CANDIDATE'S DECLARATION

I, , hereby declare that the work which is being presented in the dissertation entitled, “CHENAB
RAILWAY BRIDGE” in partial fulfillment of requirement for the award of degree of B.Tech.
(CIVIL Engineering) and submitted in the Department of Civil Engineering, GRIMT affiliated
from Kurukshetra University, Kurukshetra, is an authentic record of my own work carried by me
under the supervision of Supervisor Name (Er. VIKAS GARG ) and Co-Supervisor Name (Er
ZUBER AHMED SEHARI).The matter presented in this dissertation has not been submitted in
this or any other University / Institute for the award of B.Tech Degree.

Signature of the Student Dated:

ANKUSH GUPTA

PRASHANT ABROL

SANDEEP SINGH

LUCKY SHARMA

HIMANSHU SUDAN

MANJEET

PRINCE SADHOTRA

PARVEEN RAO

1
 Department of Civil Engineering
GRIMT, RADAUR
(Affiliated From)
Kurukshetra University, Kurukshetra
(Established by the state legislature Act XII of 1956)
(“A+” Grade, NAAC Accredited)

CERTIFICATE
This is to certify that the dissertation entitled “CHENAB RAILWAY BRIDGE” submitted by
....in partial fulfillment of requirement for the award of the degree of B.Tech. (Civil Engineering)
and submitted in the Department of Civil Engineering,to (Er VIKAS GARG) , is a record of
student’s own work carried out by him/her under my/ our supervision. The dissertation is, in
my/our opinion, worthy for consideration, for the award of B.TECH (civil Engineering) in
accordance with the rules and regulation of Kurukshetra University, Kurukshetra.

With best wishes for success in his/her all endeavors.

External Supervisor Internal Supervisor

Er. VIKAS GARG

Head of department
Civil Engineering
GRIMT

2
 ACKNOWLEDGEMENT

I have taken efforts in this project. However, it would not have been possible without the
kind support and help of many individuals and organizations. I am highly indebted to members of
AFCONS INFRASTRUCTURE.LTD for their guidance and constant supervision & also for their
support in completing my Major Project.

I express my sincere and heartful thanks to Mr. D.P Singh , Project Manager, To Mr.
Raghevendra (Geologist) Mr. Mandal, Mr. Reddy (Execution department), and Mr. VPN (Slip
Form Engineer) ,To Mr. Jitender Singh, Mr. Sandeep Sharma, Mr.Harendra Singh, HR & P&A
dept for his constructive support, constant encouragement, guidance and challenging efforts in the
right direction without which this report would not have attained the present form.

I would like to thank my HOD Er. VIKAS GARG & Er. ZUBER AHMED SEHARI
for their advice, support and assistance throughout this thesis work.

I express my sincere gratitude to GRIMT and Kurukshetra University, Kurukshetra for

giving me the opportunity to work on the Dissertation during my final year of B.Tech.

ANKUSH GUPTA (4614474)

LUCKY SHARMA (4614123)
SANDEEP SINGH (4614418)
MANJEET (4614452)
HIMANSHU SUDAN (4614123)
PRASHANT ABROL (4614414)
PARVEEN RAO (4614021)
PRINCE SADHOTRA (4614416)

3
 ABSTRACT

Indian Railways has undertaken the mega-project of construction of a new railway line in the State
of Jammu and Kashmir. The project includes a large number of tunnels and bridges which are to
be implemented in highly rugged and mountainous terrain. The alignment crosses a deep gorge of
the Chenab River, which necessitates construction of a long-span railway bridge. The main feature
of the Chenab Bridge is its 467 metres long steel arch main span located about 320 metres above
the surface of the river. The paper describes mainly the conceptual design, but partly also the
structural design of this bridge. In the design work both national Indian codes as well as several
international codes had to be followed considering that the design standards match the construction
standards.

4
 ABOUT COMPANY

Welcome to the world of Afcons Infrastructure Limited, where we believe in walking the
distance that has never been crossed before. Our first step forward was in the year 1959, when
Rodio Foundation Engineering Limited, Switzerland, and Hazarat & Co came together to form
Rodio Hazarat & Co for undertaking construction works.

Today, Afcons Infrastructure Limited is part of the Shapoorji Pallonji Group, the second-
largest Engineering & Construction group in India. It stands proudly as one of the top infrastructure
development companies in India with its presence in various parts of the world.

1. Best Executed Highway Project Jammu-Udhampur Highway, Construction Times

December 2016
2. Confederation of Indian Industry (CII) award (western region) June 2016 India's Fastest
Growing company (Large Category) - Construction World - October 2015

5
 INDEX

TITLE PAGE NO.

