PRESENTATION

ON
“CONSTRUCTION TECHNIQUES USED IN
CONSTRUCTION OF FLYOVER”
By
RUPESH RAMESH PATIL (11372)
ME (Construction and Management)

Under the guidance of

DR.D.A.JOSHI
Head Of Department

Department of Civil Engineering

Dr. D. Y. Patil Institute of Technology
Pimpri, Pune-411 018
Savitribai Phule Pune University, Pune
Academic Year 2018-19
CONTENTS
INTRODUCTION
 NECESSITY OF FLYOVER

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METHODOLOGY
 GENERAL INFORMATION ABOUT FLYOVER
CONSTRUCTED IN NASIK
 DESIGN FEATURES OF MAIN CORRIDOR
 SCHEME OF CONSTRUCTION
 MEASURES TO TIMELY COMPLETION
 SEGMENTAL CONSTRUCTION
CONCLUSION
 PRECONSTRUCTION ACTIVITIES:
 UTILITY SERVICES
 SPEEDY WORK DUE TO CO-ORINATED EFFORTS AND
INNOVATIVE PROVISIONS IN THE TENDER
 SUPERVISION THROUGH PMC’s
 SEGMENTAL CONSTRUCTION 2
INTRODUCTION

Like any metropolitan city in India, Nasik faces serious transportation which
have assumed acute proportion during last five years. A number of factors are

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responsible for this unprecedented increase in the population of city & its suburbs
during few years. In recent year there has been phenomenal growth in number of
vehicles plying on the city road & this has further accentuated the vehicular traffic
problems. With view to mitigate this problem, the government of Maharashtra decided
to construct flyovers in Nasik at a cost about 760 crore within 3 years

NECESSITY OF FLYOVERS
Nasik is the one of the main & important city of Maharashtra. It has very high
traffic congestion as compared to other cities of Maharashtra. Considering the future
aggravation of problems the public works department of Maharashtra, Nasik
municipal cooperation& city and industrial cooperation ltd. (CIDCO) had planned to
construct flyover on main intersections to decongest the arterial routs. While selecting
the location of this flyover a corridor approach was adopted by government of
Maharashtra. The public works department suggested decongestion of traffic in the
3
city as measure to reduce the pollution level.
 LITERATURE REVIEW
Sr. Title /Journal Author (s) Description Conclusion
No
1 A case study on Anil

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Schedule delay Upadhyay
analysis I
construction Dr.Mukesh
project Pandey

Construction
02 delay: a Al- Momani
quantitative
analysis

Rahul
Case study on Shewale
3 flyover at Nasik on
NH3 Bhagyashri
Dhandre

4 4
METHODOLOGY
PRELIMNARY ACTIVITES:-
 The following activities were required to be carried out before starting the actual
construction of Flyover Bridge at every junction.

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 Traffic survey
 Plane table survey of the junction
 Identifying utility services
 Sub-soil investigation
 Preparation of alternative layouts for various option
 Preparation of general arrangements drawings (CAD) for the selected option
 Evaluation of design criteria
 Preparation of draft tender paper
 Preparation of detailed tender
 Award of the work
 Appointment of the project management consultants (PMCs) for supervision

PRECONSTRUCTIONS ACTIVITIES BY PWD SERVICE AND INVESTIGATIONS/LAYOUTS

 The work of carrying out the preliminary investigations such as the plane table survey of the
flyover side
 traffic survey
 sub-soil exploration
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 preparation of alternate layouts
 getting same discussed and approved through meeting with the relative authorities.
GENERAL INFORMATION ABOUT FLYOVER CONSTRUCTED
IN NASIK
 NAME OF PROJECT:- CONSTRUCTION OF FLYOVER IN NASHIK.
 ROUTE:- AT GARWARE-PATHARDI-LEKHANAGAR-ADGAON-HAL-ONION MANDI
AND PIMPALGAON VANI.

