INDUSTRIAL TRAINING

REPORT 0N

CONSTRUCTION WORK
Submitted in Partial Fulfillment of the Requirements for the Award of degree of

BACHLOR OF TECHNOLOGY

IN

CIVIL ENGINEERING

Submitted to:- Submitted by:-

Mr. Sandeep Yadav Mr. Deepak

B.tech (Civil) 8 TH Sem.

191401013003
DEPARTMENT OF CIVIL

ENGINEERING

RPS GROUP OF INSTITUTIONS

BALANA, MAHENDERGARH, HARYANA - 123029

SESSION - 2019 - 2023

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2
 ACKNOWLEDGEMENT
This project report bears the importance of many people who were either directly
or indirectly involve in the successful completion of this project work. Wish to
accord my sincere gratitude to Mr. Vikas Yadav, Head of project for providing me
opportunity for training in their organization.
I express my sincere in indebtedness to my project guide Mr.Pankaj Tomar
& Mr. Harender engineer, from the core of my heart for their willing help, timely
co-operation and excellent guidance. They all infused in me the everlasting
inspiration that not only lead to the successful completion of this project work but
also added a new face to my personality.
I also extend my gratitude to all officers & others staff of Jai Bharat Construction
Company who helped me throughout the duration of my project training without
their co-operation & guidance it would not have been possible for me to
successfully completion this internship.

Date Paras
Place

3
 Preface

Working in an industry provides us a practical approach to our theoretical basis of

knowledge acquired in our classroom. It has been a great pleasure, training at Jai
Bharat Construction Company basically a Real Estate industry which helped me
boost up my practical skills in implementing the theories of book into actual work
environment.
The following implant training reports presents all my observations, analysis made
during my training of 4 months. The report concerns mainly with the flyover
elements where I have been deputed in the training.

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 CONTENT
1.
INTRODUCTION…………………………………………………………
………….. 1

2. COMPANY
PROFILE………………………………………………………………… 2

3.
ACKNOWLEDGEMENT…………………………………………………
…………. 3

4. EXECUTION OF
PROJECT………………………………………………………… 7
.
5. NOTATION AND
SYMBOLS……………………………………………………… 8

6.
SURVEYING………………………………………………………………
……………. 10

7.
FOUNDATION……………………………………………………………
…………… 14

8. TYPE OF
FOUNDATION……………………………………………………………
15

9. PILE
FOUNDATION……………………………………………………………
…… 23

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 10. PILE
BORING……………………………………………………………………
…… 27

11. ESTIMATING PILE

CAPACITY………………………………………………… 29

12. PILE
CAP…………………………………………………………………………
…… 37

13. PILE
SHAFT………………………………………………………………………
…… 39

14. SEISMIC
STOPPER…………………………………………………………………
43

15. CURING OF
STRUCTURE………………………………………………………47

16. BORE
HOLE………………………………………………………………………
… 48
17. EXECUTION OF BORE
HOLES……………………………………………… 48

18.
SUPERSTRUCTURE……………………………………………………
………… 49

19.
SEGEMNTS………………………………………………………………
6
 …………… 50

20.
GIRDERS…………………………………………………………………
…………… 52

21. LAUNCHING OF
SEGMENTS………………………………………………… 53

22.
PRESTRESSING…………………………………………………………
………….. 55

23.
GROUTING………………………………………………………………
…………… 56

24.
BEARING…………………………………………………………………
…………… 61

25.
GIRDERS…………………………………………………………………
……………. 62

26. CRASH
BARRIER…………………………………………………………………
… 64

27.
ABUTMENT………………………………………………………………
…………… 66

28. DACK
7
 SLAB………………………………………………………………………
…… 67

29.
AGGREGATE……………………………………………………………
……………74

30. TEST ON
AGGREGATE……………………………………………………………
78

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EXECUTION OF PROJECT

1) Sequence of construction:
2) Surveying
3) Analysis and design of the structure
4) Piling
a) Drilling
b) Pile cap Construction
5) Construction of Pier shaft and Pier cap
6) Construction of Pedestal and seismic stopper
7) Construction of segments and/or girders
8) Launching and gluing of segments
9) Construction of road over bridge

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 Notation and symbols
lx        =       Effective length about XX axis
ly       =       Effective length about YY axis
leff     =       Effective length

L       =       Overall length

B       =       Breadth of the member

D       =       Overall depth

d        =       Effective depth

W      =       Total load

Wu    =       Design load

ax1   =       Negative moment coefficient of continuous edge

ax2   =       Negative moment coefficient at mid span

Mx1   =       Negative moment at continuous edge

Mx2   =       Positive moment at mid span

MR    =       Moment of resistance

Mu     =       Factored moment

Ast    =       Area of steel required for tension

bf      =       Breadth of flange

Df      =       Depth of flange

fck     =       Characteristic compressive strength of concrete

fy       =       characteristic compressive strength of steel

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P       =       Axial load on a compression member