Chapter 1 INTRODUCTION
1.1 Introduction
1.2 Salient Feature
1.3 Health Hazards & Safety

Chapter 2 EXCAVATION WORK

2.1 Excavation Work at P4 foundation
2.2 Construction Equipment’s
2.3 Construction Procedure
2.3.1Marking of Layout
2.3.2 Barricading of Area
2.3.3 Preparation & Maintenance of Dumping Area
2.3.4 Construction of Approach Roads
2.3.5 Breaking of Rock
2.3.6 Excavation Procedure

Chapter 3 STABILISATIONS
3.1 Slope Stabilization
3.2Rock Bolting
3.2.1 Marking of Layout
3.2.2 Drilling of Holes
3.2.3 Installation of Prefabricated Rock Bolts
3.2.4 Grouting of Drilled Holes
3.2.5 Tightening of Rock Bolts
3.2.6 Installation of Weep Holes
3.3 ShotCreteing
3.3.1Curing
3.3.2Testing

6
 3.4 Slip Form
3.5 Risk Involved

Chapter 4 QUALITY ASSURANCE & QUALITY CONTROL

4.1 Control Panel
4.2 Quality Assurance
4.3 Quality Control
4.4 Typical Responsibilities of Quality Assurance Manager
4.5 Quality Objects

Chapter 5 EXPERIMENTAL TESTS

5.1 Test on Aggregates
5.1.1 Sieve Analysis
5.1.2 Impact Value Test
5.2 Test on Cement
5.2.1 Fineness
5.2.2 Consistency
5.2.3 Initial & Final Setting Time
5.2.4 Soundness Test
5.3 Test on Concrete
5.3.1 Slump Test
5.3.2 Compression Test

Chapter 6 PROJECT STUDY

6.1 Scope of Work
6.2 Site Location
6.3 Details
6.4 Design Innovation
6.5 Arch Design
6.6 Challenges in Construction Method
6.7 Salient Features

7
8
 CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

The Konkan Railway Corporation Limited has taken up a challenging project Kashmir Railway to
connect the state of Jammu & Kashmir with the rest of the country. The Kashmir Railway project
is one of the most difficult new railway line project under construction in India in the present time.
One of the major landmarks in this project is the bridge that is being built on the ferocious Chenab
River.

1.2 SALIENT FEATURES:

9
1.3 HEALTH HAZARDS & SAFETY:-

Safety at construction sites must be always in the spotlight and all the concerned stakeholders
cannot take their eyes away from it. Ensuring proper standards of safety at such sites is an ongoing
process and workers and owners alike must be fully conversant with the laws, policies and safety
features that are a part of such accident prone workplaces. Safety measures of people working on
construction sites:

Scaffolding for Fall Protection: One of the common reasons for accidents at the workplace are
workers falling from a height because they slip or lose their balance. This is why solidly erected
scaffolding is an absolute must on construction sites.

The Proper Use of Ladders: Another reason for injuries and fatalities resulting from falls is the
improper use and placement of ladders at the construction place. Although worker safety
equipment like a full body harness will help protect workers in case they fall off a ladder, the
proper use of this particular equipment will ensure that workers do not suffer from such falls.

Protection for The Face and Eyes: One important but often ignored aspect of worker safety on
construction sites is eye and face protection. Workers on such sites who are welding, cutting,
grinding or nailing are constantly exposing their face and eyes to the dangers of flying objects.
Therefore, they must wear eye protectors depending on the kind of flying objects or other hazards
they are exposing their eyes and face.

10
 CHAPTER2

EXCAVATION WORK

2.1 EXCAVATION WORK AT P4 FOUNDATION:-

Excavation is defined as removal of rock strata from the surface in order to attain the desired slope
profile of the rock strata. Firstly surveyor marks the points on the surface of rock where excavation
is to be done with suitable reduced levels. Then marking is done throughout the periphery of the
surface at which work is to be done. The corners of the excavation is provided by proper marking
due to spraying of red colour.

The excavation required at P4 for open foundation is in sloped manner of 3 Vertical: 1 Horizontal.
The required levels are checked continuously during excavation in order to know the depth of
removal of rock strata at the required position. The excavated material is loaded into tyre mounted
dumpers in order to free the surface area.

2.2 CONSTRUCTION EQUIPMENTS:-

1. Excavator
2. Dozer/JCB
3. Dumpers
4. Air Compressor
5. Jack Hammer

2.3 CONSTRUCTION PROCEDURE:-

1. Marking of Layout with KRCL representative

2. Preparation and maintenance of dumping yard

2.3.1 MARKING OF LAYOUT:-

The vegetation cover, shurbs and unwated material should be removed from the surface on which
layout is done for cutting with the help of surveyor. The surveyor uses total station for providing
the layout on the surface for excavation. The layout is done with the help of spraying red colour
between the points along the tape which is holded in position for marking brtween the points. The
cutting of rock strata is done according to the points provided by the surveyor. The depth of cutting
is maintained according to the required slope profile.

