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Signature Bridge
Wazirabad Bridge Project
in
SUMMER TRAINING






Department of Civil Engineering
Indian Institute of Technology Delhi
Hauz Khas, New Delhi- 110016







Submitted by
Amit Kumar
2011CE10327
e-mail:iamkumaramit@yahoo.com


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Acknowledgements

I would like to express my special gratitude to my training supervisor at DTTDC
(Delhi Tourism & Transport Development Project), Mr. Priyank Mittal
(Superintending Engineer, DTTDC) whose support and direction immensely
helped in the smooth progression of the internship. He took active interest in
explaining me the concepts and was available for clarification at all junctures.
I would also extend my gratitude towards, Mr. YD Sharma who was the chief
engineer at the Casting Yard. He was always available for guidance. Also, I would
like to thank Mr. Rajesh Singh and Mr. PK Singh who were the chief engineers at
the Western Approach and the Eastern Approach respectively and were very
helpful in explaining the ongoing work at these sites.
Also, I would like to acknowledge the great support extended by Dr. Sashi Mathur,
I.I.T. Delhi who supervised and guided me during the internship.
I would also like to thank my fellow interns for their support during the internship.










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This is to certify that the report submitted by Amit Kumar describes the work carried
by him in the summer training under the overall supervision of Mr. Priyank Mittal
at the Signature Bridge, Wazirabad Bridge Project.







Signature of Student














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Table of Content:
1. Introduction
2. Western Approach
2.1 Erection of Precast segments
2.2 Crash Barrier
2.3 Pre Stressing
2.3.1 Components used in pre-stressing
2.3.2 Methodology
2.3.3 Grouting
3. Eastern Approach
3.1 Components:
3.2 Well foundation:
3.2.1 Components of well foundation:
3.2.2 Well Sinking:
3.2.3 Inspection of well foundation:
3.3 Culvert:

4. Casting Yard:
4.1 Concrete Mix design:
4.1.1 Ingredients
4.2 Casting of structural elements:
4.3 Self compacting concrete:
4.4 QC (quality control) lab:

5. Health and Safety:
6. Conclusion:

7. References




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1. Introduction
Signature bridge project is a landmark construction project of DTTDC (Delhi
Tourism & Transport Development Project) wherein a cable-stayed bridge is being
constructed across the Yamuna River at Wazirabad. The ambitious project will
connect North Delhi with East Delhi by linking NH -1 near existing T- point at
Wazirabad on western bank and Bund road at Khajuri Khas on Eastern Bank of
Yamuna River. The population explosion in the region has culminated into a heavy
demand for better infrastructural facilities leading to traffic congestion and delays.
Another factor that led to the sanction of the project was the absence of a modern
landmark structure in the city leading to lesser tourists.
With a length of about 575 meters and a height of 175 meters the proposed Signature
Bridge would have a bow-shaped pylon in the middle making it a promising tourist
attraction in Delhi. Two high towers will be there to provide double cable support in
the inner periphery of the carriageway. Plans are also afoot to construct a pedestrian
sub-way at an approximate cost of Rs 29 lakh.
Fig 1: Signature Bridge
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Equipped with eight lanes, this engineering masterpiece will have 1.2 meter wide
central verge, space for anchoring cables, maintenance walkway and crash barrier
on either side of the central verge. The deck will be composite (steel and concrete)
while pylon will be in steel.
Schlaich Bergermann and Partner of Germany have been appointed as consultants
for designing the bridge while M/s Systra SA of France has been appointed as Proof
Consultant.
Construction of bridge will be in phase-I while in phase-II, area around the bridge
will be developed, for example cleaning of Yamuna River for nearly 1 km
downstream of Wazirabad barrage, creation of water bodies for tourists, construction
of walkways from Wazirabad to Majnu ka Tilla.

