PROJECT

REPORT

REPORT INFORMATION
Internship Program
Duration:1 Month
Location: NCC Casting yard, Patan Road,
Madan Mahal Extradosed Cable Stay
Bridge

Trainee Details
Name- Yashika Ahirwar
Position- Trainee
Institute- Shri Govindram Seksaria Institute of
Technology and Science, Indore
 TABLE OF CONTENTS

S. no. Title Page no.

1. Introduction 2

2. Company Overview 3

3. Foundation Of Project 4

4. Precast Yard 6
• Precast Concrete
• Prestressed Concrete
• Precast Girder
• Testing Machines In Lab
5. Steps of construction 20

6. Machinery and equipment used 26

7. Extradosed Cable stay bridge and cable 34

installation
• Components of cable system
• Process of cable installation
8. Conclusion 42

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 INTRODUCTION
This report presents the findings and observation from industrial training at NCC Ltd.

Focused on understanding the concept of Precast structures, prestressed concrete, flyover and

extra dose cable stay bridge. This report provides a comprehensive overview of above-

mentioned topics.

Madhya Pradesh Public Works Department (MPPWD) as initiated work for construction of

elevated corridor flyover from Damoh Naka to Ranital Chowk to Madan Mahal Chowk up to

Medical road in the city of Jabalpur of Madhya Pradesh. The project comprises construction

of approximately 5.9 05 km long and three Lane wide garage via duct and at grade

improvements in the city of Jabalpur. The elevated Road consists about 4.02 km of land

viaduct of 12.9-metre-wide deck and 5 grams measuring about 1.954 km having deck width

of 8.4m. This also consist of extra dose bridge crossing Madan Mahal railway station having

per span arrangement 96+193.5+96 m.

Flyover construction and extradose cable stay bridge are two significant engineering marvels

that contribute to the development and enhancement of transportation infrastructure.

Flyovers, also known as overpasses or elevated highways, provide efficient solutions for

managing traffic congestion and improving road connectivity in urban areas. On the other

hand, extradose cable stay bridges offer elegant and efficient alternatives to traditional cable-

stayed bridges, with their unique design and construction methods. This discussion aims to

explore the importance and impact of flyover construction and extradose cable stay bridges in

modern infrastructure development.

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 COMPANY OVERVIEW
❖ Madhya Pradesh Public Works Department (MPPWD)
Public Work Department (B&R) and Project Implementation Unit (PWD PIU) is the premier
agency of Government of Madhya Pradesh engaged in Planning, Designing, Construction and
Maintenance of Government assets like Roads, Bridges, ROB's, Fly Overs and Buildings.
The main activities of the PWD (B&R) are Construction, Upgradation and Maintenance of
National Highways, Major District Roads, Other District Roads, Village Roads and
Construction of Bridges, Fly Overs and ROB's in the State.
❖ NCC Ltd. (Nagarjun Construction Company)
NCC Ltd has dedicated itself to building infrastructure of uncompromising standards. NCC
Ltd has all fields of Civil Engineering Works including Design, Development & Construction
of Industrial Structures, Residential & Industrial Buildings and Execution of Infrastructure
Projects for Highways and Airports.
❖ Freyssinet India
Founded over 70 years ago by Eugène Freyssinet, the inventor of prestressing, Freyssinet
brings together an unrivalled range of skills in the specialist civil engineering sector, offering
integrated technical solutions in the fields of construction and structural repair. Freyssinet is
involved in numerous projects across five continents, making it the world leader in its
specialist areas of: · prestressing, · cable-stayed structures, · construction methods, ·
structural accessories, · structural repair and reinforcement, · structural maintenance.
❖ AECOM
AECOM is the world’s trusted infrastructure consulting firm, delivering professional services
throughout the project lifecycle – from advisory, planning, design and engineering to program
and construction management. On projects spanning transportation, buildings, water, new
energy and the environment, our public- and private-sector clients trust us to solve their most
complex challenges.
❖ Assystem Stup
Assystem Stup is a full-service project delivery consultancy company offering master
planning, comprehensive building design, engineering and project management services. We
serve many clients in decarbonised energy, transportation, cities & territories, buildings and
commercial, institutional, recreational and manufacturing facility infrastructures.

