Case study bridge construction upto pier and road construction

Construction of Flyover bridge along SP Ring Road at Bopal

Junction, Ahmedabad Practical Site Training (8th semester)

Presented By :-

Satish Kambaliya

11bcl016

Guided By :-Prof. Hemanth Kamplimath

Contents

• 1). Introduction to project

• 2). Pile construction

• 3). Pile cap construction

• 4). Pier construction• 4). Pier construction

• 5). Pier cap construction

• 6). Road construction

Introduction to project

• The Sardar Patel (SP) Ring Road of 76 km encircling city ofAhmedabad was planned with a long-term vision consideringthe road network and growth structure of Ahmedabad.

• To improve connectivity and prevent traffic congestion infuture, AUDA hasproposedover six flyovers or underpassesfuture, AUDA hasproposedover six flyovers or underpasseson the road.

• Of its scopes includes the construction of the Flyover Bridge atBopal Junction along SP rind road and of which we were apart of it.

• The construction of this bridge is carried out by Vijay M.Mistry Construction Pvt. Ltd. Ahmedabad.

Key plan

Project Structure

Client

AUDA

Structural Contractor PMCStructural consultants and

ArchitectSAI Consultants

Contractor

Vijay M. Mistry Construction

Subcontractor

(Road)Ashish Infracon

PMC

Multimedia Engineers

Name of project Construction of Flyover Bridge

along SP ring road at Bopal

Junction, Ahmedabad.

Project cost 120 cr.

Earnest money deposit 1 % of total cost of project

Salient features of the project

Security deposit 10 % of total cost of project

Total length of bridge 1415.27 m

Viaduct portion 805.27 m (deck slab)

RE wall towards Vaishnodevi 275 m

RE wall towards Sarkhej 335 m

Total No. of spans 2×31

Salient features of the project cont.

PSC box girder 2×2 i.e.

� 2 @ Ambli junction and

� 2 @ Bopal junction

Other spans of PSC girder 2×29 approximately 25m

Total no. of other PSC girder 2×5 m×29=290Total no. of other PSC girder 2×5 m×29=290

Time period 30 months

No. of pier 2×30

No. of abutments 2×2

No. of pile cap 2×32

Total width of Bridge 27.05 m

Salient features of the project cont.

Clear median 0.05 m

Total width of each bridge span 13.5 m

Carriage way width of each span 12.5 m

Length of service road 1700 m

Width of Serviceroad 2×10 mWidth of Serviceroad 2×10 m

Special contract condition

• Wastage of steel and cement has to been bear by company.

• If grade of concrete changes in the mix design, money for only

the amount of excess cement has to be bear by the client.

• The client should provide proper facilities to labour as per

codesuchascanteen,sanitation,labourcolonyetc.codesuchascanteen,sanitation,labourcolonyetc.

• PSC girder which is to be used as slab should be stored 2 km

around the site under the observation of AUDA.

• Drilling of pile is to be done only by hydraulic rig.

• Cement to be used is only of Ultratech, ACC, Sanghi.

• Steel to be used is only of TATA, sail and Electrode.

Longitudinal Plan of Viaduct portion

Section of longitudinal plan

•Deck Slab

•Crash Barrier

•PSC Girders

•Pedestal with bearing

Components of Bridge

•Pedestal with bearing

•Pier cap

•Pier

•Pile cap

•Pile

VMC

CHAIRMAN

GENERAL

MANAGER

PROJECT

MANAGER-1

PROJECT

MANAGER-2

STOREACCOUNTS

DEPARTMENT

CIVIL

ENGINEERING

MECHANICAL

ENGINEERING

PROJECT

MANAGER-3

Organizational

Structure of VMC

STOREACCOUNTS

DEPARTMENTENGINEERING

DEPARTMENT

SITE

ENGINEER-1

SUPERVISOR-

1

SUPERVISOR-

2

SKILLED

LABOUR

UNSKILLED

LABOUR

SITE

ENGINEER -2SITE

ENGINEER -3

SURVEYOR

VMC

HEAD

SUPERVISOR

SKILLED

LABOUR

UNSKILLED

LABOUR

ENGINEERING

DEPARTMENT

Detail of Infrastructure Facilities on Site• Different site offices for AUDA, site Incharge, PMC, Account

section

• There are separate offices for site Engineers

• One meeting hall and storage room

• There is availability of RMC plant on site

• Workshop for repairing of machines

• There is also availability of weigh bridge and laboratory facilities

• Steel yard for storage of steel

• There is a labour colony for approx. 120 labors, in addition to these, there is proper availability of proper sanitation facilities.

• Site is well equipped with necessary medical facilities

• On this there is availability of canteen which is a big hall with kitchen which provides lunch and dinner for 50 staff members.

Site layout

Equipments used on this site

Sr. No. Description Quantity Capacity Company

Name

1 Hydraulic rig

(MAIT

1 60 m HR 180-

MAIT

•Foundation equipments

(MAIT

machine)

MAIT

2 Piling Auger 3 For dia 1150

mm to 1500

mm

Ruston engine

3 Bentonite

mixing unit

3 - -


Name

1 Ready Mixed

concrete Plant

1 30 cum/hr. Schwing Stetter

2 Concrete pump 1 - SchwingStetter

•Concreting equipments

2 Concrete pump 1 - SchwingStetter

3 Concrete vibrators 6 - Killick Nixon

4 Form vibrators 6 - Killick Nixon

5 Concrete breakers

sets

5 - Bosch/Ingersoll

rand

6 Concrete Buckets 5 - -

7 Tremie pipe sets 3 250mm dia -

Sr. No. Description Quantity Capacity Company Name

1 Roller machine for

Liner formation1

--

2 Welding Machines 8 - Adore

3 Grinding Machine -

• Material handling equipments

3 Grinding Machine

Set4

--

4 Generators 5 Various capacitiesKirloskar

5 Dragline 1 Tata Hitachi

6 Backhoe 2 L&T Komatsu

7 Hydra Crane 2 15 MT Rhino 110C ACE

8 Trucks/Dumpers 4 - Ashok Leyland

•Dewatering equipments


Name

1 Submersible 12 - Kirloskar

pumps

2 Mud

pump(electric)

5 - Kirloskar

3 Diesel pump 4 5 HP to 10

HP

Kirloskar

Sr. No. Description Quantity Company Name

1 Total station 1 Sokkia

2 Auto level 1 Sokkia

3 Compression

testing machine

1 -

• Surveying and laboratory testing instruments

testing machine

4 Cube Moulds 100 -

5 Vibrating table 1 -

6 Slump cones 8 -

7 Sieve sets 5 -

8 Density testing set 1 -

9 Moisture content

testing set

1 -

Construction of bridge

• Tender to the VMC was obtained in month of May.