Fig 2: Plan of signature Bridge



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Figure 3: Perspective View of the bridge



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1.1 Project brief
PROJECT NAME: Signature Bridge (Yamuna Bridge at Wazirabad)
COST OF PROJECT: Rs 631.81 cr (revised) [original was Rs460 cr]
TOTAL LENGTH: 575m (8 lanes)
PYLON HEIGHT: 151.14m (5400 ton)
FOUNDATIONS: 6 open and 18 well foundations
ADDITIONAL WORK: Eastern and Western approaches
COMBINED COST: Rs 1,131 cr partially funded by JNNURM (Rs 380.6
cr)
NATURE OF CONTRACT: Construction of bridge & its approaches over
Yamuna River at Wazirabad Delhi SH-main bridge (cable stayed)
REINFORCED CONCRETE: 45,000 m
3
REINFORCEMENT: 4,700 tons
DATE OF COMMENCEMENT: June 2008
TARGET DATE OF COMPLETION: Dec 2013










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1.2 Design Consultants:

Bridge Approaches



Preliminary Design
M/s Stup Consultants Pvt M/s Stup Consultants Pvt


Ltd Ltd



Main Design Consultant M/s Schlaich M/s Tandon Consultants

Bergermann & Patners, Pvt Ltd (TCPL)

Germany

Associates to Main M/s Construma M/s L R Kadiyali

Consultant Consultancy Pvt Ltd
M/s Archom

(CCPL)



Proof Consultant M/s7 Systra, France M/s Construma

Consultancy Pvt Ltd

(CCPL)

Associates to Proof M/s Tandon Consultants -

Consultant Pvt Ltd (TCPL)

Soil investigation M/s Cengers Pvt Ltd





Features of bridge:

The Bridge Length is 575m and an additional 100m West extension.
It has 2 x 4 Lanes along with a Service Track.
The carriageway has a width of 14 m on either side with a central verge of 1.2m
and service track of 2.5m on either side.
The bridge has a cable stayed deck with front and back stays.



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Pylon:

The pylon is a bow shaped, eccentric steel structure with height of 154 m and main
span of 251m. The secondary spans which are 9 in number are of 36m.
15 Stay Cables are used on the front side and 4 back stays on the other side


Deck:

The deck is RCC Precast / In-situ Steel- Concrete Composite with plate girders up
to 2m depth and thickness of 250 to 700mm

Foundations:



















Figure 4: Foundations of the Piers


Two types of foundations were used:
1. Open Foundations with Sheet Pile Coffer (9 nos)
Pylon Foundation:
Diameter -22m, Thickness - 4m
Depth of Foundation : 19m below River Bed
Rectangular Coffer : 28x 28m size
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2. Well Foundations (Rock Anchored) (18 nos)
Well Dia : Varying from 8 to 17.5m at Cutting Edge & 8 to 15.75m at Top

Approaches:

Contract Amount : Rs. 348.9 Cr.
Commencement of Work : June 2008

Duration of Work : 42 Months
Schedule Completion : December 2011
Target Completion : June 2013

Contractor : Gammon India Ltd.




Geometric features of approaches:

No. of Lanes on Main Flyovers : 3+3 Lanes
No. of Lanes on Loops/Ramps : 2 Lane
No. of Lanes on Lower level loops : 2 Lanes + Cycle trek



Width of Carriage Way
Main Flyover Carriageway : 11+11m
Central Verge : 1.2m
Loops/Ramps Carriageway : 9.0m
Cycle Trek : 2.5m






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2. Western Approach
It includes construction of flyovers, loops and ramps at the proposed intersection of
bridge with Road no.45 and existing intersection at Timarpur, Nehru Vihar and
Wazirabad.
Figure 5: Western Approach

Components:
1.8 km long main flyover along ring road integrating 3 intersections.
8 loops & ramps for right and left turning traffic, connecting to the main
bridge.



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2.1 Erection of Precast segments
The precast segments of the bridge were constructed in the casting yard and then
erected at the site either using launching girder or under slung support systems as
shown in the figure below:














Fig 6: Erection of Precast Segments Using Launching Girder














Fig 7: Erection of Precast Segments using Under-Slung Support System



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2.2 Crash Barrier:



















Fig 8: Crash Barrier


Crash barrier is designed to restrain vehicles from crashing off the side of a bridge
and falling onto the roadway, river or railroad below. It is usually higher than
roadside barrier, to prevent trucks, buses.

