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8/3/2019 Bandra Worli Sea Link 1111
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BandraWorli Sea Link
Official name : - Rajiv Gandhi Sea Link
Carries : - 8 lanes of traffic
Crosses : - Mahim Bay
Locale : - Mumbai, India
Owner : - MSRDC
Designer : - Seshadri Srinivasan
Design : - Cable-stayed main spans; concrete-steel precast
segment viaducts at
either end
Total length : - 5.6 kilometers (3.5 mi)
Height : - 126 metres (413 ft)
Longest span : - 2 x 250 metres (820 ft)
Clearance below : - 20 metres (66 ft)
Constructed by : - Hindustan Construction Company
Constructions begin : - 2000
Construction end : - 24 March 2010
Opened : - 30 June 2009
Toll : - 50 (US$1.01) one way
75 (US$1.52) return journey
Connects : - Bandra to Worli
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Coordinates : - 19.03648N 72.81725E
TECHNICAL DETAILS OF RAJIV GANDHI (BANDRA-WORLI) SEA LINK PROJECT(PACKAGE-IV)
APPROACH BRIDGE
General:
Bridge is arranged into units of typically five or six continuous spans of 50m.
Length of bridge: 800m + 200m + 1600m
Span: 50m
Carriageway: 15m
Side walk: 2.2m on one side
Crash barrier: 400mm on both sides
Pile:
Load bearing piles socketed into hard rock to a minimum of 4m length.
4 nos. of bored cast in-situ pile of 1.5m dia of length varying from 5m to 36m designed for loadcarrying capacity of 1000T (approx.).
M50 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 12mm thick permanent steel casing for all piles.
Total nos. of pile: 372
Pile cap:
Hexagonal shape pile cap of size 10m x 9.5m x 3.5m for fixed pier location and 10m x 8m x 3mfor sliding & expansion pier location.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Tremieseal (PCC) of M30 grade concrete 1m thick below pile cap.
Cofferdam: Interlocking liner type, Circular type & Sheet pile type.
Total nos. of pile cap: 94
Pier:
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Hammer head shape hollow pier of size 4m x 2.5m, height varies from 5m to 18m. Pier isdivided as Fixed type, Sliding type & Expansion type.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of pier: 94
Segment:
Fish belly shaped precast segmental concrete box of size 18.1m x 3m x 3m with 3 voids.Segments match cast by short line method.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Segment weight: 110T to 130T
Total nos. of segment: 1554
Erection:
Span by span construction using over head launching truss of capacity 1600T. One spanconsists of 16 segments.
Epoxy glue is used to join the segments. Temporary post-tensioning is done using 6 nos. stressbars during gluing.
2 nos. cast in-situ wet joints of 200mm width in each span is provided.
Bearings: Disc bearing (fixed & sliding type) of capacity varying from 700T to 1400T.
Post tension: 30 nos. of tendons each having 19 x 15.2mm strands and 6 nos. of tendons eachhaving 4 x 15.2mm strands.
Expansion Joint: Modular type expansion joint with movement range of 320mm.
CABLE STAYED BRIDGE
Bandra Cable Stay
General:
Length of bridge: 600m
Span: 50m + 250m + 250m + 50m
Carriageway: 15m
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Side walk: 2.2m on both sides
Crash barrier: 400mm on both sides
Pile:
Load bearing piles socketed into hard rock.
For tower, 52 nos. of bored cast in-situ piles of 2.0m dia of length 30m designed for loadcarrying capacity of 2000T (approx.). For pier, 4 nos. of bored cast in-situ pile of 2.0m dia oflength varying from 22m to 26m.
M50 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 16mm thick permanent steel casing for all piles.
Total nos. of pile: 84
Pile cap:
H shape pile cap of size 57m x 30m x 6m for tower. Hexagonal shape pile cap of size 10m x12m x 5m for pier.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Tremieseal (PCC) of M30 grade concrete 2m thick below pile cap.
Cofferdam: Interlocking liner type.
Post tension: 28 nos. of tendons each having 19 x 15.2mm strands.
Total nos. of pile cap: 9
Tower/Pier:
125m height tower above pile cap with varying cross-section. 4 inclined legs of tower meet at70m from deck level and continue straight for another 30m. The 30m straight portion is providedwith anchorages for stay cables. Grooves are provided on the curved faces of the tower foraesthetics.
Hammer head shape hollow pier of size 4m x 2.5m with height 18m.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of Tower: 2
Total nos. of Pier: 8
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Segment:
Fish belly shaped precast segmental concrete box of size 22.7m x 3m x 3m with 3 voids.Segments match cast by short line method. Anchorage for stay cables provided in alternatesegments.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Segment weight: 130T to 150T
Total nos. of segment: 394
Erection:
Segment by segment erection by balance cantilever method using Derrick system of capacity150T.
Epoxy glue is used to join the segments. Temporary post-tensioning is done using 22 nos.stress bars during gluing.
Cast in-situ wet joints of 50mm width is provided at every 50m interval.