• The construction work started in month of August.

• The construction proceeds initially with construction of site

office, labour colony, ready mixed concrete plant etc.

• Then further the work proceeds with construction of test pile

and anchor pile on the site for static pile load test and dynamic

pile load test.

• Parallel work proceeds with construction of service road on

right hand side after erection of barricades.

• After site clearing the construction of pile started in month of

January.

Work breakdownstructure of project

Work progress during training

period

Pile

Construction

All 408 pile constructed

Pile cap

construction

PL1-PL5,

PL10-PL16,

Pier

construction

PL10-PL16,

Pier cap construction

PL10 upto

Shuttering

Road

construction

Road constructiconstructed

PL10-PL16,

PL23-PL30,

PR24-PR30

Were completed

PR23, PR10,PL6,PL7 were

in progress

PL10-PL16,

PL23-PL30,

PR30, PR29

were completed

PR28, PR27

were in progress

Shuttering construction on LHS

PILE CONSTRUCTIONPILE CONSTRUCTIONPILE CONSTRUCTIONPILE CONSTRUCTIONPILE CONSTRUCTIONPILE CONSTRUCTIONPILE CONSTRUCTIONPILE CONSTRUCTION

Pile details• Type of pile - Bored cast in situ, friction pile

• Diameter of pile - 1200 mm

• Depth of pile bored - 28 m approximately

• Depth of pile required 26 m from the cut off level (top of PCC).

• Construction of total 408 piles in 64 groups

• Construction of two type of piles

1). Regular piles - 336 piles

2). Obligatory piles at junctions - 72 piles

Piles arrangement

Steps for pile construction

Pile boring

Laying out of pile points

Removing of guide liner

Concreting

Pile reinforcement

Concreting

Pile reinforcement

Pile boring




• Bench mark is established referring mean sea level.

• Center line of bridge work is carried out.

• Thus at various location on both side of centre line change point

(CP) are marked referring benchmark.

• Thus referring to change point (CP), width of bridge and design

data the easting and northing coordinates of various pile is decided.

• Thus marking of pile points is done through total station and

prism, as per data available of easting and northing for individual

pile.

Pile boring• On this site boring of pile is done upto

28 m from ground level.

• Boring of pile is done through augerattached with multi tasking hydraulicrig machine. Concreting

Pile reinforcement

Pile boring


• Initial boring upto 4 m is done throughrock auger and further boring is donethrough soil auger.

• Pile boring includes1). Centering of pile points2). Installation of liners3). Pouring of bentonite slurry


Augers•Two types of

augers are

used-

1). Rock auger

of (1500 mm)

2).Soil auger

of (1200 mm)

Rock Auger Soil Auger

of (1200 mm)

Centering of pile points with auger

Installation of liners

• Liners act as formwork for pile. Twoliners are used i.e.principle liner andguide liner.

• After completion of• After completion ofboring upto 4 m, linersare inserted.

• They are inserted byhammering.

Principle liners

3.8 m length Sheet, 1.5 m1.5 m0.5 m0.5 m

• Principal liner used is 4 m in length

• Liners are prepared from 0.6 mm thick MS sheet of Fe 250.

• Liner is prepared by connecting four different parts of 1.5 m, 1.5 m,0.5 m, 0.5m and upper 0.5 m (shoe)i.e. is comparatively is thickerthan other parts.

3.8 m length Sheet, rolled to form1200 mm diameter

1.5 m1.5 m0.5 m0.5 m

Guide liner

• This liner is of 5 m lengthof standard available size,it is placed above principleliner.

• Both liner are connected

Hole for Overflowing concrete

• Both liner are connectedthrough 8 mmΦ bar bywelding, so afterconcreting this guide linerhaving hook is liftedthrough crane.

Pouring of bentonite slurry

• Bentonnite slurry is use to stabilize soil by filling pores in soil,this forms layer over loose sand.

• This is to be inserted after around 22 m depth when water tableis available.

• Approximately 13 bags of bentonnite is required to prepareslurry for apile.slurry for apile.

• Each bag weights 50 kg. Thus approximately 650 kg ofbentonnite is required in one pile.

• As bentonnite is poured to 13 m of depth and pile diameter is1200 mm, so 14.7 m3.

• So we can conclude around 44 kg of bentonnite is mixed withwater to prepare 1 m3 of slurry.

• Slurry is prepared by mixing bentonite clay with water in movablebentonite tank.

• Tank is equipped with the pump, line transferring bentonite and it iskept near the place where boring is carried out.

Pouring of bentonite slurry

Pile Reinforcement• Steel used in pile is TMT bars of

Fe500 grade of Electrode Company.

• Reinforcement cages are prepared incasting yard.

• Cover in pile is 75 mm.

• Reinforcementdetailing of all piles

Concreting

Pile reinforcement

Pile boring


• Reinforcementdetailing of all pilesare almost same.

• Total 20 numbers of mainreinforcing bars of 32 mmΦ areused in regular piles and in case ofobligatory piles total 24 numbers ofmain reinforcing bars are used.

•


Pile reinforcement• Reinforcement cage are

inserted in three layers.

• Lengths of bars varies asper cage.

• Cages are connectedthrough the helicalthrough the helicalreinforcement of 10 mmΦbars at 150 mm c/cspacing.

• As well as throughproviding continuouswelding of 100 mm lengthon alternate bars.

Reinforcement detailing of pile

Section X-X

xx

Bar

Diameter

(mm)

Spacing

(mm) Shape No.