2.3 Pre Stressing
Pre-stressed concrete is a method for overcoming concrete's natural weakness in
tension. It can be used to produce beams, floors or bridges with a longer span than
is practical with ordinary reinforced concrete. Pre-stressing of concrete is the
application of a compressive force to concrete members and may be achieved by
either pre-tensioning high tensile steel strands before the concrete has set, or by post-
tensioning the strands after the concrete has set. The common terms used in pre-
tensioning are as follows:
a) Tendon: A stretched element used in a concrete member of structure to impart
pre-stress to the concrete. Generally, high tensile steel wires, bars, cables or strands
are used as tendons.
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b) Anchorage: A device generally used to enable the tendon to impart and maintain
pre-stress in concrete.
c) Pre-tensioning: Pre-tensioning is the application, before casting, of a tensile
force to high tensile steel tendons around which the concrete is to be cast. When
the placed concrete has developed sufficient compressive strength a compressive
force is imparted to it by releasing the tendons, so that the concrete member is in a
permanent state of pre-stress.
d) Post-tensioning: Post-tensioning is the application of a compressive force to the
concrete at some point in time after casting. When the concrete has gained strength
a state of pre-stress is induced by tensioning steel tendons passed through ducts cast
into the concrete, and locking the stressed tendons with mechanical anchors. The
tendons are then normally grouted in place.
e) Bonded Pre-stressed Concrete: Concrete in which pressure is introduced to
concrete through a bond between the cables and surrounding concrete. Pre-tensioned
members belong to this group.
f) Non Bonded Pre-stressed Concrete: Concrete in which pre-stress is introduced to
concrete through anchorage devices and tendons or cables vare not bounded to
concrete.
2.3.1 Components used in pre-stressing:
HT Stands
HDPE Sheathing
Guide (transfers pre-stressing force from bearing plate to the concrete)
Bearing Plate
Grips and Circlips
Mono Jack SC-2
2.3.2 Methodology
The concrete is cast around a plastic curved duct, to follow the area where otherwise
tension would occur in the concrete element. A set of tendons are fished through the
duct and the concrete is poured. Once the concrete has hardened, the tendons are
tensioned by hydraulic jacks that push against the concrete member itself. When the
tendons have stretched sufficiently, according to the design specifications (see
Hooke's law), they are wedged in position and maintain tension after the jacks are
removed, transferring pressure to the concrete. The duct is then grouted to protect
the tendons from corrosion. This method is commonly used to create monolithic
slabs for house construction in locations where expansive soils (such as adobe clay)
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create problems for the typical perimeter foundation. All stresses from seasonal
expansion and contraction of the underlying soil are taken into the entire tensioned
slab, which supports the building without significant flexure.

After Stressing of segments water treatment and grouting is done. Water treatment
is done to check the presence of air voids inside the segments which may corrode
the HYSD bars used for stressing. In grouting, water & cement are mixed in ratio
0.4:1.

2.3.3 Grouting
The purpose of grouting the cable is to provide permanent protection to the post
tensioned steel against corrosion and develop bond between pre-stressing steel and
surrounding concrete. The grout ensures encasement of steel for corrosion protection
and fills the duct space to prevent water/air passage.
The materials used here are OPC-43 grade cement, clean water, FORSOC
Admixture.
Checks done in grouting:

Water temp. maintained below 25 degrees Celsius
Density of grout
Pressure of grout pump maintained at 5 Kg/cm2



Figure 9: Ongoing Activities at Western Approach

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3. Eastern Approach

Figure 10: Eastern Approach
3.1 Components:

A 1.8 km Long and 10 to 12m High Embankment.

Ground Level Rotary on High Embankment (120m Diameter)
A 850m long Flyover at Khajuri Khas Intersection.

Guide Bunds, Launching Apron & Slope Protection Works.


3.2 Well foundation:
Well Foundation have their origin in India. Well Foundation have been used in India
for hundreds of years for providing deep foundation below the water level for
Monuments.
A well foundation is similar to open cassion. Well Foundations can be constructed
on the dry bed or after making a sand island. At locations where the depth of water
is greater than 5m to 6m and the velocity of water is high, wells can be fabricated on
the river bank.
It is suitable for deep water where it is difficult to carry construction equipment
suitable for river bed, alluvial soil which mainly consists of sandy.



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Well cap

Slab


Water fill

Top plug (500 mm)
Steining wall


Sand fill



Bottom plug Cutting edge








Top view of well B.M-2







B.M-1 B.M-3





800 mm
800 mm
B.M-4

5900 mm


7500 mm

Figure 11: Well Foundation

4 bench marks are provided on every quarter of well so as to notice tilting and
shifting of the well.
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3.2.1 Components of well foundation:

Cutting Edge:
The lower most portion of the well curb is the cutting edge
It cuts into the soil during sinking. It is fabricated in 5 or 6 pieces and are numbered
for ease in assembly. Then these cutting edges are assembled and placed on a
levelled platform and are compacted uniformly to preclude possibility of settlement
during curb concreting.