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 FOUNDATION
Foundation is the lowest part of the building or the civil structure that is in direct contact with
the soil which transfers loads from the structure to the soil safely.
Generally, the foundation can be classified into two categories
1. Shallow Foundation - A shallow foundation transfers the load to a stratum present in
a shallow depth.
2. Deep Foundation - The deep foundation transfers the load to a deeper depth below
the ground surface. A tall building like a skyscraper or a building constructed on very
weak soil requires deep foundation. It is further classified into Pile Foundation and
Caisson Foundation.
Pile Foundation are generally used for soils where soil conditions near the ground surface is
not suitable for heavy loads. The depth of hard rock strata may be 5m to 50m (15 feet to 150
feet) deep from the ground surface. Type of pile used in this project are as follows-
1. End bearing Pile-In this type of piles foundation, the loads pass through the lower tip
of the pile. The bottom end of the end-bearing piles rests on a strong layer of soil or
rock.
2. Friction Pile-The Friction pile transfers the load from the structure to the soil by the
frictional force between the surface of the pile and the soil surrounding the pile such
as stiff clay, sandy soil, etc.

In this project both friction and end bearing cast in-situ piles are provided in foundation. No.
of piles provided from LIC to Mahanadda are 4, at Garha and Malviya Ramp are 3 and at pier
77 are 6 with a capacity of 400 ton having diameter 1.2m.

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Below the Lower Pilon of Extradosed cable stay bridge i.e., at pier 75 and 76, 24 piles are
provided 25-30 m deep having diameter 1.2 m with a capacity of each pile being 700-750 ton.
Piles are spread over an area of 19.5 m X 19.5 m of octagonal shape with pile cap of
thickness of 1.5m to 2m.
Grade of concrete used for pile is M-35 and for pile cap is M-45 and M-40.

Pile Foundation
❖ Soil Investigation and tests performed
• Soil Investigation
• The standard penetration test (SPT)
• Core Recovery
• Matching sample to core box
• Static load test etc..

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 PRECAST YARD
❖ PRECAST CONCRETE
Precast concrete is a construction product produced by casting concrete in a
reusable mold or "form" which is then cured in a controlled environment, transported to the
construction site and maneuvered into place; examples include precast beams, and wall
panels for tilt up construction. In contrast, cast-in-place concrete is poured into site-specific
forms and cured on site.

Precast concrete is used in the following ways:

• To make beams, columns, floor slabs, foundations, and

other structural members for buildings.
• To make wall or cladding panels for buildings.
• To make precast pre-stressed elements for buildings.
• To make components for infrastructure projects: elements such as bridge spans, or
metro line viaducts are often precast in a casting yard.
• To make products such as precast water tanks, septic
tanks, drainage chambers, railway sleepers, floor beams, boundary walls and water pip
es.

As it is done in a purpose-built precasting yard or factory, it makes construction easier for the
following reasons:

• The construction is done on the ground rather than at height.

• It can be done inside a climate-controlled structure, eliminating problems
of rain, dust, cold, or heat.
• Specialised formwork (moulds) can be built for doing many repetitions of the
same component.
• Specialised equipment can be used to make, move, and pour the liquid concrete.
• Curing takes place in a controlled environment.

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❖ PRESTRESED CONCRETE
Prestressed concrete is a system devised to provide sufficient precompression in the concrete
beam by tensioned steel wires, cables, or rods that under working conditions the concrete has
no tensile stresses or the tensile stresses are so low that no visible cracking occurs.

Principle of prestressed concrete

High-strength seven-wire strands, high-strength steel wire, or alloys of grade and type (as
specified by the designer) should be used in prestressed concrete. Also, stronger concrete is
required in prestressed than normal RC.

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 HT Strand
Here 7 ply HT (High Tension) strands are used for post tensioning. The weight of 1 m being
1.5 kg with diameter of 15.7mm
➢ Types of Prestressing System
1. Pre-Tensioning System
Pre-tensioning is accomplished by stressing wires or strands, called tendons, to
predetermined amount by stretching them between two anchorages prior to placing concrete.
The concrete is then placed and tendons become bonded to concrete throughout their length.
After concrete has hardened, the tendons are released by cutting them at the anchorages. The
tendons tend to regain their original length by shortening and in this process transfer through
bond a compressive stress to the concrete.