Stay cable: Parallel wire system with 7mm dia. galvanized steel wires and 2 layers of HDPE.The number of steel wires in stay cable varies from 61 to 121 and the capacity of stay cablevaries from 390T to 770T. The length of stay cable varies from 85m to 252m. Dead end of staycable is anchored to the tower head and the live end is anchored to both sides of deck at 6minterval. There are 33 nos. of stay cables on either side of the tower.
Total nos. of stay cables: 264
Post tension: 134 nos. of tendons each having 19 x 15.2mm strands of various lengths.
Bearings: POT type PTFE bearing (sliding type) of capacity varying from 750T to 1850T.
Expansion Joint: Modular type expansion joint with movement range of 480mm.
Worli Cable Stay
General:
Length of bridge: 350m
Span: 50m + 50m + 150m + 50m + 50m
Carriageway: 15m
Side walk: 2.2m on both sides
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Crash barrier: 400mm on both sides
Pile:
Load bearing piles socketed into hard rock.
For tower, 6 nos. of bored cast in-situ piles of 2.0m dia of length 30m designed for load carryingcapacity of 2000T (approx.). For pier, 4 nos. of bored cast in-situ pile of 1.5m dia of lengthvarying from 22m to 26m.
M50 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 12/16mm thick permanent steel casing for all piles.
Total nos. of pile: 56
Pile cap:
Hexagonal shape pile cap of size 19m x 12m x 3m for tower. Hexagonal shape pile cap of size10m x 8m x 3m for pier.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Tremieseal (PCC) of M30 grade concrete 1m thick below pile cap.
Cofferdam: Interlocking liner type.
Total nos. of pile cap: 12
Tower/Pier:
55m height tower above pile cap 2 inclined legs with strut at top. The tower top portion isprovided with anchorages for stay cables. Grooves are provided on the curved faces of thetower for aesthetics.
Hammer head shape hollow pier of size 4m x 2.5m with height 16m.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of Tower: 4
Total nos. of Pier: 8
Segment:
Fish belly shaped precast segmental concrete box of size 22.7m x 3m x 3m with 3 voids.Segments match cast by short line method. Anchorage for stay cables provided in alternatesegments.
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M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Segment weight: 130T to 150T
Total nos. of segment: 234
Erection:
Segment by segment erection by balance cantilever method using Derrick system of capacity150T.
Epoxy glue is used to join the segments. Temporary post-tensioning is done using 22 nos.stress bars during gluing.
Cast in-situ wet joints of 50mm width is provided at every 50m interval.
Stay cable: Parallel wire system with 7mm dia. galvanized steel wires and 2 layers of HDPE.
The number of steel wires in stay cable varies from 85 to 139 and the capacity of stay cablevaries from 540T to 885T. The length of stay cable varies from 30m to 81m. Dead end of staycable is anchored to the tower head and the live end is anchored to both sides of deck at 6minterval. There are 10 nos. of stay cables on either side of the tower.
Total nos. of stay cables: 160
Post tension: 70 nos. of tendons each having 19 x 15.2mm strands of various lengths.
Bearings: POT type PTFE bearing (sliding type) of capacity varying from 700T to 1200T.
Expansion Joint: Modular type expansion joint with movement range of 320mm.
LINK BRIDGE
Segmental bridge portion
General:
Bridge is arranged into units of typically three continuous spans of 50m and seven continuousspans of 30m.
Length of bridge: 150m + 210m
Span: 50m and 30 m
Carriageway: 15.65m
Side walk: 1.55m on one side
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Crash barrier: 400mm on both sides
Pile:
Load bearing piles socketed into hard rock to a minimum of 4m length.
4 nos. of bored cast in-situ pile of 1.5m dia of length varying from 9m to 11m designed for loadcarrying capacity of 1000T (approx.).
M50 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 12mm thick permanent steel casing for all piles.
Total nos. of pile: 48
Pile cap:
Hexagonal shape pile cap of size 10m x 9.5m x 3.5m for fixed pier location and 10m x 8m x 3mfor sliding & expansion pier location.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Tremieseal (PCC) of M30 grade concrete 1m thick below pile cap.
Cofferdam: Circular type.
Total nos. of pile cap: 12
Pier:
Hammer head shape hollow pier of size 4m x 2.5m, height varies from 8m to 11m. Pier isdivided as Fixed type, Sliding type & Expansion type.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of pier: 12
Segment:
Fish belly shaped precast segmental concrete box of size 18.1m x 3m x 3m with 3 voids.
Segments match cast by short line method.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Segment weight: 110T to 130T
Total nos. of segment: 128
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Erection:
Span by span construction using over head launching truss.
One span (50m) consists of 16 segments and (30m) consists of 9 segments.
Epoxy glue is used to join the segments. Temporary post-tensioning is done using 6 nos. stressbars during gluing.
2 nos. cast in-situ wet joints of 200mm width in each span is provided.
Bearings: Disc bearing (fixed & sliding type) of capacity varying from 400T to 1400T.