11
2.3.2 BARRICADING OF AREA:-

The marked area will be barricaded with G.I sheets and wodden Props / M.S Pipes.

2.3.3 PREPERATION & MAINTENANCE OF DUMPING AREA:-

The Dump yard will be maintained and developed at desired location and will be cleared of major
obstructions dor the maneuverability of construction equipment.

2.3.4 CONSTRUCTION OF APPROACH ROADS:-

After marking layout on ground and decision of work front, approach will be constructed
connecting dump yard. Utmost care will be taken to avoid rock falling during the excavation

2.3.5 BREAKING OF ROCK:-

The breaking of rock by using breaker machine is done to provide accuracy in required slope
profile. The chiesal movement during cutting is controlled by hydraulic pressure provided by
breaker machine. The depth of rock cutting is maintained throughout the foundation. The required
levels are regularly checked to know the cutting depth at the proper positions. The corners are
properly maintained with the help of breaker machine. This stage of excavation involved removal
of any loose soil or overburden by using excavator. Excavated muck will be loaded into tippers
and shifted to the dumping yard. The slope of the cutting will be sloped to 3Vertical: 1 Horizontal
and there will be berm of 1m. Horizontal width after every 3m vertical height as per drawing.

12
 CHAPTER 3

STABLISATIONS

3.1 SLOPE STABLIZATION:-

The slope stabilization is the ability of rock mass to resist disruption when outside forces are
applied. Slope stability is the potential of soil covered slopes to withstand and undergo movement.
Stability is determined by the balance of shear stress and shear strength.

To avoid the failure of the slope the open cavities in the rock are filled with grout to as single unit
to resist the external forces. The grouted holes again drilled and insert passive and active anchors
up to the required depth. The space left inside the hole due to inserting of anchors are again filled
by cement grout.

Shotcreting, Rock bolting and Dywidag anchoring is done to stabilize the rock and avoid the
formation of wedge in the rock mass in future due to action of external forces.

There are 4 main types of slope failure they are as follows:

1. Plane failure
2. Wedge failure
3. Circular faiure
4. Topping failure

3.2 ROCK BOLTING:-

1. Drilling of holes for Rock Bolting and Weep Holes

2. Installation Of Rock Bolts
3. Installation of Weep Holes
4. First layer of shotcrete of 50mm thick
5. Fixing of wire mesh (if SFRS is not used)
6. Application of Torque On Rock Bolt
7. Final Layer of Shotcrete of 50mm thick

13
3.2.1 MARKING OF LAYOUT:-

Position and location of rock bolts will be marked on the slope in accordance with approved layout
drawing.

3.2.2 DRILLING OF HOLES:-

Drilling of holes will be done preferably by air percussion drilling depending on the ground
condition. The diameter of the drilled hole will be 100mm and diameter of the rock bolt will be 32
mm. The depth of the drilled hole will be 300mm more than the designed length of the rock bolt.
The position of the hole for the rock bolt will be perpendicular to the slope angle and spacing of
rock bolts shall be as per drawing.

3.2.3 INSTALLATION OF PREFABRICATED ROCK BOLTS:-

The drilled holes will be flushed by means of air jet to remove any loose materials which can
potentially reduce the grout ground interface resistance. After inspection of hole, the rock bolt will
be inserted into the hole carefully along with centralizers and grout pipe.

3.2.4 GROUTING OF DRILLED HOLE:-

The hole will be cleaned with the jet of air prior to the commencement of grouting. A neat water
cement grout mix design. The minimum 28 days compressive strength of grout should be 30MPa.
Grout mix will be pumped into hole by grout injector through grout pipe. Grouting will be done
from bottom of the hole to the top and grout pipe will be gradually removed as grouting progressed
till fresh grout returns from hole. After waiting for about 15-20 minutes, the depth of grout inside
the grouted rock bolt will be checked. Once it is ensured there is no loss of grout , top surface of
the rock bolt hole will be neatly sealed with grout.

3.2.5 TIGHGENING OF ROCK BOLT:-

This has to be done after application of first layer of shotcrete of grout attaining 50% of
compressive strength. After the application of 50mm thick first layer of shotcrete, a bearing plate
of size 150mm X 150mm X 12mm with central hole of diameter 40mm will be installed for the
rock bolt. A 4mm thick plane washer will be fixed on the rock bolt over base plate and tightened
with M30 Nut using torque wrench to develop axial tension equivalent to 25% of design capacity
of rock bolt as provide in drawing. Torque will be applied on the rock bolts a after grout attains

14
50% of required compressive strength which will be ascertained by conducting tests or
compressive strength of cubes.