Cutting

Length

(mm)

Total

Length(m

)

Unit

Weight

(kg/m)

Total

Weight

(kg)

a 32 - 20 28075 561.5 6.31 3543.07

BBS of pile

s1 10 150 167 3700 616.67 0.62 382.33

s3 20 1500 17 3435 57.25 2.47 141.41

Total Weight (kg) of steel for single pile 4066.81

laps and wastages 606.45

Total steel for pile 4673.26

Concrete quantity for single pile (cum) 29.4 m3

Kg/cum (excluding laps and wastages) 158.95

Concreting

Concreting

Pile reinforcement

Pile boring


•Concrete used in pile construction is of M 35 grade.

•Concrete is prepared in RMC plant.

•Total about 30 m3 of concrete is required


•Total about 30 m3 of concrete is required in construction a pile so 5 transit mixers are required.

Concrete mix design for pile

Concrete

grade

Cement

0PC 53

Grade

Water Fine

Aggregate

Coarse

Aggregate

M35 400 kg 172 kg 802.5 kg 1120.7 kg

Admixture used – sika 4661 NS =3.667 kg/ m3

M35 400 kg 172 kg 802.5 kg 1120.7 kg

M35 1 0.43 2.01 2.8

Feeding of material in respective hopper

Weighing of material as per the mix

design

Cleaning of pan after

final completion

Working of RMC

design

Mixing of batch in rotating

pan

Empty the batch

prepared in transit mixer

completion of RMC

plant

Concreting• Concreting is done

through tremie pipe.

• Tremie pipe of total

length 27.4 m is inserted

in piled bored, through

Tremie pipe

in piled bored, through

crane.

• Tremie pipe are inserted

by connecting 16 circular

pipes each of 1400 mm

length and last part of 5 m

length.

Concreting cont.• Treamie pipe is attached withhopper and above the it screen isplaced.

•As concreting proceeds treamiepipe is lifted up through crane andeach circular part of 1400mm oftreamie pipe is opened up andcleaned for next process.

Concreting

Process

•After concreting guide liner isremoved.

•This process is carried out to savecost of the project.

Removing Guide Liner

•Piles constructed is covered withmud with back hoe, so it does notinterpret construction of othernearer pile.

Pile construction process

Quality checks for pile

• Compressive strength test

� Total 12 cubes casted from one pile from alternate mixers� Cubes are tested on site for 7days and 28days� From the total cubes casted 10% of them are sent to private

testing laboratory� 1% of total cubes casted are sent to GERI� 1% of total cubes casted are sent to GERI

• Slump test

� Required Slump – 135mm.

Pile

35

40

45

50

ST

RE

NG

TH

IN

MP

A

Compressive strength at 28 days

compressive strength desired

0

5

10

15

20

25

30

PL1

0

PL1

1

PL1

2

PL1

3

PL1

4

PL1

5

PL1

6

PL2

3

PL2

4

PL2

5

PL2

6

PL2

7

PL3

0

PR

1

PR

2

PR

3

PR

4

PR

5

PR

6

PR

7

PR

10

PR

11

PR

12

PR

13

PR

14

PR

15

PR

16

PR

23

CO

MP

RE

SIV

ES

TR

EN

GT

H I

N

ONE PILE FROM EACH GROUP

Dynamic Pile Load test

• This test is going to beperformed on 2% totalpile available.

• Thus this test will beperformed on 8 pile.

• It is performed on• It is performed onroutine pile.

Static pile load test

•This is most reliablemethod of determiningthe static load carryingcapacity of a pile.

•Permissible limit ofsettlement is 18mm.

•Settlement observedwas 3 mm

Integrity test• Pile integrity test is a rapid way of assessing the continuity and

integrity of concrete piled foundations.

• This test is able to find defects corresponding to cracks, reductionsin section and zones of poor quality concrete.

• Thetestis basedon wavepropagationtheory.• Thetestis basedon wavepropagationtheory.

• Changes in cross sectional area - such as a reduction in diameter - ormaterial - such as a void in concrete - produce wave reflections.

• Accelerometer or geophone placed on top of the pile to be tested tomeasure the response to the hammer impact.

Average cycle time for a pile construction

Activities Time Required

Boring 1 hr and 15 min

Liner installation(both) 30 minutesLiner installation(both) 30 minutes

Reinforcement cage lowering in three layers 45 minutes

Tremie pipe installation and concreting 2.5 hours

Total 5 hours

Average manpower required in a Pile construction

Category of manpower required Numbers of manpower

Site engineer (contractor), PMC 2

Supervisor 1

Hydraulic rig driver (skilled)-2, Assistant for rig – 5 7

Concreting (skilled labour) 6

Reinforcement cageReinforcement cage

Skilled labour 20

Unskilled labour 4

Foreman 1

Liner installation

Supervisor 1

Skilled labour 7

Total 49

Material cost analysis of a pile

• Total steel = 4.673 t

• 1 t steel = 51000 Rs.

• Steel cost = 2,38,323 Rs.

•Total Concrete = 29.4 cum•1cum concrete = 4700 Rs.•Concrete cost = 1,38,180 Rs.

Labour cost = 20 % total material cost = 75 ,301 Rs.

Total cost = 4,51,804 Rs.

Total material cost = 3,76,503 Rs.

Cost distribution for a pile

Concrete

Labour

Cost 16.67%

Total Cost For one pile

Concrete

cost 30.58%

Steel Cost

52.75%

Concrete

steel

Labour cost

PILE CAPPILE CAPPILE CAPPILE CAP

CONSTRUCTIONCONSTRUCTIONCONSTRUCTIONCONSTRUCTION

Pile cap details

• Construction of total - 64 pile caps i.e. 32 piles on one side.

• All pile caps are rectangular in shapes having dimensions8700× 5100 mm.

• Except obligatory pile cap which are square in shape andhavingdimensions8700 × 8700mm.havingdimensions8700 × 8700mm.

• Almost all pile caps consist of group of six piles in it. Exceptin case of obligatory piles in it consist of group of nine piles.

• Construction of all pile caps is of 1800 mm height from top ofplain cement concrete.

Pile cap arrangement

Plan of pile cap

Steps involved in Pile cap Construction

Straightening of pile reinforcement

PCC

Chiseling

Excavation

Curing

Concreting

Shuttering

Pile cap reinforcement

Straightening of pile reinforcement

Excavation• Excavation of piles in group is carried out by dragline

• Rectangular excavation of 11200×5700 and upto 2500mm (as percutoff level) depth is carried out.