Post tension: 30 nos. of tendons each having 19 x 15.2mm strands and 6 nos. of tendons eachhaving 4 x 15.2mm strands in 50m span. 18 nos. of tendons each having 19 x 15.2mm strandsin 30m span.
Expansion Joint: Modular type expansion joint with movement range of 240mm.
Girder bridge portion
General:
Bridge is arranged into units of four to seven continuous spans of 24m
Length of bridge: 421m
Span: 24m and 13m
Carriageway: 15.65m
Side walk: 1.55m on one side
Crash barrier: 400mm on both sides
Pile/Pier:
Load bearing piles socketed into hard rock to a minimum of 7m length.
2 nos. of bored cast in-situ pile of 2m dia of length varying from 15m to 20m designed for loadcarrying capacity of 2000T (approx.).
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 16mm thick permanent steel casing for all piles.
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Total nos. of pile: 30
Pier cap:
Solid pier cap of 1.6m height, 2.4m wide over the two piles with cantilevers at both ends.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of pier: 18
Girder:
T shaped precast girder of 1.1m height, 400mm wide at base and 1.99m wide at the top. Girderlength varying from 20m to 22.5m.
Post tension: 3 nos. of tendons each having 7 or 12 nos. of 15.2mm strands.
1.5m wide diaphragm provided to connect girders to make the span continues.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Girder weight: 50T
Total nos. of girder: 162
Erection:
Span by span construction using over head launching truss.
One span consists of 9 girders erected one at a time.
Cast in-situ deck slab of 240mm thick over the girders is provided.
Stitch cable of 9 nos. each having 4 x 15.2mm strand is provided in deck slab at supportlocation.
Elastomeric bearing of size 360 x 360 x 96 mm is provided at expansion joint location. In otherlocation the pier is integral with the deck/girder.
Modular type expansion joint with movement range of 240mm & 160mm. Strip seal type
expansion joint with movement range of 50mm.
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Various agencies involved during the construction of Package IV are listed below:
Client / Owner
Maharashtra State Road Development Corporation Ltd.
Design Consultants
Consortium of Consultants:
Sverdrup Asia Ltd. (India)
AGRA Earth & Environmental INC. (USA)
KPMG India Pvt. Ltd.
Shrikhande Consultants India Pvt. Ltd.
TPG (India)
with
HNTB (USA)
Ratan J. Batliboi Architects (India)
Design Consultants (for cable stay bridges) & Project Management Consultants
Dar Consultants (U.K) Ltd.
in association with
Dar Consultants (India) Pvt. Ltd.
Design Consultants (for portion of Link Bridge)
STUP Consultants India Pvt. Ltd.
Proof Consultants
Consortium of Consultants:
Construma Consultancy
Mott Mc Donald
Schlaich Bergermann
http://www.msrdc.org/http://www.in.kpmg.com/http://www.scplasia.com/http://www.hntb.com/http://www.rjbx.firm.in/http://www.dargroup.com/http://www.bandraworlisealink.com/dar.htmlhttp://www.stupco.com/http://www.mottmac.com/http://www.sbp.de/http://www.in.kpmg.com/http://www.scplasia.com/http://www.hntb.com/http://www.rjbx.firm.in/http://www.dargroup.com/http://www.bandraworlisealink.com/dar.htmlhttp://www.stupco.com/http://www.mottmac.com/http://www.sbp.de/http://www.msrdc.org/8/3/2019 Bandra Worli Sea Link 1111
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Proof Consultants (for cable stay bridges)
T.Y. Lin International
Main Contractor
Hindustan Construction Company Ltd.
with
China Harbour Engineering Company Ltd.
Consultants to Main Contractor
VSL International Ltd.
http://www.tylin.com/http://www.hccindia.com/http://www.chec.bj.cn/ens/gsgk/zgjj/index.htmlhttp://www.vsl.com/http://www.tylin.com/http://www.hccindia.com/http://www.chec.bj.cn/ens/gsgk/zgjj/index.htmlhttp://www.vsl.com/8/3/2019 Bandra Worli Sea Link 1111
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Various products used in Package IV is listed below along with the name of the Manufacturer
/ Supplier:
Cement:OPC 53 Grade Ambuja Cements Ltd
Concrete Admixture:
BASF Construction Chemicals (I) Pvt. Ltd.
Sika India Pvt. Ltd.
Fosroc Chemicals (I) Pvt. Ltd.
Master Builders Technologies
Microsilica:
Elkem
Reinforcement Steel:Fe415 gradeTata Tiscon
Steel Authority of India Limited
Vizag Steel
Stay Cable:Parallel wire system Shanghai Pujiang Cable Co., Ltd
Bearing:Disc Bearing, POT Bearing & Elastomeric Bearing Metal Engineering & Treatment Co. (P) Ltd.
MAGEBA Bridge Products Pvt. Ltd.
Expansion Joint:Modular type MAGEBA Bridge Products Pvt. Ltd.