Section for Pre-Tensioning

2. Post-Tensioning System
In a post-tensioned beam, the tendons are stressed and each end is anchored to the concrete
section after the concrete has been cast and has attained sufficient strength to safely withstand
the prestressing force.
In post-tensioning method, tendons are coated with grease or a bituminous material to prevent
them from becoming bonded to concrete. Another method used in preventing the tendons
from bonding to the concrete during placing and curing of concrete is to encase the tendon in
a flexible metal hose before placing it in the forms. The metal hose is referred to as sheath or
duct and remains in the structure.

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 Section for Post-Tensioning
❖ PRE-CAST GIRDERS
Precast prestressed girders are a type of concrete girder that facilitates the rapid construction
of a bridge using girders fabricated off-site and then transported and erected into place at the
job site. Because these girders require little to no falsework, they are a preferred solution for
jobs where construction speed or minimal traffic disruption is required. Prestressed girders
are particularly economical when longer beam lengths are required; some types are suitable
for spans of up to 200 feet.
Various types of girders (I, U, Box, and T) are possible. Generally, due to the pre-tensioned
characteristics, the shape of the Tendon profile is often straight. It is often used for composite
girder bridges where the slabs and girders are combined.

➢ BOX TYPE GIRDER

It is a bridge in which the main beams comprise girders in the shape of a hollow box
(rectangular or trapezoidal shape). The box girder normally comprises either prestressed
concrete, structural steel, or a composite of steel and reinforced concrete.

A box girder is formed when two web plates are joined by a common flange at both the top
(Deck slab) and the bottom (Soffit). The closed cell which is formed has a much greater
torsional stiffness and strength than an open section and it is this feature which is the usual
reason for choosing a box girder configuration.

Plan of Segment resting on pier

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Male and female keys are provided in segment to interlock 2 segments to each other during
launching in site. Diaphragm is provided at segments resting on pier for installation and
further maintenance.

Midspan Segment

Fe 500D TMT bars are used for reinforcement of different diameter like
12mm,16mm,20mm,25mm,32mm.

M-45 grade concrete is used which consists of OPC 43 grade cement,flyash,R sand, Crushing
sand, 20mm and 10mm Aggregate, water, admixtures and plasticizer like Shaliplast-
PCE200.It is cured for 14 days to gain characteristic strength.

Box girder at Pre cast yard

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 Reinforcement of Box type girder

HDPE (High Density Polyethylene) Pipes are inserted in reinforcement provided for post
tensioning over which anchor cone is fixed. Anchor cones are provided at web and soffit with
dummy cones in case of future tensioning and maintenance. LRPC cables are inserted in
these cones for tensioning. Post tensioning and grouting of box type girder is done after
launching of all segments between two piers in site. Parabolic profile is provided for cables.

Position of Anchor cone and keys

Parabolic profile of post tensioned cables

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➢ I-TYPE GIRDER

These girders consist of a horizontal top flange, a vertical web, and a horizontal bottom
flange, forming an "I" shape in cross-section. The web decreases in thickness at the centre
while thickening at the ends where it rests on the bearing. The top flange almost remains
same throughout the length of the beam, while the bottom flange may thicken at the centre or
as per design requirement.
The top and bottom flanges provide lateral stability and resistance to bending moments, while
the web serves as the primary load-carrying member, resisting shear forces and torsion. The I
section beams are connected by a diaphragm at the ends and at the centre. The diaphragm
increases stiffness and flexural capacity of the entire edifice.

I-Girder at precast yard

Rienforcement and concrete used is same as for box girder.I- girder is provided for span upto
30m and at rotary.

Details of Section of I-Girder

The post tensioning of I- Girder is done at precast yard itself using hydraulic jack.Grouting is
done after prestressing.Cement slurry is used in grouting in which Cebex 100 admixture (for

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cementitious grouts where a reduced water/cement ratio and positive expansion is required.)
is mixed. 5 Bags of cement get consumed in grouting of 1 hole.

Before Grouting After Grouting

Parabolic Profile Of cables

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 ❖ Testing Machines in Lab
1. Digital Compression Testing Machine

• A compression Testing Machine (CTM) is used to measure the compressive

strength of a material.
• The CTM machine is used in construction industries to test the quality of concrete.
The compressive strength of concrete is determined by testing concrete cubes or
cylinders using the CTM machine.
• Here compressive strength of 289 days cured M-55 Concrete cube was found to be
76.37 MPa

2. Permeability Test

• Permeability is the ability of a given sample of concrete to permit liquids or gases to

pass through it.
• Permeability causes development of cracks on concrete begins, and also the concrete
starts spalling.