•Excavation - uptobottom of PCC bymeasuring through autolevel.

Excavation

•After excavationthrough dragline it is tobe leveled throughlabour for PCC.

Chiseling• Top layer of pile contains bentonite

mixed with concrete.

• Thus top concrete is loose and does

not have enough strength.

• So chiseling of piles to be done

upto availability of loose concrete.

• Chiseling of pile is done upto 50

mm above top RL of PCC of pile

cap.

Plain Cement Concrete(PCC)

• PCC is done to obtainplain surface for pilecap reinforcement.

• PCC is done of M15grade concrete in 1:2:4ratio.ratio.

• PCC is done indimensions of9000×5400×150 mm.

Straightening of Pile Bars• Straightening of

piles bars are doneby heating throughgas welding.

• After straighteningof bars it is to bebent by 475 mm atbent by 475 mm attop after keeping1300 mm straightreinforcement barswhich is to beembedded in pilecap.

Pile cap reinforcement

• Reinforcement detailing of rectangular pile caps varies depending on

height of piers.

• Reinforcement detailing of pile cap is divided in two parts i.e.

• GroupA (Pierheightfrom 5 m to 6.85 m) for Pile cap- PL4 TO PL7,• GroupA (Pierheightfrom 5 m to 6.85 m) for Pile cap- PL4 TO PL7,

PR4 TO PL7, PL10 TO PL20, PR10 TO PR20, PL23 TO PL28, PR23

TO PR27.

• Group B (Pier height from 3 m to 4.9 m) for pile cap PL1 to PL3,

PR1 to PL3, PL29 and PL30, PR28 to PR30

•At top of pcc there is construction of reinforcement mesh of 8 mmΦbars at 200 mm c/c spacing.•Mesh is provided in reinforcement for preventing concrete fromtemperature crack at bottom surface of pile cap.

Reinforcement meshmesh

Reinforcement of pile

Reinforcement Detailing of pile cap

Reinforcement detailing of Pile cap

Section C-C of plan of pile cap reinforcementSection C-C of plan of pile cap reinforcement

Section D-D of plan of pile cap reinforcement

Bar

Diameter

(mm)Spacing(mm) Shape No.

Cutting Length (mm)

Total Length(m)

Unit Weight(kg/m)

Total Weight (kg)

b 20 125 70 6750 472.5 2.471167.0

8

1022.5

BBS for group A of pile cap

c 20 125 40 10350 414 2.47 8

d 25 125 70 6750 472.5 3.851819.1

3

e 32 125 40 10350 517.5 6.312612.3

4

t 12 - 4 27600 110.4 0.89 98.26

Bar

Diameter


Cutting Length (mm)

Total Length

(m)

Unit Weight(kg/m)

Total Weight

(kg)

s5 12 100 86 285502455.3

0 0.89 2185.22

BBS for group A of pile cap cont.

Mesh

8 200 26 2700 70.20 0.39 27.38

8 200 14 5100 71.40 0.39 27.85

Total Weight (kg) of steel for single pile cap 10254.54

Add 5% for laps and wastages 512.73

Total steel for pile cap 10767.27

Concrete quantity for single pile cap(cum) 79.87m3


BBS for group B of pile cap

Bar

Diameter


Cutting Length (mm)

Total Length

(m)

Unit Weight(kg/m)

Total Weight

(kg)

b 20 125 70 6750 472.5 2.47 1167.08

c 20 100 50 10350 517.5 2.47 1278.23

d 25 125 70 6750 472.5 3.85 1819.13

e 32 100 50 10350 517.5 6.31 3265.43

t 12 - 4 27600 110.4 0.89 98.26

BBS for group B of pile cap cont.

Bar

Diameter


Cutting Length (mm)

Total Length

(m)

Unit Weight(kg/m)

Total Weight

(kg)

s5 16 150 57 285501627.3

5 1.58 2571.21

Mesh

8 200 26 2700 70.20 0.39 27.38

8 200 14 5100 71.40 0.39 27.85

Total Weight (kg) of steel for single pile cap 8959.82

Add 5% for laps and wastages 447.99

Total steel for pile cap 9407.81

Concrete quantity for single pile cap (cum) 79.87m3


Shuttering of pile cap

• After reinforcement shuttering of pile cap is done and various

members used in shuttering are as follow

� Solder

� Channel

� Tie

� Jack

� Plates

• Cover used in pile cap is 75 mm.

Shuttering of Pile cap

Tie bars

Shutter

SolderJack

Concreting of pile cap•Concrete of grade M35 is used in pile cap.

•Total 79.87m3 of concrete is required in one pile cap and it is preparedin RMC plant. Total about 13 transit mixers are required for one pile cap.

Mix design for pile cap

Concrete

grade

Cement

OPC 53

Grade

Water Fine

Aggregate

Coarse

Aggregate

M35 365 kg 183.5 kg 777.2 kg 1186.4 kg

M35 1 0.5 2.13 3.25

Admixture used - sika 4661 NS =3.6 kg/ m3

•Vibrator is used for

compaction as

concreting proceeds.

•After concreting top

layer of pile cap are

to be leveled.

Curing of Pile cap•Curing of pile cap is donethrough pounding at topsurface.

• After 2 days of concretingshuttering of pile cap isopened.

•After removing shuttering,soil filling around pile capis done.

Quality checks for pile cap• Compressive strength test� Total 20 cubes casted from one pile cap from alternate mixers.

� Cubes are tested on site for 7days and 28days.

� From the total cubes casted 10% of them are sent to privatetesting laboratory.

� 1% of total cubes casted are sent to GERI.

• Slump test� Required Slump – 135 mm.