Post-tensioning Components:
VSL India Private Limited
Prestressing Strand:
http://www.gujaratambuja.com/index1.htmlhttp://www.basf-cc.co.in/http://www.sika.in/http://www.fosroc.com/http://www.mbtaus.com.au/http://www.elkem.com/http://www.tatatiscon.co.in/http://www.sail.co.in/http://www.vizagsteel.com/http://www.spccc.com/http://www.metcocal.com/http://www.mageba.in/http://www.mageba.in/http://www.vsl.com/http://www.gujaratambuja.com/index1.htmlhttp://www.gujaratambuja.com/index1.htmlhttp://www.basf-cc.co.in/http://www.sika.in/http://www.fosroc.com/http://www.mbtaus.com.au/http://www.elkem.com/http://www.tatatiscon.co.in/http://www.sail.co.in/http://www.vizagsteel.com/http://www.spccc.com/http://www.spccc.com/http://www.metcocal.com/http://www.mageba.in/http://www.mageba.in/http://www.vsl.com/8/3/2019 Bandra Worli Sea Link 1111
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Tata SSL Ltd
Rebar Couplers:
Dextra India Pvt. Ltd.
Metal Crash Barrier:
Case Cold Roll Formings Ltd
Fracasso Group
Metal Hand Rail:
Pioneer Fabricators (P) Ltd.
Epoxy Glue:For joining segments Sika India Pvt. Ltd.
Fosroc Chemicals (I) Pvt. Ltd.
Epoxy Paint:For splash zone area Coating & Foaming Inc
Choksey Chemicals Pvt. Ltd.
Coal Tar Epoxy Paint:For structures below soil Coating & Foaming Inc
Toll Instrumentation:On board unit, Transceiver, Manual booth controller, Smart CardReader
EFKON India Pvt. Ltd.
Variable Message Sign Board:
Imago Group
Sensor:For vehicle classification system Sensor Line GmbH
Vishay (Height sensor)
User Fare Display, Over head lane signal & Traffic Light:
Crystal Peripherals & Systems Pvt. Ltd.
http://www.tatawire.com/http://www.dextragroup.com/http://www.casecold.com/http://www.fracasso.com/http://www.pioengg.com/http://www.sika.in/http://www.fosroc.com/http://www.coatingandgoogle.co.in/http://www.chokseychem.com/http://www.coatingandgoogle.co.in/http://www.efkon.com/http://www.imagoscreens.com/http://www.sensorline.de/http://www.tatawire.com/http://www.dextragroup.com/http://www.casecold.com/http://www.fracasso.com/http://www.pioengg.com/http://www.sika.in/http://www.fosroc.com/http://www.coatingandgoogle.co.in/http://www.chokseychem.com/http://www.coatingandgoogle.co.in/http://www.efkon.com/http://www.imagoscreens.com/http://www.sensorline.de/8/3/2019 Bandra Worli Sea Link 1111
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Automatic Barrier:
Magnetic Auto Control
Receipt Printer:
Epson
Lane Camera:
Samsung
Incident Capture Software:
Omni
Vibration Survey System:
Kinemetrics
Road Signages
Protek Traffic Devices Pvt. Ltd.
Road Stud:Over wearing course 3M India Limited
Toll Booth:
Windoors International Limited
Paver Blocks:
Super Tiles & Marbles Pvt. Ltd.
Flood Light fixtures:
Keselec Schreder Private Limited
Street Light & High Mast:
Bajaj Electricals Limited
Electrical Cables:
Polycab Wires Pvt. Ltd.
UPS System:
http://www.ems-limited.co.uk/http://www.pos.epson.co.uk/http://www.samsungcctv.com/http://www.kinemetrics.com/http://www.protekindia.net/http://www.3m.com/inhttp://www.windoors-india.com/http://www.superexternaltiles.com/http://www.schreder.co.in/http://www.bajajelectricals.com/http://www.polycab.com/http://www.ems-limited.co.uk/http://www.pos.epson.co.uk/http://www.samsungcctv.com/http://www.kinemetrics.com/http://www.protekindia.net/http://www.3m.com/inhttp://www.windoors-india.com/http://www.superexternaltiles.com/http://www.schreder.co.in/http://www.bajajelectricals.com/http://www.polycab.com/8/3/2019 Bandra Worli Sea Link 1111
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Emerson Network Power
Fun facts about the Bandra-Worli sea link
The long-awaited Bandra-Worli sea link, seen as an engineering marvel, weighs equivalent to that of 50,000 African
elephants!
The steel wire used is equivalent to the circumference of the earth.
The 5.6 kilometre-long cable stayed bridge, to be opened by Congress President Sonia Gandhi on June 30, is 63
times the height of the Qutub Minar. Earlier, the bridge was to be opened to public on June 16.
It has consumed 90,000 tonnes of cement, which would suffice to make five ten-storied buildings, informed a
Maharashtra State Roadways Development Corporation official.
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The BandraWorli Sea Link (BWSL) also known as the Rajiv Gandhi Sea Link is a
cable-stayed bridge with pre-stressed concrete-steel viaducts on either side that
links Bandra and the western suburbs of Mumbai with Worli. The bridge is a part of
the proposed West Island Freeway system that links the western suburbs toNariman Point in Mumbai's main business district.