Vu     =       Shear force

tc      =       Shear strength coefficient of concrete

tv      =       Nominal shear stress

?        =       Strain in compression steel

Ø       =       Diameter of mild bars

#        =       Diameter of HYSD bars

N       =       Newton

kN     =       Kilo Newton

Z       =       Lever arm

C/C   =       Centre to Centre distance

m       =       Modular ratio

S       =       Spacing of stirrups

u.d.l   =       uniformly distributed load

Ld     =       Development length

Fe 415=      High yield strength deformed bars

M20   =       grade of concrete

sst     =       Permissible stress in steel in tension

ssv    =       Permissible stress in shear reinforcement

scbc  =       Permissible stress in concrete in bending compression

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SURVEYING TOPOGRAPHICAL SURVEY:
Topography is used to determine the position or any point in both the horizontal
and vertical coordinates (Latitudes, Longitudes, and Altitudes).
Survey includes Reconnaissance. Then various maps are studied and then detail is
done by Total station and layouts are given on AutoCAD.
With the help of this total space for the construction of the flyover, no. Of lanes
are total carriage are decided.

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 TRAFFIC SURVEY:
Is done carry out design improvement traffic system and management. Traffic
forecasts predict the future traffic levels on the road. In this flyover design is so
made to meet for next 25 yrs.

TRAFFIC MONITORING:
Traffic control includes CCTV and other means for monitoring traffic by local and
state roadways to manage traffic flow and providing advice concerning traffic
congestion.

TRAFFIC CONTROL:
Traffic controllers (T.C) usually knew as Lollipop men shows their Stop/Slow sign
known as STOP. A camera is also installed to detect the traffic rule violations,
including speeding of vehicles.

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14
 SOME PRECAUTIONS DURING INDUSTRIAL TRAINING
• Always wear a good quality helmet on the site.
• Always wear shoes on the site.
• Wear safety belts if required.
• Safety nets should be provided wherever it is necessary.

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 FOUNDATIONS:
Foundations are the structures which are constructed below existing ground level.
It sustains the loads coming from the sub structures and superstructures.
Bridges had to carry a big load so PILE FOUNDATION is preferred.
It is a type of foundation which was good soil is at the depth of 10-15m or soil
having low bearing capacity.
In this flyover Group of piles drilled for piling:
For P1 to P14- 10 Piles (140 nos.), for P21, P23, P24, P26, P27, P29, P30, P32, 33 &
P21A- 4 Piles (40 nos.), for P22, P25, P28, P31, P22A-6 Piles (30 nos.), P16 to P19-8
Piles(32 nos.)
Total nos. Of piles =242 piles

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Types of Foundation

The selection criteria for a foundation depends on the soil and load on the structure,
so before choosing a foundation for a construction project, it is advisable to know the
suitability.
In this article, we will learn about the various types of foundations used in civil
engineering with sketches.

Functions of foundation

 Distribution of load.
 Sliding and turning direction.
 Avoid settlement.
 Provide a level floor.
 Reduce disaster to the motion of soil.

Different Types of Foundation in Construction

1.Shallow Foundation
 In shallow foundation the depth of the foundation is less than or equal to its
width.
 These foundations are constructed where the soil layer is at shallow depths (up to
1.5 m) and capable of supporting structural loads.
 The depth is usually less than its width.

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2. Wall or Strip Footing
Wall foundations spread continuously along the direction of the wall and
help in transmitting the load of the wall into the ground.
This footing is suitable where the loads to be carried are small & economical in dense
sand and gravels.
In this types of foundation, the width is 2-3 times the width of the wall on the floor
stage.

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3. Isolated or Pad or Spread Footing

Isolated footing is most suitable for depths greater than 1.5 m.

This footing is in the form of flat slabs and it can be constructed by plain or reinforced
concrete.
In this types of foundation, the base of the column is large.

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 4.
Combined Footing:

Combined footing is types of foundation that are made wider by providing two or more
columns in a row.
It is used when the footing property for a column can extend beyond the line.
It is also suitable when the two columns are closely spaced and the soil on which the
structure resists low bearing capacity.

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5. Cantilever or Strap Footing:
When an edge footing cannot extend beyond the property line, it is combined with
other internal footings using a strap beam called strap footing.

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6. Mat or Raft Foundation:
A mat foundation is a joint notch that covers the entire area under a structure, it
supports all the walls and columns known as the fleet foundation.
The mat foundation economical when:
 The allowable bearing pressure is low.
 These types of foundation are heavyweight structures.
 The site is with a highly compressed layer.

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7.Deep Foundation:

In a deep foundation, the depth of the foundation is greater than its width, these foundations are
constructed very deep below the ground surface.
Typically at depths 3 m below ground level.