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 ESTIMATED COST: - 760 CRORES.
 DURATION OF PROJECT:-3 YEARS.
 CONTRACT TYPE:- BOT(TOLL) ON DBFOT PATTERN.
 OWNER:- NATIONAL HIGHWAYS AUTHORITY OF INDIA.
 CONCESSIONAIRE:-M/S PNG TOLLWAYS LIMITED.
 EPC CONTRACTOR:- M/S L&T-INFRASTRUCTURE-METROS,PORTS & SPECIAL
BRIDGES BU.
M/S ASHOKA BUILDCON LIMITED.
 INDEPENDENT ENGINEER:- SHELADIA ASSOCIATES INC.
 DESIGN CONSUTANT:-M/S RAMBOLL CONSULTING ENGINEERS LIMITED.
 PROJECT MANAGEMENT CONSULTANT:- M/S LEE ASSOCIATE SOUTH ASIA PVT
LTD.(LASA)
 COMPANY INVOLVED:- LARSEN & TOURBO LIMITED.
ASHOKA BUILDCON LIMITED.
 NO OF FLYOVERS:- SEVEN FLYOVER AND TWO MAJOR BRIDGES.
 OTHER FEATURES:- SIX VEHICULAR UNDER PASSES AND SIX PEDESTRIAN
UNDER PASSES AND A SUBWAYS 6
DESIGN FEATURES OF MAIN CORRIDOR
 ROUTE OF MAIN CORRIDOR:- INDIRANAGAR-DWARKA-K.K.WAGH.
 WIDTH OF SEGMENT:- 19.7M
 LENGTH OF MAIN ELEVATED CORRIDOR:-5.15 KM
 CONCEPT OF EXTERNAL STRUTS IS ADOPTED.COULD MANAGE LONG CANTILEVER UPTO ABOUT
7.0 M. CROSS PRE-STRESSING TO CONTROL TENSION ON THE DECK. SUPPORTED ON SINGLE
COLUMN.

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 PRECAST SEGMENTAL BOX.
 MAXIMUM HEIGHT OF DECK SLAB:-7 M
 THICKNESS OF DECK SLAB:-200 MM
 LENGTH OF SPAN:-30 M.
 WIDTHOF SEGMENT:-2ES(1 M),2RS1(1.5 M),RS2 TO RS9(3 M)
 WIDTH OF EXPANSION JOINT:-0.5M.
 TOTAL NO OF SEGMENT:-2500 NO.
 NO OF SEGMENT PER SPAN:-12 SEGMENT(30M) AND 15 SEGMENT(40M).
 DIAMETER OF TENDENS:7PLY (15.7 M)

 SIZE OF PIER:-1. AT BOTTOM-2.5M X 3.7 M

2. AT TOP-2.5M X4.7 M
 BOX REINFORCEMENT PROVIDED AT TOP OF CENTRE OF PIER FOR EARTHQUAKE RESISTING STRUCTURE

 TYPE OF FORMWORK:- DOKKA FORMWORK

 NO OF LANES:-4 LANES (INDIVIDUAL SINGLE FOR RAMP 1.8 TO 3 M EACH)

 VARIOUS GRADE USED:- 1.FOR FOUNDATION(PCC):-M15

2.FOR PIER:-M35 3.FOR SEGMENT:-M60

 GLUING MATERIAL USED FOR CONNECTING OF SEGMENT:-FOSROC MIXED FROM

1. BASE (2KG) 2. HARDENER(4 KG)
 DIAMETER OF POT HOLES USED FOR PRETRESSING:-40 INCHES

 TYPE OF FOUNDATI0N;- OPEN FOUNDATION(4M DEPTH)& PILE FOUNDATION(BELOW 4 M UPTO 22M) 7

 EQUIPMENT USED FOR FLYOVER:-LAUNCHING GIRDER(1000 TONNE),
LAUNCHING GANTRY(200 TONNE) AND VARIOUS EQUIPMENTS
 % STEEL USED:- PIER(16%) AND SEGMENT(9%)
 SCHEME OF CONSTRUCTION
 Due to the crash programmed of flyover it was essential to
decide efficient scheme of construction with the help of modern
construction techniques.

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 The following provision were made obligatory in the tender-
 Boring of pile with rotary drilling machine only
 Use of ready mix concrete only
 Piers to be cast in a single lift only
 The girder shall be cast precast girders-prior post-tensioned
 Modified designers criteria to follow
 Anti-crash barriers to be provided with kerb laying machines
 Anti-corrosive treatment FBEC and CPCC anti-corrosive
treatment
 Strip seal-expansion joint only to be used
 PTFE/POT bearing to be used
 Traffic diversion scheme to be prepared in stages so that there
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may be minimum hindrance to traffic.
Measures for timely completion:
Considering the time bound of completing this mega project in the
period of 21 months. The PWD has affected a number of important changes in
the convention process & procedures are simplified considerably. Some of
these measures are indicated below.
1. The contractors for project have been prequalified and registers with PWD