The 16 billion (US$324.48 million) bridge was commissioned by the Maharashtra
State Road Development Corporation (MSRDC), and built by the Hindustan
Construction Company. The first 4 of the 8 lanes of the bridge were opened to the
public on 30 June 2009. All the 8 lanes were opened to traffic on 24 March 2010.
BWSL reduces travel time between Bandra and Worli from 4560 minutes during
peak hours to 7 minutes. As of October 2009, BWSL had an average daily traffic of
around 37,500 vehicles.
1 History
Mahim Causeway was the only road link connecting the western suburbs to
Mumbai's central business district. This north-southwestern corridor became a
bottleneck and was highly congested at peak hours. The West Island Freeway
project was proposed to span the entire western coastline of Mumbai to ease
congestion. BWSL, a bridge over Mahim Bay, was proposed as the first phase of this
freeway system. Offering an alternate route to the Mahim Causeway.
BWSL connects the intersection of the Western Express Highway and SwamiVivekananda Road (S.V. Road) in Bandra to the Khan Abdul Ghaffar Khan Road
(Worli Seaface) in Worli. From Worli Seaface, it connects to Mumbai's arterial Annie
Besant Road.
The project was commissioned by the Maharashtra State Road Development
Corporation Limited (MSRDC). The contract for construction was awarded to the
Hindustan Construction Company (HCC), with project management led by the UK
offices of Dar Al-Handasah.
The foundation stone was laid in 1999 by Bal Thackeray. The original plan estimated
the cost at 6.6 billion (US$133.85 million) to be completed in 5 years. But theproject was subject to numerous public interest litigations, with the 5 year delay
resulting in the cost escalating to 16 billion (US$324.48 million), with the additional
interest cost alone accounting for 7 billion (US$141.96 million).[12]
BWSL was opened to the public in June 2009. It was named in the memory of late
Prime Minister Rajiv Gandhi. All the 8 lanes were opened to traffic in March 2010.
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2 Planning
The overall project consisted of five distinct parts, contracted separately to
accelerate the overall schedule.
Package I: Construction of a flyover over Love Grove junction in Worli
Package II: Construction of a cloverleaf interchange at the intersection of the
Western Express Highway and S.V. Road in Bandra
Package III: Construction of solid approach road from the interchange to the Toll
Plaza on the Bandra side along with a public promenade
Package IV: Construction of the central cable-stayed spans with northern and
sourthern viaducts from Worli to the Toll Plaza at the Bandra end
Package V: Improvements to Khan Abdul Gaffar Khan Road
Package IV was the main phase of Bandra-Worli Sea Link Project, with the other
packages providing supporting infrastructure for the sea link.
Package IV is largest and main phase of Rajiv Gandhi (Bandra-Worli) Sea Link Project. Projectdesign is complete and project is under execution. Main features of this package are :-
Cable Stayed Bridge including viaduct approaches extending from Worli up to TollPlaza
Modern Toll Plaza
Intelligent Bridge System (IBS)
The work under this package has been awarded to M/s Hindustan Construction Companyand work is in progress.MAIN BRIDGE STRUCTURE
The proposed Link Bridge consists of twin continuous concrete box girder bridge sections for
traffic in each direction. Each bridge section except at the cable - stayed portion issupported on piers typically spaced at 50 meters. Each section is meant for four lanes oftraffic complete with concrete barriers and service side walks on one side. The bridgealignment is defined with vertical and horizontal curves. The Link Bridge layout iscategorized into three different parts :-
Part 1 - The north end approach structure mainly with precast (PC) segmentalconstruction
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Part 2 - The Cable Stayed Bridge at Bandra channel is with 50m - 250m - 250m - 50mspan arrangement and the Cable Stayed Bridge at Worli channel is with 50m - 50m -150m - 50m - 50m span arrangement
Part 3 - The south end approach structure mainly with precast segmentalconstruction
PART - I NORTH END APPROACH STRUCTUREThe bridge is arranged in units of typically six continuous spans of 50 meters each.Expansion joints are provided at ends of each unit.
Provision for access ramp to connect to Bandstand road below Searock Hotel. Spanarrangement for this structure provides for cast in-situ spans.
The superstructure & substructure are designed in accordance with IRC codes. Specificationsconform to the IRC standard with supplementary specifications covering special items. Thesub - structure consists of 1.5 meters diameter drilled piles with pile caps & some of thepiers near Worli end will be directly socketed into the rock.
Bridge bearing supports are of Disc & POT type. Longitudinal and lateral support at variouslocations along the unit are provided to limit displacements.
Bridge is proposed to be built utilizing the concept of precast, post - tensioned, twinsegmented concrete box girder sections. An overhead gantry truss crane with self -launching capability is proposed. The PC segments can be epoxied together with nominalprestressing. The end segments adjacent to the pier would be short segments "cast - in -situ". Geometrical adjustments are expected to be made by this segment before primarycontinuous tendons are stressed.