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9. Pier Foundation:
The pier foundation is an underground cylindrical structural member that supports heavy loads of
structure that cannot resist shallow foundations.
Unlike pile foundation, this foundation can only transfer loads by bearing.

10. Caissons Foundation:

The term caisson refers to a box or a case, they are hollow blocks usually constructed on-site and drown
in hard-bearing parts.
As they are expensive to construct, usually restricted to major foundation works.
Well foundation is suitable when the soil has large boulders obstructing entry during the installation of
the pier or pile foundation.

Sr. No. Foundation Suitable Depth

1 Shallow Foundation Up to 1.5 m

2 Wall foundation More than 0.5 m

3 Isolated footing Up to 1.5 m

4 Combined footing Less than 0.75m

5 Strap footing Up to 0.6 m

6 Mat foundation Up to 0.5 m

7 Deep foundation More than 3 m

8 Pile foundation 3.5m to 20m

9 Pier foundation Up to 5 m

10 Caisson foundation Up to 35 m

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 PILE FOUNDATION

All piles have Dia. =1200mm Depth =25m (except for P1A, P1B, P1D which have
30m piling) M35 Grade of concrete
Piles are structure that is made up of steel, concrete, timber. They are used to
build pile foundation, and use of piles is necessary to ensure safety.
PILES are divided in given category:

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 Driven and cast-in-place piles :
These are widely used in the displacement pile group. A tube closed at its lower
end by a detachable shoe or by a plug of gravel or dry concrete is driven to the
desired penetration. Steel reinforcement is lowered down the tube and the latter
is then withdrawn during or after placing the concrete. These types have the
advantages that: (1) the length can be varied readily to suit variation in the level
of the bearing stratum; (2) the closed end excludes groundwater; (3) an enlarged
base can be formed by hammering out the concrete placed at the toe; (4) the
reinforcement is required only for the function of the pile as a foundation
element, i.e. not from considerations of lifting and driving as for the precast
concrete pile; and (5) the noise and vibration are not severe when the piles are
driven by a drop hammer operating within the drive tube. Driven and cast-in-
place piles may not be suitable for very soft soil conditions where the newly
placed concrete can be squeezed inwards as the drive tube is withdrawn causing
'necking' of the pile shaft, nor is the uncased shaft suitable for ground where
water is encountered under artesian head which washes out the cement from the
unset concrete. These problems can be overcome by providing a permanent
casing. Ground heave can damage adjacent piles before the concrete has
hardened, and heaved piles cannot easily be redriven. However, this problem can
be overcome either by preboring or by driving a number of tubes in a group in
advance of placing the concrete. The latter is delayed until pile driving has
proceeded to a distance of at least 6.5 pile diameters from the one being
concreted if small (up to 3mm) uplift is permitted, or 8 diameters away if
negligible (less than 3 mm) uplift must be achieved.22 The lengths of driven and
cast-in-place piles are limited by the ability of the driving rigs to extract the drive
tube and they cannot be installed in very large diameters. They are unsuitable for
river or marine works unless specially adapted for extending them through water
and cannot be driven in situations of low headroom.

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 CONCRETE PILES
In this flyover, Piles used are Concrete cast in-situ piles. Types of Concrete Piles:

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 PILE BORING:
Digging in ground for strong foundation is Pile Boring. For excavation on top soil
2-3 m an instrument named AGAR is placed on the top of the digging machine.
Liner is used to maintain the stability of the soil.

SOFT GROUND DIGGING HEAD:

It is being made for digging clay and it is made of heavy duty high carbon. It is
being is done in 3 phases:
A) EXCAVATION- Digging is done by Auger Machine (MAT) up to 28m. After
digging flushed Bentonite to prevent the bore hole from collapse and installing
the bottom section of temporary casing in ground by oscillating and jacking.

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 B) CONCRETE PLACEMENT:
Concreting is done by transit Mix Truck and it has got ability to take 7 cubic m of
concrete which are casted in foundation and settled by TREMIE Pipe.
The pile shaft will be concreted by underwater Tremine technique the pipe is
inserted to the bottom of pile leaving cover of "500mm". Concrete will be poured
by tremine pipe by using concrete skip.

C) INSTALLATION OF REINFORCEMENT:
After completion of concreting, dowel bars of required length and nos. Will be
installed to pile shaft and down to the predetermined level before extraction of
bottom steel casing.
Reinforcement is done by steel, cage and Liner.