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to ensure that only capable contractor scan bid for the work to be done in
various packages Rs. 30-40 Cr. as a part of registration condition only the
contractor who have done at least one the bridge projector flyover costing 50
core or 1000m m length ware considering the for registration.
2. Project manager consultant who will also be proof consultant are being
prequalified & restrained with MSRDC for this project, to ensure quality &
speedy execution.
3. The tender document has been standardized & split into two volumes. The
first will be common for flyovers while second will give pertinent details of
particular project. The first volume have purchased by contractor only once.
4. Incentive & disincetive clauses-since they were laid for timely completion &
tender conditions are modified to achieve this.
5. Some of important changes are follows:
•Mobilization advance 5%, machinery advance 5% on request additional 5%
for mobilization has been providing.
•The MSRDC has offered & substantial bounds of 1 Lac per day for early
completion, for deled completion a penalty of Rs.1.25 Lac per day has been
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provided.
•It has been decided that the bills will be paid within 10 days or contractor
would be eligible for interest at rate of 15%.
SEGMENTAL CONSTRUCTION
 Segmental construction in the field of prestressed hollow box
girders concrete bridges can be considered one of the most
interesting and important achievements in bridge engineering in

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the last decades.
 The usage of precast elements instead of in-situ concrete leads to
an economical, durable and safe design and a fast and versatile
construction.
 That is the reason why precast segmental hollow box girder
bridges have become the preferred constructions method for many
elevated highway projects in the last years

Components of segmental bridge

 Superstructure
 Abutments
 Piers
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 Advantages and Disadvantages of Segmental Construction
Advantages:
 Short construction time (segments are prefabricated while the substructure is being built)
 No interruption of traffic
 Precast ‘mass’ production
 Cost efficient

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 Good, controlled quality, shapes
 Weather independent construction (dry joints)
 Small light segment shollow box section
 Reduced dead load
 Cost (reduced reinforcement)
 Recycling
Disadvantages:
 safety (e.g. in case of fire)
 extra cost (more pre-stressing required, single spans, truss)
 high construction loading (over slung truss)
 new construction method – technology (e.g. geometry control of segments, design)
General Requirements:
 The design of a segmental bridge has to be done for the serviceability and the ultimate
limit state with the following distinctions to monolithic structures: Serviceability Limit
State:
 - Full pre-stressing – min. compressive stress 1 MPa
 - Shear transfer in the joints Ultimate Limit State
 - Opening of the joints has to be considered
 - Load transfer in the joints under service condition the concrete compression in the dry
joints has to be greater than 1.0 – 1.4 MPa. Therefore the whole structure is under
compression during normal loading. As there is no tension within the concrete, forces and 11
moments can be calculated based on a linear elastic behavior of the structure. In addition
to monolithic bridges, all joints have to be designed for shear loads.
CONCLUSION
PRECONSTRUCTION ACTIVITIES:
 A considerable no. of preconstruction activities needed to be carried out prior to
taking up the construction work of flyover such as surveys and investigation, layouts of fly

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over, tender paper of flyover help in diversion of traffic etc. Carried out through co-ordinate
effort by the PWD staff to ensure the start and completion of the flyover in time. The
duration of project is 3 years.

UTILITY SERVICES:-
 The utility services are known to affect the work of the urban flyovers by hindering
the work of the project. However by the appropriate and timely co-ordination with the
various dept. As well as re designs the foundation system at some places, the work of the
flyover was not allowed to be hampered on the account of utility.

SPEEDY WORK DUE TO CO-ORINATED EFFORTS AND INNOVATIVE

PROVISIONS IN THE TENDER:-
 Speedy execution of works could be attributed to the co-ordination efforts as above
the innovation approval such as rotary piles, precasting of super structures, the provisions
of incentives such as bonus for early completion and penalty for delay etc.

SUPERVISION THROUGH PMC’s:-

 Scheme of supervision through PMC’s was implemented on a very large scale in the
project. However, some short coming was indeed noticed in the performance of the PMC’s
and it can be said that there is scope for improvement in the manner of execution through
PMC’s.

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 SEGMENTAL CONSTRUCTION:-
 This method is ideal for bridge construction.
 Bridge give Aesthetical view or good quality.
 Longer span bridge now possible.

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 Longer bridge over water now possible construction of long bridges now easy.
 Construction time is less. Environment friendly construction.
 Construction line is highly mechanized by this method.
 The bottom line when choosing a construction technique for a particular segmental
bridge is economics and correctly.
 The prospective contractor should thoroughly investigate all systems complying with
specified parameters and choose the one which provides the least cost.
 The casting method, post-tensioning system or erection procedure cannot be
evaluated separately for each is only a part of the entire construction technique to be
used.

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REFERENCE

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