Segment types are further defined by the changes in the web thickness and type ofdiaphragms cast in cell. The segment weights vary from 75 tons to 120 tons per segment.
The segment length varies from 1500 mm to 3100 mm. Deck post tensioning is performed
at the completion of the erection of each bridge unit.
PART- II CABLE STAYED BRIDGEThe cable - stayed portion of the Bandra channel is 600 meters in overall length betweenexpansion joints and consists of two 250 meters cable supported main spans flanked by 50meters conventional approach spans. A centre tower with an overall height of 128 metersabove pile cap level supports the superstructure by means of four planes of stay cables in asemi - fan arrangement. Cable spacing is 6.0 meters along the bridge deck.
The cable - stayed portion of the Worli channel is 350 meters in overall length betweenexpansion joints and consists of two 150 meters cable supported main spans flanked by 50meters conventional approach spans. A centre tower with an overall height of 55 metersabove pile cap level supports the superstructure by means of four planes of stay cables in asemi - fan arrangement. Cable spacing is 6.0 meters along the bridge deck.
The superstructure comprises of twin precast concrete box girders with a fish belly crosssectional shape, identical to the approaches. A typical precast segment length is 3.0 meterswith the heaviest superstructure segment approaching 120 tons. Balanced cantileverconstruction is envisioned for erecting the cable supported superstructure as compared tospan - by - span construction for the approaches. For every 2nd segment, cable anchoragesare provided.
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A total of about 264 stay cables will be required for the cable - stayed spans at Bandrachannel with cable lengths varying from approximately 85 meters minimum to nearly 250meters maximum. The tower is cast - in - situ reinforced concrete using the climbing formmethod of construction. The overall tower configuration is an inverted "Y" shape with theinclined legs oriented along the axis of the bridge. Tower cable anchorage's are achieved byuse of formed pockets and transverse and longitudinal bar post - tensioning is provided in
the tower head to resist local cable forces.
A total of about 160 stay cables will be required for the cable - stayed spans at Worli channelwith cable lengths varying from approximately 30 meters minimum to nearly 80 metersmaximum. The tower is cast - in - situ reinforced concrete using the climbing form method ofconstruction. The overall tower configuration is "I" shape with the inclined legs. Tower cableanchorage's are achieved by use of formed pockets and transverse and longitudinal bar post- tensioning is provided in the tower head to resist local cable forces.
The foundations for the main tower are comprised of 2 meters drilled shafts with estimatedlength of 25 meters. Cofferdam and tremie seal construction is envisioned in order toconstruct the 6 meters deep foundation in the dry.
PART - III SOUTH END APPROACH STRUCTUREThis portion of the bridge is similar to the North end approach structure in constructionmethodology with span by span match cast concrete box girder sections. Similar to thenorth end approach detailed, access ramps shall be provided for connection to the westernfreeway i.e. extension upto Nariman Point.
TOLL PLAZAA modern toll plaza with 16 lanes and an approximate length of 410 meters will be providedat the Bandra end. The toll plaza will be equipped with "State - of - the - art" toll collectionsystem. A structure will be provided at this location to house the control system for the ITS.
INTELLIGENT BRIDGE SYSTEMThe toll station (TP) and collection system will provide for three different types of tollcollection, as follows :-
Fully automatic system: Electronic payment through a toll - tag & transponder etc.,which allows passage without stopping.
Semi - automatic system: Electronic payment through a smart card, which allowspayment without having to pay cash, but requires stopping.
Manual toll collection: Payment of toll by cash, requiring to make cash payment to atoll attendant, and stopping cash exchange.
The toll plaza will be designed to permit toll operations. The toll plaza will also be designedto act as a control centre for toll plaza area and the traffic surveillance, monitoring andcontrol system for the intelligent bridge. The control centre at the toll plaza will house
control facilities for electronic tolling, CCTV, traffic counting and classifying variablemessage signs, remote weather information station, and emergency telephones.
The intelligent bridge systems will provide additional traffic information, surveillance,monitoring and control systems. It will be comprised of CCTV's, traffic counting and vehicleclassification stations, variable message signs, a remote weather information system andemergency telephones. The control centre will be located at the toll plaza and will be housedwith the electric tolling controls. The communications system will be comprised of fiber -optic cable housed in PVC running parallel to the Bandra - Worli corridor. In addition,
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facilities to assist enforcement will be provided in the form of pollute locations, which willallow drivers and enforcement officers to safely pullout of traffic.
POWER SUPPLY DISTRIBUTION AND ROAD LIGHTING SYSTEMFor the entire project, a reliable and dependable power supply shall be arranged. It isproposed to install diesel generator sets and auto mains failure panels to cater to critical
load e.g. monitoring, surveillance, communication equipment emergency services likeaviation obstruction lights. Adequate levels of lighting levels shall be maintained andenergy saving luminaries shall be installed. Special emphasis has been given to incorporatelighting protection at bridge tower and control room building to protect those building /structures and the sophisticated monitoring and communication equipment installed therein.