3.2.6 INSTALLATION OF WEEP HOLES:-

Position and location of weep holes for subsurface drainage will be marked on ground as per
drawing. Drilling of holes will be done preferably by air percussion drilling depending on ground
condition. The diameter of the drill hole will be 100mm and the diameter of weep hole will be
50mm. The depth and slope of drill hole will be as per approved drawing. A rigid semi perforated
PVC pipe of 50mm diameter and length given in approved drawing will be wrapped with
NonWoven type Geo-Textile inserted into drain hole for a given depth.

3.3 SHORTCRETING:-

Shotcrete is concrete conveyed through a hose projected at rate of 6.5-7kg/cm2 onto a surface.
Steel fiber reinforcement is used for stabilization of slope. The steel fiber is used in quantity of
30kg/m3 of shotcrete. Shotcrete is done in two layers with total thickness of 100mm applied on
the sloped surface.

Wet-mix shotcrete involves pumping of ready-mixed concrete, to the nozzle. Compressed air is
introduced at the nozzle to impel the mixture onto the receiving surface. The greatest advantage of
the wet-mix process is that all the ingredients are mixed well with the water and larger volumes
can be placed in less time. Nailing of 130mm is done on the rock surface in order to distribute the
Shotcrete in two layers properly. Surface should be damp before applying shotcrete.

15
 Fig. showing .Shotcreted Surface

Detail design mix of M25 shotcrete

S.no Material Quantity (weight /m3)

1 Cement 500 kg

2 Sand 1133 kg

3 Coarse aggregates 10mm 381 kg

4 Micro silica 37.5 kg

5 Steel fiber 30 kg

6 Water 215 kg

7 Admixture Superplasticizer 5.375 kg

8 Accelerator Sodium silicate 35 kg

Application of Shotcrete:

Shotcrete is built up layer by layer. Each layer of Shotcrete is made in several passes of nozzle
over the working area. The nozzle shall be held at a distance of 1m (but in no case greater than 1.5
meter) from the surface to be covered. The stream of flowing material shall be applied as early as

16
possible at right angles to the surface. Nozzle shall be held in steady motion so that the shotcrete
is applied uniformly in order to build up required thickness of layer. Shotcrete should consist of
dense and uniform concrete without segregation. The pressure during shotcreting is maintained
about 6.5-7kg/cm2. Shotcrete will be done in two layers of thickness 50mm each. Final layer of
50mm thick Shotcreting will be applied after the rock bolting operation.

3.3.1 CURING:-

Immediately after finishing, Shotcreting surface will be cured with water until the succeeding
shotcrete layer is placed. Curing will be done by continuous sprinkling or covering with absorptive
mat namely hessian cloth which will be kept wet continuous.

Placing of wire mesh:

After application of about 50mm thick 1st layer of Shotcreting, wire mesh of size 150mm x 150mm
x 6mm will be fixed with the rock Bolt. After fixing the wire mesh, final layer of 50mm thick
Shotcreting will be applied.

3.3.2 TESTING:-

Concrete test specimen of 15cm cube mould will be cast from the Shotcreting in order to check
the compressive strength of the shotcrete. The compressive strength of the specimens shall be
conducted at the age of 7 and 28 days. The 28 days compressive strength of Shotcreting shall not
be less than 25MPa.

3.4 SLIP FORM:-

Slip form is a very innovative technique for construction of continuous concrete structures. This
is a type of mould which is continuously moving over the just and sufficiently set concrete so that
the concrete withstand self-load. The concrete is poured in the layers continuously with continuous
fixing of the reinforcements and other fixes and the shutter is lifted simultaneously. The speed of
the lifting and other activities is so adjusted so that the layer of concrete just emerging from the
shutter is just sufficiently set to withstand the pressure of self-load and the horizontal buckling
load of the jack pipe from the system. This way the entire structure is cast continuously and rapidly
saving much time compare to the conventional methods.

17
Storage & Handling of Materials

Slip form materials like steel components will be stocked over a raised platform of 200mm and
kept open yard. Hydraulic components will b stored in covered stores and will be shifted manually.
Reinforcement steel shall be stored in open yard on raised platform and will be handled by
crane/manually to work spot using vehicle. Cement shall be stored in covered store and will be
shifted to work site through vehicle

Setting out Works

All the works will be set out and got checked with reference to certified survey points. The
dimensions of elements will be as per relevant drawings and the same will be recorded in the check
list after a joint inspection with client representative.

Slip form System & Operations

Here we propose to use 18 units of slip form modular structures One modular structure consists of
shuttering plates of both the inside & outside faces, pair of yoke legs and pair of yoke beams , one
no of jack and the related accessories. All the jacks will be evenly spaced throughout the structure
so that the lifting remains uniform. Slip forming of shell wall will be done in single stage. Slip
form system consists of yoke assembly. The Slip form consists of following main components.