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 Estimating Pile Capacity :
The ultimate load-carrying of a pile is given by a simple equation as the sum of the
load carried at the pile point plus the total frictional resistance ( skin friction )
derived from the soil-pile interface.
Qu = Qp + Qs
Where
Qu = ultimate pile capacity
Qp = load-carrying capacity of the pile point
Qs = frictional resistance

Pile Groups :
Pile groups are used to transmit the structural load to the soil. A pile cap is
constructed over group piles. The pile group can be contact with the ground, or
well above the ground.
Determining the load-bearing capacity of group piles.
When the piles are placed close to each other, a reasonable assumption is that
the stress transmitted by the piles to the soil will overlap, reducing the load-
bearing capacity of piles. Ideally, the piles in group should be spaced so that the
load-bearing capacity of the group should not be less than the sum of bearing
capacity of the individual piles. In ordinary situations center-to-center pile spacing
is 3 – 3.5D.
In our design it is taken 3D = 3 *1.2m = 3.6m
The efficiency of the load-bearing capacity of a group pile may be defined as
Ƞ=Q g(u) /(∑Q u)
Where Q g(u) = ultimate load-bearing capacity of the group pile
Q (u) = ultimate load-bearing capacity of each pile without the group effect

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32
Types of Piles for Pile Foundation Based on Load Transfer and Function
Classification of piles with respect to load transmission and functional behavior are:

 End bearing piles (point bearing piles)

 Friction piles (cohesion piles )
 Combination of friction and cohesion piles

End bearing piles

These piles transfer their load on to a firm stratum located at a considerable
depth below the base of the structure and they derive most of their carrying capacity
from the penetration resistance of the soil at the toe of the pile (see figure 1). The pile
behaves as an ordinary column and should be designed as such. Even in weak soil a pile
will not fail by buckling and this effect need only be considered if part of the pile is
unsupported, i.e. if it is in either air or water. Load is transmitted to the soil through
friction or cohesion. But sometimes, the soil surrounding the pile may adhere to the
surface of the pile and causes "Negative Skin Friction" on the pile. This, sometimes have
considerable effect on the capacity of the pile. Negative skin friction is caused by the
drainage of the ground water and consolidation of the soil. The founding depth of the
pile is influenced by the results of the site investigate on and soil test.

Combination of friction piles and cohesion piles

An extension of the end bearing pile when the bearing stratum is
not hard, such as firm clay. The pile is driven far enough into the lower material to
develop adequate frictional resistance. A further variation of the end bearing pile is piles
with enlarged bearing areas. This is achieved by forcing a bulb of concrete into the soft
stratum immediately above the firm layer to give an enlarged base. A similar effect is
produced with bore piles by forming a large cone or bell at the bottom with a special
reaming tool. Bored piles which are provided with a bell have a high tensile strength and
can be used as tension piles

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Friction or cohesion piles
These piles transmit most of their load to the soil through skin
friction. This process of driving such piles close to each other in groups greatly reduces
the porosity and compressibility of the soil within and around the groups. Therefore
piles of this category are sometimes called compaction piles. During the process of
driving the pile into the ground, the soil becomes molded and, as a result loses some of
its strength. Therefore the pile is not able to transfer the exact amount of load which it
is intended to immediately after it has been driven. Usually, the soil regains some of its
strength three to five months after it has been driven.Cohesion piles

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Friction piles
These piles also transfer their load to the ground through skin friction. The process of
driving such piles does not compact the soil appreciably. These types of pile foundations
are commonly known as floating pile foundations

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Bored Pile Foundation
Bored pile, also called drilled shaft, is a type of reinforced-concrete
foundation that supports structures with heavy vertical loads. A bored pile is a cast-in-
place concrete pile, meaning the pile is cast on the construction site. This differs from
other concrete pile foundations, like spun pile and reinforced concrete square pile
foundations, which use precast concrete piles. Bored piling is commonly used for bridge
work, tall buildings, and massive industrial complexes, all of which require deep
foundations.

Bored Piling Process

Installing a bored pile starts with drilling a vertical hole into the soil, using a
bored piling machine. The machine can be outfitted with specially designed drilling tools,
buckets, and grabs to remove the soil and rock. Piles can be drilled to a depth of up to
60 meters and a diameter of up to 2.4 meters. The drilling process may include driving a
temporary steel cylinder, or sleeve, into the soil. This remains in place in the upper
portion of the hole until the pile is poured.

Once the hole is drilled, a structure of reinforcing steel rebar is built and lowered into
the hole, then the hole is filled with concrete. The top of the pile may be capped with a
footing or pier near ground level to support the structure above.

Bored piling work must be done by bored piling contractor, It is a highly specialized
operation requiring extensive knowledge and experience of bored pile construction and
engineering as well as soil and site conditions.

Bored Pile Applications

When used for foundations, bored piles are specified for buildings and other
structures that impose loads in the thousands of tons. They are also particularly well
suited to unstable or difficult soil conditions. In addition to foundation systems, bored
piles are used to create structural underground walls for earth retention. Piles can be
placed close together, with 75 to 150 mm between piles (called a contiguous pile wall),
or they can be placed so they overlap, to create a secant pile wall, which is often used to
control migration of groundwater.

