholden to executive engineer at site Mr. Parth Patel for helping me understand
all the process of construction in detail with pleasant response and also gave healthy efforts to make all
things thoughtful.

Last but not least , I would like to thank the supreme Almighty god for the successful completion of my
training. Without his grace this project could not become reality.

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Chapter : 1

Introduction :
General

The bridge is a structure of facilitating a communication route for carrying road traffic or other moving
loads over a depression or obstruction such as river, stream, channel, road or railways.

The bridge is a major achievement of engineering science. It is an art of individuality. The story of
great bridges is hardly a hundred years old, and though it is not apparent at first glance, many of the
types in use today.

Broadly a bridge can be divided into major parts: components of bridges

Superstructure – The superstructure of a bridge is analogous to a single-story building roof and

substructure to that of the wall, column, and foundation. The superstructure consists of structural
members carrying a communication route.Deck slab, roller , bearing, pedestal , pier handrail, guards
stone and flooring supported such as beams, girder, arches cables. components of bridges

Substructure – substructure is a supporting system for the superstructure. It consists of the following
abutment, pier, Wingwall, and foundation consisting of PCC , pile , pile cap etc.

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Planning

Surat had already completed it's Century in Flyovers which contains ROB, FOB, Multi layer Road
Bridge, Multi layer Railway Bridge, Cable Bridge, Cable Stayed Bridge, Longest Four lane bridge
under municipality limit, River Bridge, Creek Bridge etc. And one more ROB came to overcome
congestion issue at Sahara darwaja near Surat railway station.

Design and contract :

In this project , Public class , non-governmental company " RANJIT BUILDCON " and for designing
and estimation work " CASAD CONSULTANT " from Ahmedabad is involved.

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Chapter : 2

Project area :
Location : Railway Over Bridge near Surat railway station between station Surat & udhna across
Surat-Mumbai railway line near R.C No. - 445 , Surat .

Details about location :

The Surat Municipal Corporation ( SMC ) has planned a multilayer bridge with 17 lanes to ease the
heavy traffic congestion on both sides of the railway station area . The bridge being built at a cost of
133 crore would give people direct access to Kapodra in Varachha from Ring Road flyover and an easy
passage from Sahara darwaja underpass.

This project received preliminary sanction from railway authorities in 2017 and after the tendering
process commenced and project is under construction .

Due to this Project traffic can flow in 17 lanes . This multi level flyover bridge will be built and it will
cross over the ring road flyover from Sahara darwaja railway line to Karni Mata junction. That will be
built at a cost of 134 crore . The important part in this project is that 8 lanes will be open soon under
the railway line . In the existing situation there are 4 lanes under railway line area and after
commencement of the other 2 lane box drains there will be 4 lanes on each side and all over there will
be 8 lanes . And also 1.5 - 1.5 lanes will be provided on the multilevel overbridge plus below sahara
darwaja junction there will be 3 -3 lanes hence it will result in 17 lanes .

How 17 lanes are distributed :

2 lanes provided for Ring Road flyover bridge to Delhi Gate and 2 lanes for Delhi Gate to Ring Road
flyover bridge.

2 lanes provided below the Ring Road flyover bridge for Delhi Gate to Udhna darwaja and 2 lanes for
Udhna darwaja to Delhi gate.

1.5 lanes are provided for the Ring Road flyover bridge to Karni Mata junction and another 1.5 lanes
for Karnimata junction to the Ring Road flyover bridge. These lanes are on multi-layer over bridge .

3 lanes are provided through (under) Sahara darwaja railway line to Bombay Market and other 3 lanes
from Bombay Market to Sahara Darwaja.

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6
Chapter : 3

Details of bridge :

Sr. Details of Detail

1 Type of bridge Railway over

bridge

2 Total Length of bridge 2785.487 mtr.

● Railway limit 97.782 mtr.

● S.M.C. limit
2687.71 mtr.

3 Length of approach -

● Rly.sta. to Sahara Darwaja (1.5 lane ) 417.51 mtr.

● Ring FOB to Sahara Darwaja ( 1.5 lane )
● Sahara darwaja to Ring Road FOB toward (1.5 lane ) 570.75 mtr.
● Sahara Darwaja to Kadodara down side (2 lane )
● Sahara Darwaja to Kadodara down side ( 3 lane ) 528.505 mtr
● Karnimata junction to Bombay Market ( 1.5 lane )
484.89 mtr.

488.20 mtr.