1. Upper distribution and working deck

2. Hanging Scaffold
3. Yoke assembly
4. Radius Screw
5. Screw for adjusting wall thickness
6. Screw for adjusting inclination
7. Horizontal turn buckles
8. Slip form jack
9. Spider beam
10. Jack rod
11. Shutters and Waler

18
Upper distribution and working deck

Upper distribution and working deck generally known as a top deck and it consists of main truss
and spider beams. The function of top deck is, to receive concrete, men & materials & to distribute
concrete in the peripherally kept hopper.

The function of working deck is to facilitate, to vibrate concrete placed inside the shutter, to carry
out adjustment an operation of slip form, to fix inserts, block outs and tying of reinforcements, to
clean the shuttering plates.

Hanging Scaffold

The function of hanging scaffold is to facilitate masons to finish exposed concrete surface, expose
inserts and carry out necessary repairs, and for curing of concrete.

Yoke Assembly

Yoke assembly consists of inside and outside yoke leg, each connected with two sets of channels
otherwise known as yoke beams. The function of yoke assembly is to transfer the lifting forces.

Radius Screw one member of radius screw is fixed with inside yoke leg and other end is suspended
from the holes provided in the main trusses / spider beams. The function of radius screw is to
reduce the radius of structure at predetermined intervals

Screw for Adjusting Wall Thickness

One set of wall thickness screw is provided for each yoke sets. The function of wall thickness
screw is to reduce the wall thickness of the structure.

Top Screw

Screw for adjusting inclination also known as top screw which is fixed with the outside yoke leg.

By operating this screw the inclination of inside and outside yoke leg as a unit can be varied.

Horizontal Turn Buckles

The function of horizontal turn buckle is to reduce the circumference of shutter. The turn buckles
will be operated in combination with radius screw.

19
Spider Beams

The spider beams are made up of ISMC 200. The spider beam assembly consists of two numbers
of channels. One of the assemblies fixed with the lower frame and the other end is supported with
yoke assembly. There is a gap of 100mm provided in the spider beam assembly to facilitate sliding
of yoke legs, while using the radius.

Slip Form Jacks

All main and normal yokes will be provided with one number of 6 ton capacity jack. The function
of slip form jack to transfer the load of slip form assembly to the jack road.

Shutters and Walers The shutter assembly consists of shutter, waler and intermediate form
supports. The shutters are connected with yoke legs with the help of form supports. One end of the
shutter is foxed with the form support and the other end is free.

20
LOAD CALCULATIONS

21
3.5 RISK INVOLVE

The process of slip form is very good only when the all the activities involved in very properly,
coordinated. Otherwise there are many risk involved described as follows:

1. Power Failure
2. Jamming of the Structure
3. Failure of Jacks
4. Improper Supervision
5. Setting of Concrete
6. Uneven Pouring of Concrete
7. Due to Rainfall
8. Sudden Stoppage of the Work

Slump Test Frequency

Slump will be checked before starting the placement and tolerance for the particular grade will be
+/- 30mm from the selected slump. Two Slump test shall be made on each days placement
randomly temperature of concrete will be checked every time after slump, as and when required.

Plumb

10 kg heavy plumbs can be used for checking the verticality of the structure. Plumb check will be
done at every 4 hrs. By lifting the form higher in point, plumbs can be corrected. It is convenient
to start with the correction of 5mm height meter. Check the result on plumbs after about 8hrs slip
forming. If structure stays on plumb line, continue with form in this position in top of structure
Rotation. A slip form sometimes has a tendency to rotate depending on horizontal forces caused
by variation of the batter of the form giving the form screw lines. Placing of the horizontal
reinforcement bars is another reason. When the form start to rotate counter forces have to be
applied.

22
 CHAPTER 4

QUALITY CONTROLS

4. QUALITY ASSURANCE AND QUALITY CONTROL:-

The contractors are responsible for constructing the work in accordance with the plans and
specifications. Each contractor is also responsible for controlling the quality of its work to meet
implementation of a program of inspections, tests, and production controls to attain the required
standards of quality and to preclude problems resulting from noncompliance. Pursuant to
Technical Specification of several code Quality Requirements, each contractor will establish an
independent QC program and write a Contractor Quality

4.1 CONTROL PLAN (CQCP):-

It must provide for tests and inspections pursuant to various technical specifications. It will define
procedures to ensure that activities affecting quality are properly documented and accomplished
in accordance with contract documents; written instructions; and industry standards, codes and
procedures. Furthermore, it will define methods for ensuring that activities affecting quality will
be accomplished under controlled conditions.

Independently of the contractors, the construction manager (CM) will provide QA through daily
and assure that the quality and contract requirements are met by the contractors.

4.2 QUALITY ASSURANCE:-

The planned and systematic activities implemented in a quality system so that quality
requirements for a product or service will be fulfilled.

Means of providing confidence that quality requirements will be met.

Quality Assurance makes sure you are doing the right things, the right way.

