Replacement of rail bearers of Bhiwandi Pipeline

bridge

Prepared by :- Shashwat Pandey

J.E. (Bridge) BSL
Rail bearers or stringers
Between two cross girders one set of built-up I-section-like plate girder is provided
called rail bearer or stringer.
Both ends of stringer are connected to web of cross girder by stiffener with rivets.
Only 3rd rail bearers from either ends for span 61.0 and 76.2 m are connected one
end to cross girder with rivet and other end is resting on brackets provided in web
of cross girder to act like free end to avoid distortion of bottom chord under load.
Stringers consist of web plate and flange angles with riveted connection to form I-
section as members.
frame or diaphragm with lateral bracing are provided to stringers for lateral
rigidity. Sleepers rest on top flange stringers and are anchored with hook bolts.
Line drawing of 45.7m OWG
Sequence of activities before any work
• Bridge Inspection

• Preparation of inspection report and recording in the bridge register then

taking necessary action

• In case of major work, prepare estimate to carry out the work

• Approval for estimation of the work

• Tendering and contract

• Work execution
General Details
Name of bridge: Bhiwandi pipeline Bridge
Br. No: 55/2
Km: 55/35-29
Section: DW-BSR Section
B/W Station: BIRD to KOPR
Type of bridge: OWG Through span
Span : 2x45.7m
Put on Road: 1979
Work: Replacement of rail Bearers
Line- UP line
Purpose : pipeline crossing
Contractor: SP Steel Maritech Pvt. Ltd.
SR-45
Inspection outcomes
• On the basis of detailed inspection of the bridge, following major outcome has been
point out:
• As the bridge lies in the coastal region , falls under severe category of environment. Due
to this corrosion has been started in cross girder, stringer and other secondary members.
• There is loss of section found in stringer , and cross girder. Flange thickness has been
found 4-12mm & originally it is 12mm & badly corroded.
• Water pocket area has been pitted and also perforation started in some area of cross
girder and stringer.
• Diaphragm plate and batten plates of bottom chord have been badly corroded.
• As there might of chances of loss of camber in OWG , so it is decided to replace the
stringer and other member which does not affect camber , and to strengthen the cross
girder.
On condition basis , works has been started to provide overall stability
and ensure to safe passage of traffic on Bridge.
Corrosion of members

Perforation in diaphragm
Corroded rail bearers

Corroded bracing

Heavily corroded Chequered plate

Tender Details
• Tender Notice No. Cr:-hq-br.Line181906 Dtd. 09/08/2018
• Name Of Work :
1. Replacement Of Heavily Corroded Floor System Of Kamanwadi Br. No. 62/3
(3/45.7m OWG) @ Kms 62/22-24 Up Line Between DW-BSR Section Of MUMBAI
Division.
2. Replacement Of Heavily Corroded Floor System Of Bhiwandi Pipe Line Br. No.
55/2 (2/45.7m OWG) @ Kms 55/29-35 Up Line Between DW-BSR Section Of
MUMBAI Division.
• Approx. Cost :Rs. 2,88,79,996.97
• Completion Period:12 Months
• Maintenance Period :6 Months
 Procedure to be followed for replacement of rail bearers

• All the initial arrangement to carry out of work

• Fabrication of rail bearers as per IRS B1 standard.
• Establishment of all tools , plant & machinery to be used
• Transportation of required material @ site
• Temporary arrangement
• Action plan
• Execution methodology
• Arrangement of the blocks as per cycle time involved in each activities.
Name of the work
Replacement of heavily corroded rail bearers of Bhiwandi pipe line, Br.
No. 55/2 (2/45.7m OWG) @ kms 55/29-35, UP line between station
KOPAR-BIRD in DW-BSR section on Mumbai division.

PUT ON RD :- 1979

Agency :- S. P. Steel Maritech Pvt. Ltd. Navi Mumbai

No. of rail bearers to be replaced :-32

Attended block date and timing of blocks
Date Start time End time Duration
01/02/2021 12:35 14:05 1.5 Hours

03/02/2021 10:45 12:45 2 Hours

05/02/2021 12:05 14:05 2 Hours

08/02/2021 10:42 13:00 2.3 Hours

Pre block activity
• Wooden planks
staging to be laid
for two panels
which is
required for rail ANGLE
bearer 75*75*10
replacement ANGLE
work.

M
65*65*8

M
00
63
2400mm

1500mm
• Connection rivets
of rail bearers and
X- girders is to be
replaced with
turned bolts by
cutting existing
rivets for one
panel.
During block time
• Removing dog bolts
and lifting the track
with the help of jack
40 to 50 mm in the
presence of P. way
staff.
• Fixing of portal beams, chain pully blocks with slings for lifting of
girder.
ISMB 200
2 TONNE
5.6 M
W=135.52 KG
• New both side
rail bearers to
be placed on
trolly with the
help of hydra
& shift at
working site.
• Dismantling of
existing old one
side corroded rail
bearer by
removing turned
bolts from
connection of X-
girder and
removing from
bridge site by
trolly.
• Left side new rail
bearer placed in
its position with
the help of chain
pully block and
complete filled
hole with turned
bolts.
• Dismantling of existing old right side corroded rail bearer by removing
turned bolts from connection of X- girder with the help of chain pully
block and removing from bridge site by trolly.
• Right side new rail bearers placed in its position with the help of chain
pully block and complete filled hole with turned bolts.
• Fixing of bottom lateral
bracing and X-frame angles
with gussets.
• Lowering the track and fixing
the dog bolts (by p.way staff).
• Removing the
erection
derrics, portal
beams, chain
pully blocks
and block to
be cleared.
Post block activities
• Turned bolts is replaced
with rivets.
• Wooden plank staging to
be laid for the third
panel which is required
for repairing work.
Register maintained on site
• Technical register
• Safety register
• Hinderance register
• Material passing register
• Site order book
• Progress register
Technical register
Safety register
Hinderance register
Material passing register
Site order book
Progress register