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 Challenges to Bored Pile Construction
Like any other deep foundation system, bored piles present challenges
for the contractor. Because the drilling method used depends on the soil type, the
contractor must complete a thorough soil investigation and report. The piling
contractor relies on the soil report and past experience to choose the best drilling
method that will minimize the disturbance of the surrounding soil.

When the soil is cohesion-less, such as with sand, gravel, and silt, or the hole extends
below the water table, the hole must be supported using steel cages or stabilizing
mud, such as bentonite suspension. This solution can be a very messy process and add
considerable complexity to the project.

Bored Pile Advantages

 Piles of variable lengths can be extended through soft, compressible, or swelling

soils into suitable bearing material.
 Piles can be extended to depths below frost penetration and seasonal moisture
variation.
 Large excavations and subsequent backfill are minimized.
 Less disruption to adjacent soil occurs.
 Vibration is relatively low, reducing disturbance of adjacent piles or structures.
 High-capacity caissons can be constructed by expanding the base of the pile shaft
up to three times the shaft diameter, thus eliminating the need for caps over
groups of multiple piles.
 For many design situations, bored piles offer higher capacities with potentially
better economics than driven piles.

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38
  Formation of pile
pile cap R.L of existing ground level-cut off
Pile cap: level
After piling Pile cap is formed by combination of pile and
completion, soil is then binding the steel followed by shuttering
excavated for
construction of pile
 Dimension of pile caps
cap. for P1 to P15:
For proper pile cap Length= 16m, breadth=5.2m, height=1.8m for
P.C.C. Is provided for P16 to P19:
separation from mud.
Length= 12.4m, breadth= 5.2m, height=1.8m for
At site 75mm thick
P21, P23, P24, P26, P27, P29, P30, P32, P33,
PCC is carried out for
P21A, P20, P23A, P20
control over seepage
Length-breadth= 5.2m, height=1.8m for P22,P25,
P28, P28, P31, P22A length= 8.8m,
breadth=5.2m, height=1.8m

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 • Reinforcement steel in Pile cap
S.no. BARS
1. 20mm @140mm c/c
2. 16mm @140mm c/c
3. 32mm @90mm c/c
4. 32mm @180mm c/c
5. 16mm @180mm c/c
• Grade of concrete used
M35

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 PIER SHAFT
A pier shaft is a raised structure provided mostly at the centre of the pile cap which
supports the structure and transfers the several types of load to the foundation.

DIMENSION OF THE SHAFT:

length= 2m, breadth= 2m, height= and length 1.5m, breadth= 1.5m, height=

REINFORCEMENTS IN SHAFT:

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 PIER CAP
Pier caps are the topmost structure of the substructure. Above these the
superstructures (segments & girders) are placed.

DIMENSIONS OF PIER CAPS:

For P1 to P14: Length= 6m, Breadth= 3.3m
For P23, P26, P29, P32, P33, P20A: Length= 5.4m, Breadth 2.8m
For P21, P24, P27, P30, P31, P21A: Length= 5.4m, Breadth=
1.9m
For P15, P19: Length= 11.4m, Breadth= 2.8m For P16 to P18: Length= 11.4m,
Breadth= 2.4m

GRADE OF CONCRETE FOR CASTING

M 35 Except pier 17,where M 40 is used.

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 REINFORCEMENTS USED IN PIER CAP

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44
 BEARINGS, PEDESTALS, SEISMIC STOPPERS
After the accumulation of all the reinforcements in pier cap a surface is formed
over which Bearings, Pedestals and Seismic stoppers are provided as per the
design.

Seismic stopper: The current designs of seismically designs

as a second line of defence. These structures allow development of in-service
moments of the deck, without transmitting loads on pier and foundation, while
during earthquake they resist the entire seismic action.
Height of stopper= 1.2m LV bars are used of 400mm & 700mm,16mm dia.

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 DIMENSIONS:
 Pedestal: Length= 700mm, Breadth= 700mm, Height= 500mm
 Bearing: Height=137mm
A bearing is an element of superstructure which provides an interface between
superstructure and sub structure. This is important because of the deformations
and dimensional changes in superstructure due to Thermal expansion, seismic
forces, wind loads etc. & here use POT PTFE bearing

REINFORCEMENTS:
A mesh of dimension 750mm*850mm is used inside pedestal at 20mm and
100 mm from the top. 8mm @75mm c/c and 12mm @100 c/c

46
47
 MAKING OF PILE AND PIER CAP
PROCESS-
 Messing of Pile caps, pier shafts & pier caps by different reinforced steel
bars.
 Welding by Arc welding method.
 Shuttering and then casting (concreting).

CONCRETING OF STRUCTURES
Concrete is a composite material made up of mainly cement, water and
aggregates in definite proportion as per the grade of the concrete to achieve
the desired physical properties.
After casting of the structures curing is done.

48
 CURING OF THE STRUCTURE:
For attaining the full strength of the concrete i.e. compressive strength curing with
water is properly done on the casted structure. It takes almost 28 to 30 days for a
concrete structure to attain its strength and durability.