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• To know the permeability of concrete, various permeability tests are performed on
concrete.
3. Flexure Testing Machine

• The Flexure Strength Testing Machines are designed to test flexural strength of
concrete beams.
• Here 600mm beam was tested.

4. Field Density Test

• The field density test of soil is conducted in the field to know whether the specified
compaction is achieved or not. Normally Sand Replacement Method is adopted for
this purpose.
• Sand Replacement Method is also known as Sand Cone Method.
• The apparatus used in this field density test consists of a sand pouring cylinder, with
pouring cone at its base. There is a shutter between the cylinder and the cone.

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5. The California Bearing Ratio(CBR) test
• California bearing ratio test is one of the soil strength evaluation tests. In this test, the
relative strength of a soil specimen is measured with respect to the standard sample.
• California bearing ratio is the percentage of stress a soil specimen can resist for a
certain amount of penetration relative to the value of stress of which a standard soil
could resist. Basically, the value is an indicator of the strength of the soil.

6. Mortar Cube Vibrating Machine

• Concrete moulds are easily cast by using a tamping bar or a vibrating table. However
air trapped in cement mortar paste cannot be thus removed while casting cement
mortar moulds. Easy method is to impart greater vibration of lesser amplitude to the
mould while casting. This is achieved in a vibrating machine.
• Vibration machine is used for the preparation of mortar cubes for the determination
of compression strength

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7. Le Chatelier’s Water Bath
• Bath is so designed to raise the temp. from from (27 °C ± 2 °C) to boiling
temp. in (27 ± 3 minutes). Complete with stand to accommodate Le -Chatlier
Moulds to keep the specimens immersed as per code requirement.

8. Hot Plate

• A laboratory hot plate is primarily made from metal or ceramic materials, but some
are made from plastic or other materials. A hot plate typically has channels in the
middle that help distribute the heat evenly throughout the surface.

9. Rapid Moisture Meter

• For quick determination of moisture content of material in powder form such as coal
pottery slip, soil, sand , cement and many more.

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 • Acetylene gas is generated when Calcium carbide comes in contact with moisture.
This principle is used in rapid moisture meter.
10. Brass Sieves

• Test Sieves are used for sieving of aggregate, sand soil and cement etc. for
sieve analysis
11. Flakiness Gauge and Elongation Gauge

12. Air Entrainment meter

13. Pycnometer

14. Hydrometer Vicat Apparatus

15. Sample Extractor

16. Aggregate impact tester

➢ Gantry Crane

A gantry crane is a type of overhead crane with a single or double girder

configuration supported by freestanding legs that move on wheels or along a track or rail
system. Gantry cranes are usually considered when there is a reason not to incorporate an
overhead runway system.

Larger gantry systems may run on a rail or track embedded in the ground, typically in a
straight line in a dedicated work area. Smaller portable gantry systems run on castors or
wheels and can be moved about a facility for maintenance or light fabrication work.

It is used to lift heavy loads of reinforcement, shuttering, segment etc.

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Gantry Crane

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 STEPS OF CONSTRUCTION
1. Soil Testing:
Using sampling machines, we collect a sample of the rock/soil to analyze and study
the soil profile and make the suitable adjustments to design of the project. These samples are
then sent to the lab, and after the approval from the lab, the Piling Machines are called in.

2. Piling
After testing and analysis, the Piling Machines are brought in for piling of the site. These
machines are huge and heavy, use for piling at desired depths and diameters, depths and
diameters are determined and approved by designer and lab.

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 3. Steel Cage Insertion:
After piling, steel cages are inserted into the piled holes.

4. Concreting:
After insertion of steel cages, the concreting is done. Concreting is done via Transit
Mixer as large amounts of concrete cannot be prepared on the site manually. The amount of
concrete required depends on the depth, diameter, shape and the number of the piles
provided.
The concreting is done under the right conditions, keeping the temperature, humidity
and rainfall in mind.

5. Breaking Pilehead:
The extra length of the exposed pile is referred to as the Pilehead. These pileheads are then
broken at suitable height for making the Pilecap. The reinforcement from these pilehead are
then used for the construction of pilecap using more reinforcement bars.