Pile cap

35

40

45

50

ST

RE

NG

TH

IN

MP

A


compressive strength desired

0

5

10

15

20

25

30

CO

MP

RE

SIV

ES

TR

EN

GT

H I

N

PILE CAP

Average cycle time for construction of pile cap

Activities Time in hrs

Excavation 4

Chiseling, liner cutting 8

straightening of reinforcement 4.5straightening of reinforcement 4.5

PCC 2

Reinforcement 24

Formwork 6

Concreting 4.5

Total 53 hrs= 2.308 days

Average manpower required for a pile cap construction

Category of manpower Manpower Required

Site engineer (contractor and PMC) 2

Forman/Supervisor 1

Excavation of Pile cap (Unskilled labour) 10

Liner cutting and chiseling (Skilled labour) 7Liner cutting and chiseling (Skilled labour) 7

Straightening of reinforcement (Skilled labour) 7

PCC of pile cap (Skilled Labour) 8

Erection of reinforcement - Skilled labour 15

Erection of reinforcement - Unskilled labour 5

Shuttering of pile cap (Skilled labour ) 8

Concreting of pile cap (Skilled labour) 8

Total Manpower required 71

Material Cost analysis of a single pile cap of group A

• Total steel = 10.77 t

• 1 t steel = 51000 Rs.

• Steel cost = 5,49,270 Rs.

Pile cap

•Total Concrete = 79.87 cum•1cum concrete = 4700 Rs.•Concrete cost = 3,75,389 Rs.

PCCPCC•Total Concrete = 7.29cum

= 9m×5.4m×.15m

•1cum concrete = 4200 Rs.•Concrete cost = 30,616 Rs.

Total concrete cost = 4,06,005 Rs.

Total material cost = 9, 55, 275 Rs.

Cost distribution for a pile cap of Group A

Labour cost

Labour cost = 20 % material cost = 1,91,055 Rs.

So, Total cost = 11,46,330 Rs.

Concrete

cost 35.42

%

Steel Cost

47.91 %

Labour cost

16.67%

Concrete

steel

Labour cost

PIERPIERPIERPIER

CONSTRUCTIONCONSTRUCTIONCONSTRUCTIONCONSTRUCTIONCONSTRUCTIONCONSTRUCTIONCONSTRUCTIONCONSTRUCTION

Pier details

• On this site there is construction of 64 piers i.e. 32 piers on one side.

• Height of pier varies from 3 m to 6.85 m. Dimension of the pier at bottom remains same i.e. 3800×1800 mm.pier at bottom remains same i.e. 3800×1800 mm.

• The slope of the pier is 1:11.6067.

• Thus according to slope and varying height the length at topvaries in every pier; but the width 1800 mm remains samethrough out in every pier.

Longitudinal plan of piers

Procedure for pier construction

Starter

Reinforcement of pier

Marking of Pier Points

Finishing

Curing

Concreting

Shuttering

Curing

Concreting

Shuttering of pier

Starter


Marking of Pier PointsMarking of pier points

•After placing reinforcement of pile cap,points for the reinforcement of pier aremarked at bottom having dimension1800 3800 mm through total station.

•Main reinforcement bars of piers areembeddedupto1025mm depthandbarsare

Finishing

embeddedupto1025mm depthandbarsaretied up with stirrups.

•Reinforcement bars of pile cap are bent by500 mm in opposite direction at both topand bottom side.

•There are total 35 bars in 3800 mm lengthand 17 bars in 1800 mm length.

Plan of pier


Finishing

Curing

Concreting

Shuttering of pier

Starter



•Main reinforcement bars are tied withstirrups of 10 mmΦ bars at 200 mm centerto center spacing.

•Cutting of stirrups is done considering


Finishing•Cutting of stirrups is done consideringaverage height.

•After stirrups, links of 8 mmΦ bars areinserted on alternate bars.

•Main reinforcing bars of pier are to be keptoutside at top of pier by 1025 mm which areto be inserted in pier cap for bonding.

•Reinforcement detailing of pier isdivided in two groups..• Group A for height from 5 to 6.85m for pier PL4 to PL7, PR4 toPR7, PL10 to PL20, PR10 toPR20, PL23 to PL28, PR23 to PR27.

•GroupB for heightfrom 3 to 4.90 m•GroupB for heightfrom 3 to 4.90 mfor pier PL1 to PL3, PR1 toPR3, PL29 to PL30, PR28 to PR30.

Section Q-Q of plan of pier


Section P-P of plan of pier

f


BBS for group A of pier for PL15

Bars Shape of Bars

Length of bars(mm)

Spacing in mm

No. of bars

Total length(m)

Bar diameter

Bar weightKg/m

Total Weightkg

f(main vertical steel)

9900 110 104 1029.6 25 3.85 3963.96

S3

(stirrups)12360 200 35 432.6 10 0.62 268.21

L1(links) 2020 220horizontal

630 1272.6 8 0.39 496.31

Total steel for single pier 4728.49 kg

Add 5% for laps & wastages 236.42 kg

Total steel for single pier including lapse and wastages 4964.91 kg

Concrete quantity for a pier 54.2 m3

kg/m3 87.25kg/m3

BBS for group B of pier for PL3Bars Shape of

Bars Length of bars(mm)

Spacing in mm

No. of bars

Total length(m)

Bar diameter

Bar weightKg/m

Total WeightKg

f(main vertical steel)

7950 110 104 826.8 20 2.47 2042.2

S3(stirrups)

12030 160 31 372.93 10 0.62 231.22

L1(links) 2020 220horizontal

558 1127.16

8 0.39 439.59

Total steel for single pier 2713.01 kg

Add 5% for laps & wastages 135.65 kg

Total steel for single pier including lapse and wastages 2848.66 kg

Concrete quantity for a pier 37.26 m3

kg/m3 72.81kg/m3

Finishing

Curing

Concreting

Shuttering of pier

Starter


Marking of Pier PointsStarter

•Starter of dimensions 3800×1800×250mm is provided.

•Starter is provided at bottom forproviding base to shuttering.

•Main purposeof starter is to support Finishing•Main purposeof starter is to supportshuttering.

•After concreting of starter, key isprovided over it.

Starter

Shuttering of pier• Elements of shuttering of pier

are as follows:-

� Shutter

� Solder

� Tie barsFinishing

Curing

Concreting

Shuttering of pier

Starter



� Trestle

� Bracing

� PVC pipe

� Through bolts

� Bracing

• Cover used in pier is 40 mm.

Finishing

Shuttering of pier

•Grade of concrete used in pier is M40.

•Quantity of concrete is varying in everypier as the height of the pier .