49
 DIA. AND DEPTH OF THE BORE HOLES:
 Diameter of the pile =1200mm
 Depth =25m (foundation level)
 Lap length =50D
 Reinforcements: 18 nos. 20mm dia. & 18mm @150c/c

The 25m of depth consists of following

4 layers:
 clay(7m)
 Gravel & clay mixes(6m)
 Clay(3m)
 Sand gravel mix

50
 SUPERSTRUCTURE

Structures which are above the pier cap and placed on the bearings are
superstructure. Roads are further constructed over it.

51
 SEGMENTS:
Placed on the bearing plate. These are used to make a span of the flyover.
Segments are precast made up of M45 GRADE concrete and FE 500. These
structures are posses both Tension and Compression members, so designs are
made by taking in account both forces on it.It consists of a deck slab, longitudinal
girders, cross girders, deck beam, pier and foundation. Structural design of one
span was made for all the above components.

52
 TYPES OF SEGMENT USED:
Pier segment(P.S)- These are placed at the end of the span on the pier cap. Length
of P.S is smaller than the normal segment and the anchor hole are inclined. Two P.S
are used in making of the span.
NORMAL SEGMENT- These are placed in between two P.S for making the span and
anchor hole are straight. Total 9 segments are used in between two pier.
Total length of span= 2*2.35+9*3.25=33.95m

S.NO. SEGMENTS LENGTH

1. PIER SEGMENT 2.35m

2. NORMAL SEGMENT 3.25m

53
 GIRDERS:
Individual beam like structure which are separately placed on the bearings. These
structures are shorter in length than segment and stressing are done precast by
using cables certain in nos. Depends on the design.
In this project l-girder of 3 and 6 span are used.

54
55
 LAUNCHING OF SEGMENT:
The segments are launched by launching girder or gantry girder. Beam are
connected both end of the segment and pressure are applied in segments. All the
segments are joined to each other by gluing.

LAUNCHING OF DECK BY LAUNCHING MACHINE:

Launching machine is used to uplift the segment of the bridge all the segments
are lifted at once by the use of lifter.
Number of segment between two pier:
no. Of segment 11
weight of one segment =600T
After placing of the segments Stressing is done by use of high tensile cables, so
that loads came to the cable & bridge should be stable

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 JOINTING OF SEGMENT:
Mixing of both type of chemical (Nitobond Pc base thixotrop epoxy adhesive &
Nitobond Pc 30 harder) is done and every time two segments are
compressed(glued) to each other. After 24 hours the process checked by flushing
water and leakage in anchor hole.

ANCHOR HOLE-
These are present in entire segment to for stressing of it. 6 nos. Of hole are present
at one side of segment. Parabolic shape.

TENSILE WIRE-
It is a high tensile steel wire inserted in all 11 segment for stressing. No. Of wire
depend on the design(12, 19,25etc.). Grade of the wire is 19T15.

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 PRESTRESSING:
Pre-stressing means creating a permanent stress in the structure. In this process
dead end are fixed with life wedge to hold the tensile wire. And the free end is
fixed with hydraulic jack and force are applied approximately 369 T.

PRE-STRESSED CONCRETE
• Prestressed concrete is the one in which there have been introduced internal
stresses of such magnitude and distribution that the stresses resulting from the
external load are counter balanced to a desired degree.
• Pre stressing can be accomplished in three ways:
pre-tensioned concrete, and bonded or unbonded post-tensioned concrete.

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 GROUTING:
Grouting involves injection of cemented material in a certain ratio of cement and
water for isolated pore or void space is often called Simple grouting.
Quantity of material:
1. Cement :1 bag
2. Water: 22 litres
3. Admixtures: cibex 100

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 SPAN:
The distance between two span is 500mm.
Total span length between two pier varies in this project P1-P5 =34m, P6-P19-37m
and rest have distance= 20m

PRECAUSTION TO BE TAKEN DURING PLACING CONCRETE-

Water should not be added to concrete during its passage from mixer to form
work.
The form work(surface) which has to receive the fresh concrete should be properly
watered (cured).
Concrete should be placed in single thickness.
Concrete should be tapped in such a way that no honeycomb surface appear on the
surface.