4.3 QUALITY CONTROL:-

The observation techniques and activities use to fulfill requirement for quality.

23
Mechanism used, such as checks or tests that are performed to ensure that requirements are met.

Quality Control makes sure the results of what you've done are what you expected.

4.4 TYPICAL RESPONSIBILITIES OF QUALITY ASSURANCE MANAGER:-

1. Determining, negotiating and agreeing on in-house quality procedures, standards

and specifications
2. Assessing customer requirements and ensuring that these are met
3. Setting customer service standards
4. Specifying quality requirements of raw materials with suppliers
5. Investigating and setting standards for quality and health and safety
6. Ensuring that manufacturing processes comply with standards at both national and
international level
7. Working with operating staff to establish procedures, standards, systems and
procedures

24
AFCONS INFRASTRUCTURE is committed to achieve and sustain excellence in its construction
business through an established Quality Management System.

We aim to achieve customer satisfaction by providing goods and services as per contractual,
statutory and regulatory requirements and in the process

We shall achieve this through continual improvement of our business processes, organizational
drive on innovation and productivity and effective human resource management.

We value training and sharing of information at all levels of the organization.

4.5 QUALITY OBJECTIVES:-

1. Enhancement of customer satisfaction

2. Timely completion of projects
3. Effective planning and monitoring system
4. Effective human resource management

25
 CHAPTER 5

EXPERIMENTAL TESTATIONS

5 TEST ON AGGREGATE:-

5.1 SIEVE ANALYSIS:-

The apparatus used are A set of IS Sieves of sizes

80mm, 63mm, 50mm, 40mm,31.5mm, 25mm, 20mm, 16mm, 12.5mm, 10mm, 6.3mm,4.75mm,
3.35mm, 2.36mm, 1.18mm, 600µm, 300µm, 150µm and 75µm.

Procedure to determine particle size distribution of Aggregates:

1) The test sample is dried to a constant weight at a temperature of 110 + 5 o C and

weighed.
2) The sample is sieved by using a set of IS Sieves.
3) On completion of sieving, the material on each sieve is weighed.
4) Cumulative weight passing through each sieve is calculated as a percentage of the
total sample weight.
5) Fineness modulus is obtained by adding cumulative percentage of aggregates
retained on each sieve and dividing the sum by 100.

26
CALCULATIONS;

27
5.2 IMPACT VALUE TEST:-

To determine the aggregate impact value of coarse aggregates

Apparatus:

Impact testing machine, IS Sieves of sizes 12.5mm, 10mm and 2.36mm, Cylindrical metal measure
of 75mm diameter and 50mm depth, A tamping rod of 10mm circular cross section and 230mm
length rounded at one end, Oven

Fig Impact testing machine

Preparation of sample:

1) The test sample should be of following grading: Passing through 12.5mm IS Sieve
100% and Retention on 10mm IS Sieve 100%
2) The sample should be oven-dried for 4 hours at a temperature of 100 to 110oC and
cooled.

28
 3) The measure should be about one-third full with the prepared aggregates and tamped
with 25 strokes of the tamping rod. A further similar quantity of aggregates should
be added and further 25 strokes of tamping rod to be provided. The measure should
finally be filled to overflow, tamped 25 times and the surplus aggregates struck off,
using a tamping rod as a straight edge. The net weight of the aggregates should be
measured and taken as WA.

Procedure:

1) The cup of the impact testing machine should be fixed firmly in position on the base of
the machine and the whole of the test sample placed in it and compacted by 25 strokes
of the tamping rod.
2) The hammer should be raised to 380mm above the upper surface of the aggregates in
the cup and allowed to fall freely onto the aggregates. The test sample should be
subjected to a total 15 such blows, each being delivered at an interval of not less than
one second.

Results:

1) The sample should be removed and sieved through 2.36mm IS Sieve. The fraction
passing through should be weighed WB. The fraction retained on the sieve should also
be weighed WC and if the total weight WB+WC is less than the initial weight WA, the
result should be discarded and a fresh test done.
2) The ratio of the weight of the fines formed to the total sample weight should be
expressed as a percentage.

29
 WB
Aggregate impact value = x 100%
WA

Two such tests should be carried out and the mean of the results should be taken.

Impact Value Test.

30
5.3 TEST ON CEMENT:-

5.3.1 FINENESS:-

Fineness Test on Cement is carried out to check proper grinding of cement. Fineness of cement
particles may be determined either by sieve test or by permeability apparatus test.

In sieve test, the cement weighing 100 gm is taken and it is continuously passed for 15 minutes
through standard BIS sieve no. 9. The residue is then weighed and this weight should not be more
than 10 per cent of original weight.

Fineness Of Cement Consistency

31
5.3.2CONSISTENCY:-

Consistency Test of Cement is carried out in order to find and determine the percentage of water
required for preparing cement pastes for other tests.