•Average concrete quantity requiredconsideringaverageheightis 46m3. Finishing

Curing

Concreting of pier

Shuttering of pier

Starter



Concreting of pier

consideringaverageheightis 46m3.

•Concreting is done through fullyautomatically operated concrete pumphaving boom pressure.

Finishing

Concrete

grade

Cement Water Fine

Aggregate

Coarse

Aggregate

M40 430 kg 187.7 kg 796.5 kg 1112.4 kg

Mix Design for pier

M40 430 kg 187.7 kg 796.5 kg 1112.4 kg

M40 1 0.44 1.85 2.59

Admixture used – sika 4061 NS – 3583 gm.

Concreting through boom pressure

Curing of pier

• After two days of the concreting, formwork of the pier is removed.

• Curing of pier is done through sacklayered around the pier. By sprayingwater around the sack so keeping it

Curing

Concreting of pier

Shuttering of pier

Starter



water around the sack so keeping itwet.

• At top of every pier two water tanksare placed which is punctured from thebottom portion so continuous curing ofpier can be done at top portion.

Finishing

Water tank for continuous

Curing of pierCuring of pier

Curing

Concreting of pier

Shuttering of pier

Starter


Marking of Pier PointsFinishing of pier

Finishing

Average cycle time for a pier construction

Activity Time in hours

Reinforcement 16

Starter 4

Shuttering 18Shuttering 18

Concreting 4.5

Total 42.5

Average manpower required for a pier construction

Category of manpower required Numbers of manpower

Engineer – contractor and PMC 2

Supervisor 1

Reinforcement

Skilled labour 10

Unskilled labour 5Unskilled labour 5

Shuttering

Skilled 10

Unskilled 6

Concreting

Skilled 4

Finishing (skilled labour) 2

Total 40

Material cost analysis for a pier of group A

•Steel

Total steel = 4.964 t1 t steel = 51000 Rs.Steel cost = 2, 53,164 Rs.

•Concrete

Total Concrete = 54.2 cum1cum concrete = 4700 Rs.Concrete cost = 2, 54, 740 Rs.Steel cost = 2, 53,164 Rs. Concrete cost = 2, 54, 740 Rs.

Total material cost = 5, 07, 904 Rs.

Labour cost = 20 % of material cost = 1, 01, 581 Rs.

Total cost of pier = 6, 09, 485 Rs.

Labour cost

16.67%

Total Material Cost For one pier

COST DISTRIBUTION OF PIER FOR GROUP A

Concrete

cost 41.79%

Steel Cost

41.54%

Concrete

steel

Labour cost

Quality checks for pier• Compressive strength test� Total 16 cubes casted from one pier from alternate mixers.

• Slump test� Required Slump – 165 mm.

• If cubesfails testingof pier is doneby reboundhammer.• If cubesfails testingof pier is doneby reboundhammer.

38

40

42

44

46

PL1

0

PL1

1

PL1

2

PL1

3

PL1

4

PL1

5

PL1

6

PL2

3

PL2

4

PL2

5

PL2

6

PL2

7

PL2

8

PL2

9

PL3

0

PR

30

PR

29

Co

mp

ress

ive

str

en

gth

in

Mp

a

Date of casting


strength desired strength ahieved

PIER CAPPIER CAPPIER CAPPIER CAPPIER CAPPIER CAPPIER CAPPIER CAP


Pier cap details

• Bottom length - 7600 mm

• Top length - 11200 mm

• Depth of pier cap - 1500 mm

• Width of pier cap varies i.e.

� 2850mm� 2850mm

� 3000 mm

• Grade of concrete used in pier cap is M40.

• The lap length shall not be less than 76 times diameter of bars.

• Welding of reinforcement is not permitted in pier cap.

• Cover in pier cap is 75 mm.

Plan of pier cap

Section A-A

Section of plan of pier

All dimensions are in mm

Shuttering of pier cap

Reinforcement of pier cap

Placing of girder

Construction procedure for pier cap

Finishing

Curing

Concreting of pier cap


Curing




Placing of girder

Placing of girders•Construction of pier cap proceeds withplacing of four ISMB-300 girder of 14 mlength.

•Girders are place above trestle of 6 mheight.

Finishing• Further work proceeds with placing ofISMB-150 girders in direction parallel totraffic of 5 m length.

•These are to be placed above ISMB-300girders.

•Total 23 numbers of ISMB-150 girdersare placed.

ISMB - 300Flange width120 mm

ISMB – 150Flange width80 mm

Plan of Girders 4-ISMB300 Girders

23-ISMB

150 Girders


• Reinforcement of pier cap is to be restsover bottom shuttering.

• Reinforcement of pier is divided in twogroups.

• Group A for pier cap of width 2.85 m atpier PL1 to PL7, PR1 to PR7, PL10 to

Curing




Placing of girder

pier PL1 to PL7, PR1 to PR7, PL10 toPL16, PR10 to PR16, PL24 to PL30and PR26 to PR30.

• Group B for pier cap of width 3 m atpier PL17 to PL20, PR17 to PR20 andPR23 to PR25.