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 6. Pilecap Construction:
Pilecaps are where the piles meet the piers. Pilecaps consists of a giant chunk of
concrete upon which the caonstrucion of pier takes place.

7. Concreting of Pilecap:
After the reinforcements are in place, the concreting begins.

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 8. Pier Construction:
For construction of Pier, the reinforcements from the Pilecap are tied together,
then the shutter in placed around this reinforcement.

After the shutter is placed, concrete is

poured.
9. Pier Protection:
Pier protection is built at the base of the pier of prevent damage to the pier from
environmental agents such as vehicles.

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 10. Piercap:
Segments are placed over piercaps. Reinforcements are used, shuttering is done and the
concrete is poured.

11. Launching Girder:

A launching gantry(or girder launcher, launching girder) is a special-purpose mobile
gantry crane used in bridge construction, specifically segmental bridges that use precast box
girder bridge segments or precast girders in highway and high-speed rail bridge construction
projects. The launching gantry is used to lift and support bridge segments or girders as they
are placed while being supported by the bridge piers instead of the ground.
While superficially similar, launching gantry machines should not be confused with
movable scaffolding systems, which also are used in segmental bridge construction. Both
feature long girders spanning multiple bridge spans which move with the work, but launching
gantry machines are used to lift and support precast bridge segments and bridge girders,
while movable scaffolding systems are used for cast-in-place construction of bridge
segments.
From one pier to another pier, between the span, segments are placed. Segments may
be placed via cranes or Launching Girder.

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 The segments are then hung one by one on the Launching Girder, and aligned
carefully, they are then glued using epoxy glue. Then the Cable Stretching process starts, after
this the segments are freed from the Launching Girder.

After stressing of the cables, the excess length is cut off

The Launching Girder now moves on for the next segment

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 MACHINERY AND EQUIPMENTS USED
i. Cranes:
Cranes in construction are used to lift or lower objects and move them horizontally. Either
way, all cranes are equipped with pulleys and cables that are useful when it comes to moving
objects around.
They are usually temporary structures that are either mounted on a custom-built vehicle or
fixed to the ground. They are controlled remotely or by a professional operator who moves in
a cab along with the crane. Like with all other items in construction, the crane operator has
the responsibility to ensure the safety of the construction site, the working crane, and the
rigging crew.
There are mainly there types of cranes, based on their mobility:
i. Tower Crane:-
ii. Crawler Crane:-

iii. Tyre-Mounted Crane:-

iv.

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ii. Form Traveller :

Front View of Form Traveller

For safety of the workers the top rail, mid rail and toe guards are installed, along with safety
net, to prevent injuries and damage from the falling debris atop the bridge.
The construction of Cable Stay bridge is carried out with the Form Traveller . As the name
suggests, it is mobile in nature, and is moved along the set rails after each segment is
placed/casted. Heavy hydraullic jacks are used to pull and the push the upper part of the Form
Traveller. Macaulay Bars are used to hold and support the Form Traveller in place, fixed with
thick plates, nuts and bolts.

iii. Transit Mixer:

Transit mixer is a piece of equipment that is used for transporting concrete/ mortar or
ready mix material from a concrete batching plant directly to the site where it is to be utilized.
Transit mixer is loaded with dry material and water. The interior of the transit drum is fitted
with a spiral blade. Spiral blade is able to move in two directions. During clockwise
movement drum is charged with concrete and in counterclockwise direction concrete

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discharge out from the transit drum. Concrete mixing drum ensures the liquid state of
materials through rotation of the drum about its own axis.

It has various parts named as hopper, discharge chute, rotating mixing drum and a water tank.
Hopper is that part through which transit mixer is charged with concrete. Water tank with
transit mixer is for washing of concrete mixing drum so that no concrete left with the internal
walls. Discharge chute is utilized during discharging of concrete from the mixer. It ensures
the same quality of concrete as it was at the mixer. Chute guides the concrete directly to the
job site.
iv. Concrete Pressure Boom:

A concrete pump is a machine used for transferring liquid concrete by pumping. There
are different types of concrete pumps.
A common type of concrete pump for large scale construction projects is known as a
boom concrete pump, because it uses a remote-controlled articulating robotic arm (called a
boom) to place concrete accurately. It is attached to a truck or a semi-trailer. Boom pumps are

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capable of pumping at very high volumes and are less labor intensive to operate when
compared to line or other types of concrete pumps.