Fig. Vicat apparatus

Test Procedure to Find the Consistency of Cement:

1) Take an empty enameled pan free from dirt and other foreign particles.
2) Now take 300 gm of cement, and put that in the pan.
3) Add water, the quantity of water should be 30 per cent by weight of cement or 90 gm
of water to it.
4) Mix the cement and water thoroughly.
5) Now, fill the cement paste in the mould of Vicat apparatus, the interval between
additions of water to the commencement of filling the mould is known as the time of
gauging and it should be between 3 to 4 minutes.

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Consistency Of Cement

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5.3.3 INITIAL & FINAL SETTING TIME:-

Initial & Final Setting Time of Cement test is used to detect the deterioration of cement due to
storage. This is a conventional type of cement test and it has no relation with that of hardening of
concrete.

Initial Setting Time of Cement Test Procedure:

1) Take 300 gm of cement and mix it with water percentage as mentioned in consistency test
of cement.
2) Now the prepared cement paste is filled in the Vicat mould.
3) The square needle of cross-section 1 mm x 1 mm is attached to the movable rod of the
Vicat apparatus.
4) Then the needle is allowed to quickly release and allowed to penetrate in the cement paste.
In initial stage, the needle penetrates completely. It is then taken out and dropped at a fresh
place. The test procedure is repeated at regular intervals till the needle does not penetrate
completely. The needle should penetrate up-to about 5 mm measured from bottom.
5) The initial setting time is found out by taking the interval between the addition of water to
cement and the stage when needle stops to penetrate completely. The time should be about
30 minutes for ordinary cement.

Final Setting Time of Cement Test Procedure:

1) The initial test procedure is same that of initial setting time test.
2) Instead of square needle, annular collar is used. The annular collar is attached to the
movable rod of Vicat apparatus.
3) The annular rod is gently released. The time at which the annular rod makes an
impression on test block and the collar fails to do so is noted.
4) The final setting time is found out by taking the difference between the time at which
water is added to cement and time as recorded in.
5) The final setting time for ordinary cement should be 10 hours.

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Initial & Final Setting Time Of Cement Soundness test

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5.3.4 SOUNDNESS TEST:-

To determine the soundness (expansion) of cement by Le-Chatelier method

Apparatus:

Le-Chatelier apparatus, Balance, whose permissible variation at a load of 1000g shouldbe+1.0g,

Water bath.

Procedure:

1) Place the mould on a glass sheet and fill it with the cement paste formed by gauging
cement with 0.78 times the water required to give a paste of standard consistency.
2) Cover the mould with another piece of glass sheet, place a small weight on this covering
glass sheet and immediately submerge the whole assembly in water at a temperature of
27o C and keep it there for 24 hours.
3) Measure the distance separating the indicator points as D1.
4) Submerge the mould again in water at the temperature of 27o C. bring the water to
boiling point in 25 to 30minutes and keep it boiling for 3hrs.

36
5) Remove the mould from the water, allow it to cool and measure the distance between
the indicator points as D2.
6) D2-D1 represents the expansion of cement.

Soundness Test

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5.4 TEST ON CONCRETE:-

5.4.1 SLUMP TEST:-

To determine the workability of fresh concrete by slump test

Apparatus:

Slump cone with top and bottom diameter 100mm and 200mm and height 300mm, Tamping rod
with graduated scale of 16mm diameter and length 325mm, Trowel, Pan and scoop.

Procedure:

1) The internal surface of the mould is thoroughly cleaned and applied with a light coat
of oil.
2) The mould is placed on a smooth, horizontal, rigid and nonabsorbent surface.
3) The mould is then filled in four layers with freshly mixed concrete, each to one-fourth
of the height of the mould.
4) Each layer is tamped 25 times by the rounded end of the tamping rod; strokes are
distributed evenly over the cross section.
5) After the top layer is tamped, the concrete is struck off the level with a trowel.
6) The mould is removed from the concrete immediately by raising it slowly in the vertical
direction.
7) The difference in level between the height of the mould and that of the highest point of
the subsided concrete is measured.
8) This difference in height in mm is the slump of the concrete.

Results:

The slump measured should be recorded in mm of subsidence of the specimen during the test.

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5.4.2 COMPRESSION TEST:-

To determine the compressive strength of concrete specimens

Apparatus:

Compression testing machine

Age at test:

Tests should be done of the test specimens, usually being 7 and 28 days. The ages should be
specified from the date casting of cubes at the concrete pouring site. The casting of cubes is done
in order to check the compressive strength of the cubes.

Procedure:

The specimens, prepared and stored in water, should be tested immediately on removal from the
water and while still in wet condition. Specimens when received dry should be kept in water for
24 hours before they are taken for testing. The dimension of the casted cube is 15cm.