Finishing

Plan of pier cap reinforcement

Section of pier cap reinforcement



BBS for group A of pier capBar Mark Shape of bar Length

of bar in mm

Spacing in mm

No. of bars

Total length of bar in m

Bar Diame

ter

Total weight kg/m

Total Weight

Kga –Bar at top perpendicular to traffic

11920_

40 476.8 32 6.31 3008.61

b - Bar at bottom perpendicular to traffic

12370_

26 321.62 16 1.58 508.16

to trafficL1 – Ring along perpendicular to pier cap

24330_

10 243.3 16 1.58 384.41

s1 – Vertical stirrups along traffic

7800 100 62 483.6 20 2.47 1194.49

s2 - Vertical stirrups along traffic

10080 100 112 1128.96 12 0.89 1004.77

BBS for group A of pier cap cont.s3 - Vertical stirrups along traffic

8530 100 50 426.5 20 2.47 1053.46

S4 -Horizontal perpendicular to traffic

9900_

32 316.8 10 0.62 192.42

s5-Vertical stirrups perpendicular to traffic

4990 150 24 119.76 10 0.62 74.25

to traffics6 - Vertical stirrups along traffic

8530 100 33 281.49 20 2.47 695.28

d - spacer pin along traffic

2770 1000 12 33.24 32 6.31 209.74

Total steel for single pier cap 8229.59

Add 5% for lapse and vastage 416.48

Total steel 8746.07

Concrete quantity for single pile (cum) 42.49


Bar Mark Shape of bar Length of bar in mm

Spacing in mm

No. of bars

Total length of bar in m

Bar Diameter in mm

Total weight kg/m

Total Weight

Kg

a –Bar at top perpendicular to traffic

11920_

40 476 32 6.31 3008.61

b - Bar at bottom perpendicular to traffic

12370_

26 321.62 16 1.58 508.16

BBS for group B of pier cap

to trafficL1 – Ring along perpendicular to pier cap

24630_

10 246.3 16 1.58 389.15

s1 – Vertical stirrups along traffic

8100 100 62 502 20 2.47 1240.43

s2 - Vertical stirrups along traffic

10480 100 112 1173 12 0.89 1044.65

BBS for group B of pier cap cont.s3 - Vertical stirrups along traffic

8830 100 50 441.5 20 2.47 1090.51

s4 -Horizontal perpendicular to traffic

10300_

32 329.6 10 0.62 204.35

s5 - Vertical stirrups perpendicular to traffic

4990 150 24 119.76 10 0.62 74.25

traffics6 - Vertical stirrups along traffic

8830 100 33 291.39 20 2.47 719.73

d – spacer pin along traffic

2920 1000 12 35.04 32 6.31 221

Total steel for single pier cap 8500.95Add 5% for lapse and vastage 425.05Total steel 8925.99Concrete quantity for single pile (cum) 44.73Kg/cum (excluding laps and wastages) 199.55


Curing




Placing of girder

•Shuttering of pier cap is divided in twopart - bottom shuttering and sideshuttering.

•Bottom shuttering is to be shuttled abovethe girder placed.

Finishing•Reinforcement of pier cap is to besupported on bottom shuttering.

• After completely tying of reinforcingbars, side shuttering of pier cap is to beplaced.

• Side shuttering of pier cap is supportedby jack resting on girders placed.

•Elements of pier cap shuttering

�Trestle�Bracing�Jack�Shutters�ISMB 300 girders�ISMB 150 girders


Cycle time for a pier cap construction

Activities Time required in hour

Placing of girders 8

Bottom shuttering 24

Reinforcement 56

Side shuttering 16

Total 104 hours

Material cost analysis of a pier cap for group A

• SteelTotal steel = 8.229 t1 t steel = 51000 Rs.Steel cost = 4, 19, 679 Rs.

•ConcreteTotal Concrete = 42.49 cum1cum concrete = 4700 Rs.Concrete cost = 1, 99, 703 Rs.

Material analysis is done considering pier cap of width 2.85 m.

Steel cost = 4, 19, 679 Rs. Concrete cost = 1, 99, 703 Rs.

Total material cost= 6, 19, 382 Rs.

Labour cost = 20 % of material cost = 1, 23, 876 Rs.

Total cost = 7, 43, 258 Rs.

Cost distribution of a pier cap for group A

Concrete cost

26.87%

Labour cost

16.67 %

Total Material Cost For one pier Cap

26.87%

Steel Cost

56.46%

16.67 %

Concrete

steel

Labour cost

Cost construction upto pier cap

� Considering PL15

• Cost of a pile = 4, 51,804 Rs.

• Cost of 6 piles = 27,10,824 Rs.

• Cost of pile cap = 11,46,330 Rs.

• Cost of pier = 6,09,485 Rs.

• Cost of pier cap = 7, 43, 258 Rs.

• Total cost = 52,09,897 Rs

� Thus we can conclude that total cost upto construction ofpier cap is approximately = 52, 09, 897 Rs.

ROAD ROAD ROAD ROAD ROAD ROAD ROAD ROAD


Introduction

• To handle the local traffic after construction of bridge, 10 mwide service road is prepared on both side of bridge. This roadis also used as service road during bridge construction.

• The construction of road work is given as subcontract by VMCtoAshishInfraconatpriceof 30cr.toAshishInfraconatpriceof 30cr.

• Total time duration for construction of road is 30 months.

• Final finishing of road after bridge construction.

• Road construction is of flexible pavement.

Flexible pavement• Flexible pavements have low or negligible flexural strength and

are flexible in their structural action under loads.

• In case of flexible pavement deformation of lower layer affects tolayer above it.

• A typical flexible pavement consists of four components:

� Soil subgrade� Soil subgrade

� Sub base course

� Base course

� Surface course

• The flexible pavement layers transmit the compressive stress tolower layer by grain to grain transfer through the points ofcontact in granular structure.

Salient Features

• Total length of road -1700 m

• Width - 10 m

• Crest - 1125 mm

• Camberof 2.5%• Camberof 2.5%

• Total chainage provided – 0 to 1900 m

• Construction of road from chainage 100 to 1800 m

• Design speed of road is 80 km/hr.

Longitudinal plan of road

Flexible pavement courses

Flexible Pavement Thickness

1). Soil Subgrade 500 mm

2). Granular sub base course (GSB) 200 mm

3). Basecourse 250 mm3). Basecourse

� Wet mixed macadam (WMM)

250 mm

4). Surface course

� Dense Bituminous macadam (DBM) - 135mm

� Bituminous Carpet (BC) - 40mm

175 mm

Total Crest 1125 mm

Cross section of road

Road construction procedure

Final Reduced Level (FRL)

Original Ground Level (OGL)

Preliminary survey

Courses of flexible pavement

Cutting and Filling

Site clearing

Erection of Barricading

Cutting and filling •From data of OGL sheet, FRLsheet and required crest, cuttingor filling required can bemeasured.

•Cutting Depth=OGL-(FRL-Crest)=OGL-(FRL-Crest)

•Cutting is done through powershovel.

Compaction ofbottom strata

•Available bottom soilstrata is sprayed withwater after cutting.

•Compacted with roller toachieve density of1.85 gm/cc.

•Further level and densityis checked by PMCengineer.