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 TECHNICAL SPECIFICATION
Diameter of pile 1200mm

Vertical & horizontal loads 250T & 30T

Depth of pile cap 1800mm

Number of Piles 110

Number of pile cap 19

Number of segment 198

OTHER SPECIFICATION:
Pile group -4 and 6
A1-P1-33.25m, P1-P17- 34m, P17-A2-33.25m

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 DIAMETER OF PILES 1800MM

VETICAL& HORIZONTAL LOADS 230T& 20T

CONCRETE USED M35(EXCEPT P17: M40)

DEPTH OF PILE CAP 1.8m

NUMBER OF PILES 267

NUMBER OF PILE CAP 38

NUMBER OF SEGMENT 182

NUMBER OF SHAFT 40

NUMBER OF HAMMER HEAD 37

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 Bearing : ( Used Elastomer Bearing in our case )

Bearing is a component of a bridge which typically provides a resting surface

between bridge piers and the bridge deck. The purpose of a bearing is to allow
controlled movement and thereby reduce the stresses involved. Movement
could be thermal expansion or contraction, or movement from other sources
such as seismic activity. There are several type of bridge bearings which are
used depending on a number of different factors including the bridge span. The
oldest form of bridge bearing is simply two plates resting on top of each other. A
common form of modern bridge bearing is the elastomeric bridge bearing.
Another type of bridge bearing is the mechanical bridge bearing.

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 GIRDERS: 20M SPAN GIRDERS
MAIN GIRDER:
These are the strong beams that carry load from superstructure to the
substructure.
A girder is a support beam used in construction. It is the main horizontal support of
a structure. Girders often have an I-beam cross section composed of two load-
bearing flanges separated by a stabilizing web. In our case girders were Prestressed
girders. Girders were casted at site.

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 END CROSS GIRDER:
The primary function of cross girders is to support the deck slab. The girders may
however need to perform secondary function of preventing the slab from buckling
in compression. Typically these are the transverse beams ( also very strong / stiff )
which are provided for transverse stiffness. This transverse diaphragm will make
sure that if you have multiple main girders, they share loads between them and
don’t behave independently.

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 CRASH BARRIER:
Crash barriers keep vehicles within their roadway and prevent vehicles from
colliding with dangerous obstacles such as boulders, walls or large storm drains.
Crash barriers are also installed at the roadside to prevent errant vehicles from
traversing steep slopes. Crash barriers are normally designed to minimize injury to
vehicle occupants, injuries do occur in collisions with crash barriers. They should
only be installed where a collision with the barrier is likely to be less severe than
collision with the hazard behind it.
To make sure they are safe and effective, crash barriers undergo extensive
simulated and full scale crash testing before they are approved for general use.
While crash testing cannot replicate every potential manner of impact, testing
programs are designed to determine the performance limits of crash barriers and
provide an adequate level of protection to road users.

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 Pedestal :
Pedestal is made of RCC And connecting to pier cap. The grade of concrete used for
pedestal is M40. The size of pedestal is 550mm*700mm as given below.

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 ABUTMENTS
An abutment is a structure that supports one end of a bridge in other word we can
say that it is structure located at the end & at the beginning of a bridge.
Functions of abutment
a) Support the bridge deck at end.
b) Retain the embankment of approaching road.
c) Connected the approach road to the bridge deck.

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 DECK SLAB
 The principal function of a bridge deck slab is to provide support to local
vertical loads (from highway traffic, railway or pedestrians ) and transmit
these loads to the primary superstructure of the bridge.
 As a result of its function, the deck will be continuous along the bridge span
and ( apart from some railway bridges ) continuous across the span. As a
result of this of this continuity, it will act as a plate ( isotropic or orthotropic
depending on construction ) to support local patch loads.

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70
 Transporting of concrete
Concrete can be imported by variety of methods and equipments Methods adopted
for transportation of concrete

 Mortar pan

 Wheel barrow

 Crane, bucket and rope way

 Truck mixers and dumpers

 Belt conveyors

 Chute

 Skip and hoist

 Transit mixer

 Pump and pipe line

 Helicopter

Mortar pan
This case concrete is carried out in small quantities

This method exposes greater surface area of concrete for drying conditions

This results a geat loss of water particularly in hot weather

Mortar pan must be wetted to start with and must be kept clean

Wheel barrow
Used for transporting concrete in ground level.

This method is employed for hauling concrete in longer distance in case of concrete
road construction.

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 If the distance is long or ground is rough it is likely that the concrete get segregated
due to vibration

To avoid this, wheel barrows are provided with pneumatic wheel.

Crane bucket and rope way

This is one of the right way for transporting concrete above the ground level

Crane can handle concrete in high rise construction project and are becoming
familiar sites in big cities

Rope way buckets of various sizes are used Rope way method is adopted for

 Concrete works in valley

 Construction work of the pier in the river

 For dam construction

Truck mixer and dumpers

For large concrete works particularly for concrete to be placed at ground level
These are ordinary open steel tipping lorries

Dumpers having 2-3 cubic meter capacity Belt conveyors also can be used for

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 Chutes
Provided for transporting concrete from ground to lower level

The surface should have same slope not flatter than 1 vertical to 2 and a1/2
horizontal

Skip and hoist

Adopted method for transporting concrete vertically for 3 to 4 floors Mortar pan
with staging and human ladder is used for transporting concrete

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 Transit mixer
This is the equipment for transporting concrete over a big distance particularky
ready mix concrete

They are truck mounted having a capacity of 4 to 7 m3 The speed of rotation of

truck mixer is 4to16 rev/min

A small concrete pump is also mounted on the truck carrying transit mixer

Pumps and pipe lines

Universally accepted method

Starts with the suction stroke for suck the concrete inside the pipe

It has a piston which moves forward and backward to have suction and delivery of
concrete

 Choosing a correct pump involves

 Length of horizontal pipe

 Length of vertical pipe

 Number of bends

 Diameter of pipe line

 Length of flexible hose

 Change in line diameter

 Slump of concrete

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75
 What is aggregate ?
• The materials used for manufacture of mortar and concrete such as sand, gravel
etc. are called as aggregate.