A built - in feature of providing reliability and available of equipment is achieved throughproviding duplicate cables for such equipment. The equipment exposed to salineenvironment, G - I poles with concealed junction boxes and epoxy cast transformer shall beutilized. Facade lighting for bridge tower and special lighting in landscaped area is alsoincluded.
ANCILLIARY STRUCTURESStreet & area lighting.Landscaping.
QUALITY ASSURANCEFollowing are some of the main features incorporated into the project to enhance theperformance of the bridge:
High performance concrete (grade M60 with micro silica slurry) will be utilized for thestructure.
40 mm thick high performance overlay will be provided over the pre-stressed deck tofunction monolithic with the deck.
Coal tar epoxy painting will be provided below the high tide level splash zone for thesub - structure.
A "State - of - the - art" electric system for the ITS.
2.1 Geology
Surveys of the seabed under the planned route were conducted before the bridge
design commenced. The marine geology underneath the bridge consists of basalts,
volcanic tuffs and breccias with some intertrappean deposits. These are overlain by
completely weathered rocks and residual soil. The strength of these rocks range
from extremely weak to extremely strong and their conditions range from highly
weathered and fractured, to fresh, massive and intact. The weathered rock beds arefurther overlain by transported soil, calcareous sandstone and thin bed of coarse
grained conglomerate. The top of these strata are overlain by marine soil layer up
to 9m thick consisting of dark brown clay silt with some fine sand overlying
weathered, dark brown basaltic boulders embedded in the silt.
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2.2 Design
Main cable-stayed span
BWSL was designed as the first cable-stayed bridge to be constructed in open seas
in India. Due to the underlying geology, the pylons have a complex geometry and
the main span over the Bandra channel is one of the longest spans of concrete deck
attempted. Balancing these engineering complexities with the aesthetics of the
bridge presented significant challenges for the project.
The superstructures of the viaducts were the heaviest precast segments to be built
in India. They were built using a span-by-span method using overhead gantry
through a series of vertical and horizontal curves.
The 20000 metric ton Bandra-end span of the bridge deck is supported by stay
cables within a very close tolerance of deviations in plan and elevation.
2.2.1 Foundation and substructure
The construction of the bridge's structure presented major engineering challenges.
These included the highly variable geotechnical conditions due to the underlying
marine geology of the seabed. At times, even for plan area of a single pile had a
highly uneven foundation bed. Further compilcations included the presence of a
variable intertidal zone, with parts of the foundation bed exposed in low tide and
submerged in high tide.
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The foundations for the BWSL's cable-stayed bridges consist of 120 reinforced
concrete piles of 2,000 millimetres (6.6 ft) diameter. Those for the viaducts consist
of 484 piles of 1,500 millimetres (4.9 ft). These 604 piles were driven between 6m
and 34m into the substrate in geotechnical conditions that varied from highly
weathered volcanic material to massive high strength rocks.
2.2.2 Pylon tower
BWSL's largest pylon towers are 128m high
The largest pylons for the bridge consist of diamond shaped 128 metres (420 ft)
high concrete tower featuring flaring lower legs, converging upper legs, a unified
tower head housing the stays and a continuously varying cross section along the
height of tower.
The bridge's pylon towers gradually decrease in cross-section with height. They
have horizontal grooves every 3m in height, which permitted inserts. Vertical
grooves in the circular sections require special form liners, as well as require
attention for de-shuttering. The tower legs are inclined in two directions, whichpresented challenges in alignment and climbing of soldiers. Construction joints were
permitted at 3m intervals only.
To build the pylons, Doka of Austria was commissioned to build a custom automatic
climbing shutter formwork system, based on their SKE-100 automatic climbing
shutter system. This was fabricated on site and employed to execute all tower leg
lifts below deck level.
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2.3 Pre-cast yard
The pre-cast yard was located on reclaimed land. The yard catered to casting,
storing and handling of 2342 concrete-steel pre-cast segments for the project. The
storage capacity requirement of yard was about 470 precast segments. As the area
available was limited, the segments were stored in stacks of up to three layers.
3 Structure
Northern viaduct in the foreground seen against the Worli skyline
BWSL consists of twin continuous concrete box girder bridge sections for traffic in
each direction. Each bridge section, except at the cable-stayed portion, is supported
on piers typically spaced 50 metres (160 ft) apart. Each section is designed to
support four lanes of traffic with break-down lanes and concrete barriers. Sections
also provide for service side-walks on one side. The bridge alignment is defined with
vertical and horizontal curves.
The bridge consists of 3 distinct parts: the north end viaduct, the central cable-
stayed spans and the south end viaduct. Both the viaducts used precast segmental
construction. The cable-stayed bridge on the Bandra channel has a 50m-250m-
250m-50m span arrangement and on the Worli channel it has a 50m-50m-150m-
50m-50m span arrangement.