Concreting using this method requires a Transit Mixer. The Transit Mixer is placed behind
the Concrete Pressure Beam. The concrete from rotation drum, now enters the hopper,
through the discharge chute, to the reducer or backend kit, the concrete now passes through
deck pipe, then the boom pipe and then the hose pipe
v. Launching Girder:

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vi. Power Paver:

vii. Chain Pulleys

viii. Slings:
Slings are lifting devices used to lift and move objects easily and safely.
Usually of three types:-
i) Web Sling:

ii)Wire Rope Sling

Iii)Rope Sling:

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ix. Hydraulic Jacks:

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x. Mechanical Bending Machine:/Rebar Bender:

Steel reinforcing bars are bent to suit the design of a structure and to ensure proper
reinforcement and tension. Manual bending can be risky, as it can cause injury and strain to
workers. Moreover, it takes time to accomplish, especially with conventional tools. To
increase safety in the construction site and to prevent injury, discerning builders invest in
modern tools, like the rebar bender, a machine that can bend, even the toughest steel bars.
The construction industry recognises the importance of rebar benders in ensuring high-
quality, accurate results, and in speeding up the process of bending bars to increase
productivity and help the project finish earlier.
The rebar bender will usually take around five seconds to bend the rebar to a specific angle.
The tool is compact and easy to grasp, making it comfortable to use, even for several hours. It
can bend in different arcs ranging from zero to 180 degrees for various applications in
construction. High-quality bending machines come with robust motors that will ensure
smooth operation and less susceptibility to wear. You can get a bending machine as a portable
unit for better portability around the construction site. This eases transport, too, so you can
take it anywhere.
xi. Needle Vibrator:

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When it comes to many concrete jobs from warehouse floors to large parking structures, a
concrete vibrator is one of many tools needed to get the best results. Concrete vibrators are
used to eliminate air pockets that can remain when pouring concrete that can ruin the
integrity of concrete. Without a concrete vibrator, concrete structures can cave in or break
apart from weather, earthquakes, and wear and tear over time.
Concrete Needles can also be used to better spread the concrete mix, these are very helpful
indeed.
xii. Doka H2O:

Doka timber formwork beams are one of the best quality timber formwork in the market, they
have effective pro-tection against moisture and UV radiation, as beam-ends are sealed around
web, high-quality beam flanges, achieved by machine stress-grading, less damage to the
beam-ends, thanks to the bevelled flange-ends incorporating beam rivets, fast, safe formwork
set-up by referring to markings on the flanges

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 EXTRADOSED CABLE STAYED BRIDGE CABLE INSTALLATION

Freyssinet India took the command of installing cables from upper pylon to deck slab of the
bridge. Scope for FMI involves the design, supply, and execution of an Extra-dosed Stay
Cable with Freyssilink system, with a total stay cable strand quantity of 190 MT; stay cable
extra-dosed anchorages, and end-to-end installation.

The Freyssinet anchorage system, which is widely used in Europe and India, consists of a
cylinder with a conical interior through which the high-tensile wires pass and against the
walls of which the wires are wedged by a conical plug lined longitudinally with grooves to
house the wires. The main advantages of the Freyssinet system are that a large number of
wires or strands can be simultaneously tensioned using the double-acting hydraulic jack.

1st set of cables installed in bridge.

7 set of cables are to be installed on the either side of both the upper pylons. The distance of
1st formwork tube is 26m and that of last is 86m from the pylon. About 20 to 30 percent of
load of structure is being supported by these cables.

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❖ COMPONENTS OF CABLE SYSTEM
1. HT Strand
7 ply High Tension Strand of diameter 15.7mm with a protective covering of HDPE (High
Density Polyethylene) is used. Such 35 cables are inserted for stressing at one side, one of
them being the master strand.

2. AVT Pipe
AVT (Anti Ventilation Tube) pipe covers the stressed bunch of cables. It is fixed in two parts
i.e., Main pipe (thickness-7.1mm for 1st cable) which is attached to formwork tube and other
is Expansion pipe(thickness-6mm) attached to freyssilink. Main pipe is inserted in expansion
pipe without any joint between them to allow future expansion due to external environment.