Well Curb:
The lower wedge-shaped portion of well staining is called the well curb
It facilitates the process of sinking. Curb casting is done in a single stage. Casting
involves reinforcement fixing where steel bars are cut and bent as per the approved
bar bending schedule (BBS); shuttering fixing, concreting and de-shuttering.

Steining Wall:
It is the main body of well which transfers load to the subsoil.
Acts as a cofferdam during sinking and provides weight for the sinking. The
procedure for reinforcement fixing, shuttering fixing, concreting and de-shuttering
is the same as in well curb.

Bottom Plug:
After the well is sunk to the required depth, the base of well is plugged with concrete.
This is called bottom plug. It transmits the load to the subsoil. On completion of
sinking up to the founding level, various parameters like final tilt & shift, strata
obtained in bore log, rock level below the cutting edge, concrete quantity for bottom
plug shall be checked. The bottom plug shall be provided in all wells and the top
shall be kept not lower than 300 mm in the centre above the top of the curb. Height
of sump should be sufficient (about 150 mm) to permit easy flow of concrete through
tremie to fill up all cavities. Concrete shall be laid in one continuous operation till
the dredge hole is filled to the required height. For under water concrete, the concrete
shall be placed by tremie under still water condition and the cement content of the
mix be increased by 10 percent.


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Sand Filling:
Sand filling shall commence after a period of 14 days of laying of bottom plug. Also,
the height of the bottom plug shall be verified before starting sand filling. Sand shall
be clean and free from earth, clay clods, roots, boulders, shingles, etc. and shall be
compacted as directed. Sand filling shall be carried out up to the level shown on the
drawing or as directed by the Engineer

Dredge Hole:
The well is sunk by excavating soil from within the well. The hole formed due to the
excavation of soil is called the dredge hole. It is later filled with sand. This sand
filling helps in distributing the load of superstructure to the bottom plug.

Top Plug:
It is a concrete plug covering the sand filling usually constructed on top. It provides
contact between the well cap and sand filling and helps in transferring the load
through the sand filling. A 300 mm. thick plug of cement concrete shall be provided
over the filling

Well Cap:
It is a RCC slab laid on top of the wall staining and is usually cast monolithically
with staining. Transmit the load of superstructure to the staining. A reinforced
cement concrete well cap will be provided over the top of the steining in
accordance with the drawing. Concreting shall be carried out in dry condition. A
properly designed false steining may be provided where possible to ensure that the
well cap is laid in dry condition.


3.2.2 Well Sinking:

It occurs in two parts- first due to self-weight (till about 10m) and then through the
jack down (about 38-40m). Jackdown sinking is basically transferring the forces
exerted by the hydraulic jacks on the earth anchors to the heavy duty pressurization
girders resting on the steining top through stools. The earth anchor pairs are placed
such that two girders systems, both crossing the well sides, can be positioned, with
hydraulic jacks at the ends of the girder, located such that they are directly above
the center of the earth anchor pair. For loading jacks we use anchorage wire HYSD
bars Fe 500.
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3.2.3 Inspection of well foundation:

Tilt is the inclination of the well from the vertical while sink is the horizontal
displacement of the center of the well at the founding level from its theoretical
position. Tilt occurs due to uneven loading and the major reason for shifting of well
is Sand blow. Sand blows beneath the well due to increase in load on one side. The
values of tilt and sink are used in inspection of well. The tilt of any well shall not
exceed 1 (horizontal) in 80 (vertical), and the shift at the well base shall not be more
than 150 mm in any resultant direction.

Methods adopted for preventing shifting and tilting of well include Eccentric
dredging, eccentric loading, Pull to well, and Push to well.


3.3 Culvert:

A culvert is a drain or pipe that allows water to flow under a road, railroad, trail, or
similar obstruction. Culverts differ from bridges mainly in size and construction.
Culverts are generally smaller than bridges, ranging from 0.3-metre (1 ft) pipes to
larger reinforced concrete structures.