REQUIREMENT OF GOOD AGGREGATE

 It must be clean i.e. it should be free from lumps, organic materials etc.
 It should be strong.
 It should be durable.
 It should not react with cement after mixing.
 It should have rough surface.
 It should not absorb water more than 5%.
 It should not be soft and porous.
 It should be chemically inert.
 It should be of limiting porosity.
 It should preferably be cubical or spherical in shape.

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 CLASSIFICATION OF AGGREGATE
 Natural Aggregate: These aggregates are generally obtained from natural
deposits of sand and gravels, or from quarries by cutting rocks. The
cheapest among them are the natural sand and gravel. Which have been
reduced to their present size by natural agents, such as water, wind and
snow, etc. The river deposits are the most common and are good quality.
 Artificial Aggregate: The most widely used artificial aggregate are clean
broken bricks and air cooled fresh blast- furnace- slag. The broken bricks of
good quality provide a satisfactory aggregate for the mass concrete and are
not suitable for reinforced concrete work if the crushing strength of brick is
less than 30 to 35 Map. The bricks should be free from lime mortar and
lime sulfate plaster. The bricks aggregate is not suitable for waterproof
construction. It has poor resistance to wear and hence is not used in
concrete for the road work.

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 Classification according to size:
1. Fine aggregate: The aggregate which passes through 4.75 mm sieve and
retained on 75 micron sieve are known as fine aggregate.
2. Coarse Aggregate: The aggregate retained on 4.75 mm IS sieve are Known
as coarse aggregate.
3. All-in-aggregate: It is the combination of both coarse and fine aggregate.

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 CLASSIFICATION ACCORDING TO SHAPE:

1. Rounded Shape: The aggregate with rounded particles (river or

seashore gravel) has minimum voids ranging 32 to33 %. The only
disadvantage is that interlocking between its particles is less and
hence the development of bond is poor, making it unsuitable for high
strength concrete and pavement
2. Irregular Aggregate: The aggregate having partly rounded particles
(pit sand and gravel) have higher of voids ranging from 35 to 38%. It
required more cement paste for a given workability.
3. Angular Aggregate: The aggregate with sharp, angular and rough
particles (crushed rocks) has a maximum of voids ranging from 38 to
40%. The interlocking between the particles is good.
4. Flaky Aggregate: An aggregate is termed flaky when its least
dimension (thickness) is less than three-fifth of its mean dimension.
The presence of these particles should be restricted to 10 to 15%.

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 TESTS ON COARSE AGGREGATE:
1. DETERMINATION OF CRUSHING VALUE (IS 2386 Part 4 - 1963):

2. This test gives a relative measure of the resistance of aggregate to

compressive stress.
3. Crushing value of aggregate is a relative measure of resistance of an
aggregate to crushing under gradually applied crushing load.
4. Aggregate passing through 12.5 mm sieve and retained on 10mm sieve is
taken. About 6.5 kg of surface dry aggregate filled in the standard cylinder
in three layers, tamping each layer 25 times by a standard tamping rod. It is
levelled off. Its weight found out(A).
5. The plunger is placed on the aggregate taking care that it does not jam
the cylinder by becoming tilted.
6. The assembly is then kept under compression testing machine and total
load of 40 tonnes is applied uniformly during 10 minutes.
7. The load is released, the aggregate is taken out and sieve on 2.36 mm sieve.
The friction passing through weight is (B).

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 This test gives the relative resistance of aggregate to wearing.
1. There are two methods prescribed in the IS code, Deval Attrition Test and
Los Angeles Abrasion Value.
2. But since LA test gives more realistic results, it is more commonly used.
3. In this method, the specified weight, 5kg or 10 kg, depending on the size of
aggregate is taken and is placed in the cylinder of the LA machine along
with the abrasive charge.
4. The abrasion charge consists of specific number of steel balls.
5. The cylinder is rotated at 20 to 33 r. p. m. for 500 or 1000 revolution,
depending on the grading of the aggregate.
6. The aggregate is removed from the cylinder and sieved on 1.75 mm sieve.
7. The fraction passing through 1,7 mm sieve is expressed as percentage of
original weight give the aggregate abrasion value.

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 THANK YOU

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