3. Freyssilink
The Freyssilink system can transfer differential forces to the pylon structure while allowing
the optimization of the pylon section. This benefits the reduction of the carbon footprint of
the project by saving construction materials. 7 freyssilink are provided in one upper pylon

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4. Formwork Pipe
Formwork pipe is provided in deck slab of segment. It contains bottom anchor head to fix the
cables after stressing. Also, main pipe is attached to it. It is provided at every alternate
segment starting from 5th segment and last one in 17th segment.

5. EPDM
EPDM (Ethylene propylene diene monomer) rubber is used between main pipe and formwork
tube.

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6. Bearing plate
Bearing plate is used to fix expansion pipe with freyssilink through bolts.

7. Anchor head and Anchorage system

Anchorages perform the following three main functions:

• they transfer the force from the stay cable to the structure
• they manage strand tension variations to ensure maximum endurance
• they protect the individual anchor elements from environmental attack, including
corrosion.

Anchor head are fixed in freyssilink and at bottom of formwork tube

8. Wedges

Wedges are cone shaped to lock the cables to anchor head. They are in 3 parts held together
by a rubber ring. These get adjusted according to the shape and size of cable. Its length is
45mm with varying diameter of 14mm to 24 mm.

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❖ PROCESS OF CABLE INSTALLATION
Once the concrete has gained its strength in the segment the process of cable installation is
started. First anchor heads are fixed inside the form work tube and in freyssilink. Then
Master strand is inserted in AVT pipe. Master strand is the very first cable that is inserted in
anchor heads and stressed. It acts as a guide for other strands in load application while
stressing.
Chair is fixed in bottom anchor head along with Load Cell and Guide pipe. Load Cell
Tracks the load that is applied in master strand throughout the process. Wedges are fixed in
guide pipe and this pipe is inserted in anchor head passing through the chair. Guide pipe acts
as a channel through which cable strands are led out of anchor head.

Chair Load Cell Guide pipe inserted in chair

AVT pipe is lifted with the help of tower crane and chain pulley system. Master strand is
fixed in upper anchor head and then guided through bottom anchor head inside form travel
pipe using single strand called king wire which are attached to each other through a couple.

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Isotension Power pack is installed to apply load in the strands via Isotension Jack. Power
pack is connected with isotension jack for both inlet and outlet of pressure and to load cell.
This system uses programmed computer designed for Post Tensioning. Stressing of master
strand is done first by entering the required load values manually. The end of the cable where
load is applied is called the live end or the active end, Stressing mark position (SMP),
Intermediate mark position (IMP) and Safety mark position is marked on live end of the
master cable. It is not stressed beyond SMP.

Isotension Power pack and computer Isotension jack

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Now active end is inserted in isotension jack and cable is stressed as per design load. Here a
load of 63.7 KN is applied to master strand. Jack is removed after the stressing value is
achieved. Once the stressing of master strand is done then one by one other cables are
inserted and stressed in same manner as the master strand. Now the load is applied to other
cables is set by system itself.

Jack held at chair for tensioning

Order of cables and details of anchorage system

After the installation and post tensioning of all 35 cables at 4 ends is done, Lift Up is done
Lift up is calculating the combine load of all strands. Here it is 2100KN.
AVT pipe is fixed with freyssilink through bearing plate and inserted inside form travel pipe
with EPDM rubber between them.

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 Before PT

After PT
Load is again adjusted after installation of all 7 set of cables at each side. Anchor heads are
covered and grouted with wax.

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 CONCLUSION
In conclusion, flyover construction and extradose cable stay bridges play pivotal roles in

modern infrastructure development, addressing the challenges posed by increasing traffic

congestion and enhancing transportation connectivity. The construction of flyovers offers

practical solutions for efficient traffic management in urban areas, improving commuting

experiences and reducing travel time. Likewise, extradose cable stay bridges present

innovative alternatives to traditional cable-stayed bridges, combining aesthetics, structural

efficiency, and cost-effectiveness.

Both flyover construction and extradose cable stay bridge projects require careful planning,

engineering expertise, and skilled professionals to ensure their successful execution. The

advancements in these construction methods not only provide practical transportation

solutions but also serve as symbols of engineering excellence and architectural beauty. As we

continue to strive for better infrastructure and improved transportation networks, the

significance of flyover construction and extradose cable stay bridges will remain crucial in

meeting the evolving needs of our modern society.

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