197.85 mtr

4 Railway Portion 97.68 mtr

Total length including approach 2785.487 mtr

Width of bridge -

● Railway Portion 7.5 mtr /10.5 mtr

● S.M.C. portion
50.5 mtr /7.5
mtr /10.5 mtr

5 Type of foundation Pile foundation

6 Sub structures R.C.C. pier pier

cap , abutment ,
abutment cap

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 Super structures Steel component
girder , PSC
7 girder

8 Bearing Elastomeric
bearing /POT -
PTFE bearing

9 Expansion joints Single strip steel /

modular
expansion joint

10 Name of contractor Ranjit buildcon

limited

11 Name of design consultant Casad consultant

12 Total tender amount 133,50,00,109=6

5 paise

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Chapter : 4

Methodology and Process

1. Methodology

ACTIVITIES IN THE PROJECTS

( 1 ) preliminary Activities
a) Settings up of site office
b) Site and topographic survey
c) Geotechnical investigation
d) Setting of batching plants
e) Setting up of fabrication yard
f) Setting up of labour camp

( 2 ) Foundation
a) Excavation of pits for foundation
b) Pile boring
c) Pile capping

( 3 ) Superstructure
a) Pier
b) Pier caps
c) Bearing
d) Pedestal
e) Cast in situ PSC girder
f) Deck slab construction

( 4 ) Finishing items
a) Anti crash barrier and railing
b) Drainage system
c) Wearing coat and expansion joints
d) Painting

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2. CONSTRUCTION PROCESSES :

Foundation Design

Type of foundation: Cast-in-situ pile foundation

Dimensions:
● Excavation pit : ( 650+3000+650 +( 2x150)) mm x (650+3000+3000+650 + 2 (cover = 150))
mm
● Height of excavation pit : 23500 mm

● Pile diameter : 600 mm

● Pile length : 22000 mm

● Height of pile cap : 1500 mm

● Grade of concrete for pile & pile cap : M35

Construction of pile :
The first and primary step involved in the excavation is to find out the extent of soil and Clearing of the
construction site is of unwanted bushes, weeds and plants.

Setting out or ground tracing is the process of laying down the excavation lines and centre lines etc. on
the ground before the excavation is started.

Maximum of 4 and minimum of 2 benchmarks are marked in the corner for the measurement of level.
These benchmarks are marked on permanent structures like, plinth, road or tree.

The tracing is marked by lime powder.

With the reference of drawing and benchmarks the depth of the excavation is fixed.

Excavation for piles is to be done auger. Boreholes are created at the desire marked area upto desire
depth. Excavated soil either removed from the site or stocked up around the excavation pit.

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Reinforcement cages which were prepared on ground , are gently placed into the boreholes. Concreting
is to be done. A pile is cast on the ground .

Construction of pile cap :

Pile cap is protecting structure of pile and supporting structure for pier.

For the construction of piles , First of all long twisted steel bars are used for preparing reinforcement of
pile caps. Bars should be shaped as designed and held on the pile and tied with steel wires ( tie - pile
and pile cap reinforcement). After that oiling and shuttering for the pile cap is to prepare around the
periphery of the pile cap to hold the concrete slurry. This process is called shuttering and reinforcing.

After shuttering concrete slurry is poured , stirring is commenced simultaneously to remove voids from
the concrete.

When it gets it's hardened state around after 14 days formwork has been removed.

Construction of pier and pier cap :

Concrete grade for : pier - M45 , pier cap - M35

Bar - HYSD or Fe -500

Pier : In multi-span bridges ,piers are required to support bridges between abutments at the both ends
of spans. Pier is upright and supports the Superstructure of the bridge.

Pier cap : The upper or bearing part of the bridge pier , usually made up of concrete or hard stone . It is
designed to distribute concentrated loads evenly over the area of the pier.

As the process of construction of pile cap , construction of pier and pier cap is the same .

As first reinforcement is prepared and then oiling and shuttering is to be done and then concrete is
poured with stirring or vibrating process for removal of air pockets. When it gains desire strength
formwork would be removed.

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Construction of PSC girder :
Concrete grade : M45

Girder : These are the strong beams that carry load from the superstructure to the substructure.

A girder is a support beam used in construction.It is the main horizontal support of the structure.
Girders often have an I - beam cross section composed of two load bearing flanges separated by a
stabilizing web . In our case prestressed concrete girders are used and we're casted on site .

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Prestressing cables : The prestressing cables serve for prestressed concrete which is kind of
reinforced concrete in which the reinforcement means are used to create an artificial load on the
element , and this artificial load oppose the element's service load and in fact offsets part of
them.prestressed concrete beam are generally used for building bridges or covering bearing great
loads over large spans.
The concrete artificial load is called tension, and is usually obtained by adding tensile stresses to the
reinforcement of the element , before applying the service loads. If the prestressing is before casting of
the structural element is called " pre tensioned " and if it is performed after building of the element it
is called " post tensioned ".

Other details about cable , strands , artificial load , offset detail is given in the below sheet.

Construction of Pedestal :
Their purpose is to provide a bearing area at the exactly correct elevation for the beam that bears upon
them to achieve the designed driving surface profile of the bridge deck above them.