3.1 Northern & Southern viaducts
The viaducts on either side of the central cable-stayed spans are arranged in 300
metre units consisting of six continuous spans of 50 metres each. Expansion joints
are provided at each end of the units. The superstructure and substructure are
designed in accordance with IRC codes. Specifications conform to the IRC standard
with supplementary specifications covering special items. The foundation consists of
1.5 metres diameter drilled piles (4 nos. for each pier) with pile caps. Bridge
bearings are of Disc Type.
The viaducts were built utilising pre-cast, post-tensioned, segmental concrete-steel
box girder sections. An overhead gantry crane with self-launching capability was
custom built on the site to lay the superstructure of the precast segments. The Pre-
Cast segments are joined together using high strength epoxy glue with nominal pre-
stressing initially. The end segments adjacent to the pier are short segments "cast-
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in-situ joints". Geometrical adjustments of the span are made before primary
continuous tendons are stressed.
Segment types are further defined by the changes in the web thickness and type of
diaphragms cast in cell. The segment weights vary from 110 tonnes to 140 tonnes
per segment. The segment length varies from 3000 mm to 3200 mm. Deck posttensioning is performed at the completion of the erection of each 50m bridge span.
3.2 Cable-stayed spans
The cable-stayed portion of the Bandra channel is 600 metres (2,000 ft) in length
between expansion joints and consists of two 250-metre cable supported main
spans flanked by 50 metres conventional approach spans. A centre tower, with an
overall height of 128 metres above pile cap level, supports the superstructure by
means of four planes of cable stay in a semi-harp arrangement. Cable spacing is 6.0
metres along the bridge deck.
The cable-stayed portion of the Worli channel is 350 metres (1,150 ft) in length
between expansion joints and consists of one 150 metres cable supported main
span flanked on each side by two 50 metres conventional approach spans. A centre
tower, with an overall height of 55 metres, supports the superstructure above the
pile cap level by means of four planes of cable stay in a semi-harp arrangement.
Cable spacing here is also 6.0 metres along the bridge deck.
The superstructure comprises twin precast concrete box girders with a fish belly
cross sectional shape, identical to the approaches. A typical Pre-Cast segment
length is 3.0 metres with the heaviest superstructure segment approaching 140
tonnes. Balanced cantilever construction is used for erecting the cable supported
superstructure as compared to span-by-span construction for the approaches. For
every second segment, cable anchorages are provided.
A total of 264 cable stays are used at Bandra channel with cable lengths varying
from approximately 85 metres minimum to nearly 250 metres maximum. The tower
is cast in-situ reinforced concrete using the climbing form method of construction.
The overall tower configuration is an inverted "Y" shape with the inclined legs
oriented along the axis of the bridge. Tower cable anchorage recesses are achieved
by use of formed pockets and transverse and longitudinal bar post-tensioning is
provided in the tower head to resist local cable forces.
A total of 160 cable stays are used at Worli channel with cable lengths varying from
approximately 30 metres minimum to nearly 80 metres maximum. Like the Bandra
channel, the tower here is also cast in-situ reinforced concrete using the climbing
form method of construction but the overall tower configuration is "I" shape with the
inclined legs. Similarly, tower cable anchorage recesses are achieved by use of
formed pockets.
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The foundations for the main tower comprise 2 metre-drilled shafts of 25 metres
length each. Cofferdam and tremie seal construction have been used to construct
the six metre deep foundation in the dry.
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4 Bridge management
4.1 Toll collection
The Bandra end of the toll plaza has 16 approach lanes. The toll plaza is equipped
with an electronic toll collection system.
At both ends, the toll collection options include:
Automatic electronic payment system through On-board Units mounted on vehicles
for frequent-commuters that enable vehicles to pass without stopping
Semi-automatic cash-less electronic payment via a smart card in unattended lanes
Manual toll collection for payment by cash, to a toll attendant
4.2 Monitoring
An intelligent bridge management system (IBS) provides traffic information,
surveillance, monitoring and control systems. It comprises of CCTVs, automatic
traffic counters and vehicle classification system, variable message signs, remote
weather information system and emergency telephones. The control centre is
located near the toll plaza alongwith the electronic tolling controls. The control
system uses fibre-optic cables running the entire span of the BWSL. The toll
management system and advanced traffic management system was installed by
Efkon India.
For traffic enforcement, the bridge includes facilities for vehicles to pull over when
stopped by enforcement officers or in the event of a breakdown.
4.3 Security
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The bridge uses mobile explosive scanners for vehicles traveling on the sea link.
Scans take less than 20 seconds for each vehicle with sensors above and below the
vehicles. Over 180 cars can be scanned per hour by each scanner.
The pillars and the towers supporting the bridge are protected by buoys designed to
withstand explosions and collisions. These inflated buoys surround each pillar of thesea link to avoid any damage.
The bridge tower and the control centers feature lightning protection, designed to
protect the bridge monitoring, communication and power equipment from possible
surges.
4.4 Power supply & lighting
The bridge has a reliable and redundant power supply, backed up by diesel
generators and auto mains failure panels for critical loads, such as monitoring,
surveillance, emergency equipment and communication services including aviation
and obstruction indicators. BWSL exclusively uses energy saving illumination
systems.
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