In signature bridge project, eastern approach has two types of culverts: 2 - cell and
4 cell


Figure 12: Ongoing Activities at Eastern Approach
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4. Casting Yard:



















Figure 13: Casting Yard

4.1 Concrete Mix design:

The concrete used in the project were:
Plain Cement Concrete: M10, M15
High Performance Concrete: Using slag cement (M35, M45, M50) or
using OPC (M25, M35, M45, M50, M60).
Self-Compacting Concrete: M60, M65
Pavement Quality Concrete: M35, M40

4.1.1 Ingredients

1. Cement: two type of cements are used OPC and Slag cement.
2. Water: Treated water from R.O plant is used to avoid degradation in quality
of reinforcement by corrosion by fluorides and various salts present in bore-
well water.
3. Aggregates:
Coarse aggregates - 10 mm & 20 mm.
Fine aggregates
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4. Admixtures
Mineral Admixture Used: Silica Fume, Flyash
Chemical Admixture Used: Naphta Based, Poly Caboxyl Ether(PCE)
Based, VMA



Yard consists of two silos for fly ash and silica fume.

4.2 Casting of structural elements:


In precast technology the segments are pre casted in casting yard far from actual site.
After casting they are transported to the site for erection. In the signature bridge, the
casting of many structural elements were done in the casting yard which was Main
advantage of pre-casting are that it saves time, it prevents hindrance in normal life
of people living near project site and it is more safe.

Signature bridge pre-casted materials are

a) Segments
b) Ribs
c) Kerb stone
d) Facia panel of crash barrier

4.3 Self compacting concrete:

Self-consolidating concrete or self-compacting concrete is characterized by a low
yield, high deformability, and moderate viscosity necessary to ensure uniform
suspension of solid particles during transportation, placement (without external
compaction), and thereafter until the concrete sets.
Such concrete can be used for casting heavily reinforced sections, places where there
can be no access to vibrators for compaction and in complex shapes of formwork
which may otherwise be impossible to cast, giving a far superior surface than
conventional concrete. In our case SCC is used for casting of piers.






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4.4 QC (quality control ) lab:


The various tests are performed here for concrete ingredients.
Tests performed for
cement
Tests performed for aggregates

Fineness test
Sieve test
Settling test

Sieve analysis
Crushing value test
Impact value test
10 % fines value test
Silt content
Specific gravity
Flakiness & elongation test



The tests performed here on concrete are:
Non-self compacting concrete Self compacting concrete
Slump test
Settling time test initial settling
time , final settling time
Crushing value test (performed
on cubes)

V funnel test
L- box test
flow test






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5. Health and Safety:
All staff including officers visiting shall wear safety gear such as helmets and
safety shoes. Welding goggles and hand gloves are also provided to welders /
cutters.
To avoid contact of grout mix gloves, eye/face protection and dust masks shall
be provided to the workers at grouting operation. In case the grout in contact
with skin it shall be washed with clean water. In case of contact with eyes it
shall be rinsed with plenty of water and medical attention shall be sought
immediately.
Use proper sling while lowering the bracket, beam & Struts in the excavated
area by crane.
Care shall be taken for lowering the Bracket, wailer & struts at the lower level
as not to touch the assembly at the upper level.
Proper stage wise ladder shall be provided for movement of workers in the
excavated area.
All the workers working in the area shall be equipped with PPE such as
helmets and safety shoes & safety goggles.
Periodic health check-up will be arranged for workers. Necessary caution /
signboards shall be displayed.
First aid box shall be kept at site.












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6. Conclusion:

The summer training period exposed us to almost all practical aspects of civil
engineering, especially construction of foundations, erection of structural elements,
reinforcement of concrete, many tests to check strength and durability of structural
elements, etc. Besides civil engineering we got opportunity to learn about
management of such a big project and steps taken to prevent cost overrun and delays.
Handling such a project requires a great dedicated team effort .This training provided
us the practical knowledge which cannot be explained in the institute campus nor in
any laboratory.






















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7. References
The Signature Bridge, Presentation given to MD, DTTDC
Steel Structures and Metal Buildings, Vol.1 Issue-4, February 2011.
Wikipedia: Foundation Engineering
http://en.wikipedia.org/wiki/Foundation_(engineering)
Signature Bridge delayed, LG slams tourism agency, Times Of India.