They are where bearing pads are placed at the exact, flat, elevation required for the beams to sit upon,
along the slope of the cap, in order to have a smooth driving surface (the deck) placed upon them at its
designed profile. Instead of having the difficult construction task of placing a large volume of concrete
(the cap) at a perfect slope with perfectly flat areas at the beam bearing points at the correct elevations,
pedestals are formed and placed separately on top of the cap to fine-tune the bearing surface elevation
for each beam (and bearing pad) on top of the caps.

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Caps are often at slopes due to curves or differences of elevation in a bridge, so pedestals provide flat,
level bearing areas for the beams. If the bridge is straight, and level with no slope, then pedestals are
largely unnecessary. However, they are still often used as a measure of quality control in the
construction of the bridge because it's often easier to separately form and place small quantities of
concrete (the pedestals) at an exact elevation than it is to place an entire, large, cap. And if the cap is
not built perfectly, then the pedestals allow for fine tuning of the bearing elevations.

Construction of bearing :
Bearing is the component of bridge on which the girder (in case of girder bridge), or Solid slab(in case
of slab bridge) rests. Bearings give the supporting conditions to superstructure. Bearings transfer loads
from super structure to sub structure.

Mainly these bearings are provided to transfer combinations of loads like vertical load, horizontal load,
longitudinal forces, and transverse forces depending on the type of bearing provided.

Bearings have many uses in bridges. In our case we used elastomeric bearing in bridges .Which is
proved between bedblock and Girder section, psc slab etc.

Some uses of bearings in bridges are as follows.

● absorption of shock.means elastomeric bearings have good shock absorption capacity.

● Provides isolation between two concrete sections that why damage to structure is eliminated.

● By use of bearings Concrete section remains free to expand and contract. it means no
restrictions to expansion and contraction so that's why no problem of distortion of concrete
members.

Construction of deck slab :

Basically the Deck slab is the part of structures which is constructed over the girders and being used by
the vehicles to cross over the bridge.

It also acts as a medium to bind the girders, as the load of vehicles is directly taken by the deck slab
and further transferred to the girders.

A solid slab is normally the slab which is being used in normal construction work.i.e. Roof Slab.

Deck slab is designed to take comparatively heavy loads coming from running of vehicles than a
normal Solid slab.

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Construction of crash barriers :

Crash barrier is a strong fence at the side of a road or in the middle of a dual carriageway or motorway,
intended to reduce the risk of serious accidents. Crash barriers keep vehicles within their roadway and
prevent them from colliding with dangerous obstacles such as boulders, sign supports, trees, bridge
abutments, buildings, walls, and large storm drains, or from traversing steep slopes or entering deep
water, if the vehicle goes out of control.

When a vehicle hits a crash barrier, both the crumple zone(if the vehicle has got one) and the barrier
will gradually reduce the speed at which the vehicle is travelling. After a vehicle hits a barrier, the
vehicle has only momentum, that is the vehicle’s mass multiplied by the velocity. An object with
momentum can be stopped if a force is applied against it for a given amount of time. This force will
change the object's momentum. As the force acts upon the object for a given amount of time, the
object's velocity is changed and hence, the object's momentum is changed. The crash barrier applies
this opposite force. In physics, this drastic change of momentum is called impulse.

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Chapter : 5

Management and safety

Management and safety are two major aspects in any construction project. Management reports of
resources like material and manpower , machines and other equipment has to be well prepared .
Scheduling of different works is well organized by the executive site engineer in our project . Propper
designing work estimation work performed by consultants in a precise way.

Saftey is one of the major issues at bridge construction sites. Because the area is so busy that it is a
major industrial and station area. Area is a pivotal link of in to out and out to in trips.Health and safety
is a main focus for any project.the area where this is most greatly affected is the traffic control. All the
criteria given below have been taken under control by the management crew.

● Saftey of pedestrians , and motorists travelling through the work zone.

● Protection of wok crews from hazards associated with moving traffic.
● Capacity of less delays.
● Maintenance of access to adjoining priorities.

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Chapter : 6

Conclusion
This project is all about a multi level bridge which is planned over the railway line.

All of the training projects give ideas about the construction process of all the bridge components with
detail of material and grade of material and approx judgement about how all things are managed at the
actual site.

Project is under progress but it will give proper traffic mass control in 17 lanes in both direction and
reduce congestion during peak hours and divide traffic in different lanes

Also give an aesthetic look to very clogged areas.

After having completed my training . I have gained basic knowledge in the field of bridge construction

This Project has familiarised me with practicality surrounded around any project

I have been exposed to the standard requirements that needs to be followed during construction

For any country to progress it needs to have proper infrastructure elso no development can proceed
from the word go.

So as a civil engineer we will have to be focused and determined on every major and minor thing
which is equally important to the qualitative construction.

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