Construction of courses of flexible pavement

Bituminous Carpet(BC)

Dense Bitumen Macadam(DBM)

Final Reduced Level (FRL)

Original Ground Level(OGL)

Preliminary survey

Wet Mix Macadam(WMM)

Granular Sub Base(GSB)

Sub GradeCourses of flexible

pavement

Cutting and Filling

Site clearing

Erection of Barricading

Procedure for a layer construction1).Dumping of material over compacted layer

2). Spraying of water•Further work proceeds with spreading of material through grader.•After spreading of material, spraying of water is carried out.

3).Compacting Layer

•Further work proceedswith compacting a layerthrough roller machine.

•After compaction densityand level of layer ischecked.checked.

•If required results areobtained further workproceeds withconstruction of other layerover it.

Sub Grade

• Total depth of subgrade – 500 mm.

• Construction of subgrade - 3 layers( approximately 150 mm,150 mm,200 mm)

• Soil which is obtainfrom cuttingis usedin subgrade.• Soil which is obtainfrom cuttingis usedin subgrade.

• Density of final layer : 1.90 gm/cc.

Material Cost analysis of sub grade• Density of soil for sub grade =1.9 gm/cc = 1900 kg/ m3

• Total soil for 10 m long sub grade construction

= 10 m(long)×10 m(wide)×0.5 m(Thick)×1900 kg/ m3

= 95000 kg of soil

=95 t=95 t

• 1 t subgrade soil = 275 Rs.

• Cost for 10 m long subgrade construction = 275 Rs.×95 t

= 26, 125 Rs.

Granular Sub Base(GSB)• Over the subgrade, GSB is to be spreaded.

• This layer is 200 mm thick.

• GSB layer mainly composed metal and coarse sand.

• This layer is compacted to achieve density of 2.16 gm/cc.

• Optimum moisture content (OMC) - 7.5%

Coarse

Sand 68%

Metal

32%

GSB

Coarse Sand

Metal

Spreading of GSB through grader

Material Cost analysis for GSB

• Density of GSB = 2.16 gm/cc = 2160 kg/ m3

• Total GSB for 10 m long road construction = 10 m(long)×10 m(wide)×0.2m(Thick)×2160 kg/ m3

= 43200 kg of GSB=43.2 t=43.2 t

• 1 t GSB = 350 Rs.

• Cost for 10 m long GSB construction = 350 Rs.×43.2 t= 15,120 Rs.

Wet Mix Macadam(WMM)• Thickness of this layer 250 mm.

• Spreaded - two layers.

• Materials - metal (0-40 mm), Stone dust and water.

• Density of first layer - 2.3 gm/cc.

• Density of second layer – 2.39 gm/cc

• Watercontent - approximately5%• Watercontent - approximately5%

• OMC – 6.5% after spraying with water and compacting

40mm

Metal 28%

20mm

Metal 18%

10mm

Metal

29%

Stone

Dust 25%

WMM

Metal of 40mm

Metal of 20mm

Metal of 10mm

Stone dust

Material Cost analysis for WMM

• Density of WMM = 2.39 gm/cc = 2390 kg/ m3

• Total WMM for 10 m long road construction = 10 m(long)×10 m (wide)×0.25m (Thick)×2390 kg/ m3

= 59, 750 kg of WMM=59.75 t=59.75 t

• 1 t WMM = 550 Rs.

• Cost for 10 m long WMM construction = 550 Rs.×59.75 t= 32863 Rs.

Application of Prime Coat

•Prime coat is applied to plug in thecapillary voids of the porous surface

•The prime coat is sprayed uniformlythrough a mechanical sprayer at a rate of7.3 to 14.6 kg per10m2 area.7.3 to 14.6 kg per10m area.

•After 24 hours of application of primecoat, dense bitumen macadam is appliedover it.

Dense Bitumen Macadam(DBM)• Total thickness of DBM- 135mm

• It is applied in two layer

• First layer - 65mm

• Density – 2.42 gm/cc.

• Bitumen is 4.5% of total weight of all material.

20mm Metal

30%

10mm Metal

27%

6mm Metal

18%

Stone dust

25%

DBM

Metal of 20mm

Metal of 10mm

Metal of 6mm

Stone dust

Scarification

•When road already exits, theconstruction over it proceeds byscarifying road surface with backhoe.

•Scarification is only possiblewhen level of existing road iswhen level of existing road isaround 150-200 mm lower thanroad to be constructed.

DBM• It is prepared in

bitumen plant attemperature of135°C whichdecreases to105°C, which is105°C, which isrequired at site.

• Just beforeapplication ofDBM tack coat isapplied at rate of4.9 to 9.8 kg per10 m2 area.

Paver machine for application of DBM

Material Cost analysis for DBM

• Density of DBM = 2.42 gm/cc = 2420 kg/ m3

• Total DBM for 10 m long road construction = 10 m(long)×10 m (wide)×0.135m (Thick)×2420 kg/ m3

= 32, 670 kg of DBM=32.67 t=32.67 t

• 1 t DBM = 3200 Rs.

• Cost for 10 m long DBM construction = 3200 Rs.×32.67 t= 1, 04, 544 Rs.

Bituminous Carpet (BC)

• After construction of bridge, second layer of DBM will be applied.

Required density of DBM – 2.42gm/cc.

• Over it bituminous carpet of 40 mm will be spreaded.

• Thisgivessmoothsurfaceto roadconstructed.• Thisgivessmoothsurfaceto roadconstructed.

• Bitumen carpet consists of coarse aggregate of 12.5 mm and 10 mm

size, premixed with bitumen.

• Required density of BC - 2.45gm/cc.

Quality checks• Density test

� This test is performed after application every layer.

� density test is performed by sand replacement method.

• Moisture test

� This test is performed in moisture meter.� This test is performed in moisture meter.

Material cost analysis for 10 m road construction

•Cost of subgrade = 26, 125 Rs.•Cost of GSB = 15, 120 Rs.•Cost of WMM = 32, 863 Rs.•Cost of DBM = 1, 04, 544 Rs.

•Total cost = 1, 78, 652 Rs.

•Thus we can conclude material cost for construction of10 m long, 10 m wide flexible pavement road of1085 mm crest = 1, 78, 652 Rs.

Thank Thank

You

Engineering

Case study bridge construction upto pier and road construction