39
 1) The bearing surfaces of the compression testing machine should be wiped clean and
any loose sand or other material removed from the surfaces of the specimen, which
would be in contact with the compression platens.
2) In the case of cubical specimen, the specimen should be placed in the machine in such
a manner that the load could be applied to the opposite sides of the cubes, not to the top
and the bottom. The axis of the specimen should be carefully aligned with the center
of thrust of the spherically seated platen. As the spherically seated block is brought to
rest on the specimen, the movable portion should be rotated gently by hand so that
uniform seating is obtained.
3) The load should be applied without shock and increased continuously at a rate of
140kg/cm2/minute until the resistance of the specimen to the increasing load breaks
down and no greater load can be sustained. The maximum load applied to the specimen
should be noted.

Calculation:

Compressive strength of M35 design mix concrete cube after 7 days

After 7 days compressive strength should be 66% of total concrete cube strength

Cube size 15cm x 15cm x 15cm

Area of the concrete cube = 225cm2

Crushing load = 1004KN

Compressive strength (fck) = ( 1004 x 1000 ) / (225 x 100 ) = 44.62N/mm2

Flexural strength of concrete cube (fcr) = 0.7 2

Results:

The following information should be recorded of each test specimen:

Date of test, Age of specimen, Date of manufacture of specimen, Weight of specimen, Cross-
sectional area, Maximum load and Compressive strength.

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Compressive Test On Concrete

41
CHENAB BRIDGE

Part of the Udhampur-Srinagar-Baramulla Railway Project, the bridge on the Chenab River is
situated near Kauri Village. Called the Chenab Railway Bridge Project, this railway line crosses
the river at about 359 m above the riverbed. The total length of the bridge is 1315 m consisting of
an arch span of 469 m across the Chenab River.

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As per AFCONS, the bridge had to be designed and constructed considering many parameters that
are unique. Some of the considerations were the high wind forces, location of the bridge in highly
active seismic zone of India, possibility of terrorist attacks, provision for future track, continuous
monitoring systems, etc. The main span of the Chenab Bridge will be an arch, made from large
steel trusses. The chords of the trusses will be sealed steel boxes, filled with concrete to assist in
controlling wind-induced forces on the bridge. The boxes will be stiffened internally. The
designers have considered the aesthetic merit of the bridge and made a strong attempt to bring a
natural cadence to the site. Also, a greater emphasis has been placed on the structural response to
wind forces. Wind tunnel tests were conducted at Force Technology Laboratory, Denmark, to
establish the topographic effects of the site on the reference wind speed; the static force coefficient,
the occurrence of any aero-elastic effects such as vortex shedding, galloping and flutter.

The design of the bridge is as per the approved design basis note prepared specially for this bridge,
drawing the experiences gained from various projects abroad and international codes and practices.
BS-5400 is the basic platform on which the design and construction of the Chenab Bridge is carried
out.

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 CHAPTER 6

PROJECT DETAILS

6.1 SCOPE OF WORK:-

Work involves the design & construction of bridge across the river Chenab.

Design and construction of auxiliary suspension/cable stayed bridge with a capacity to support the
launching equipment, bridge segments need to be developed.

River bank protection on both sides 100m each on u/s & d/s side by suitable method of rock
bolting, grouting or any other measures.

6.2 SITE LOCATION:-

Fig. Google map view

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6.3 DETAILS:-

PROJECT
Udhampur-Srinagar-Baramulla Rail Link Project (USBRL project)

AGENCY Chenab Bridge Project Undertaking (CBPU)

Joint Venture of Ultra-Afcons-VSL

*Currently Undertaken by AFCONS Infra. Ltd

CLIENT Konkan Railway Corporation Ltd (KRCL) and Northern

Railways India

END USER Indian Railways

PROJECT Km 50/800 at Katra-Laole section of the Udhampur-Sringar-

LOCATION
Baramulla Rail Link Project

ORIGINAL Rs 5000 millions

CONTRACT
VALUE

O&M PERIOD NIL

CONTRACTUAL 31/05/2004

START DATE

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6.4 DESIGN INNOVATION:-

Indian Railway Standards (IRS Standards) have been used while designing the bridge. For final
structural analysis, full-scale models of the bridge were prepared and the test results of the bridge
were used to extract equivalent static wind loads. In wind analysis, special programs developedthe
design consultant were used.

One special feature in this bridge is that all steel structures will bemodeled by 3D software
TEKLA. design consultant were used. One special feature in this bridge is that all steel structures
will be modeled by 3D software TEKLA.

During the initial stage, the design speed of the railway was set at 100 km/h and the design life
120 years. These equivalent static wind loads take into account wind-induced dynamic actions of
the bridge. The service wind load corresponds to a maximum wind pressure of 1500 Pa. In addition
to all conventional railway bridge loads, the Chenab Bridge had to sustain special blast loads and
provide for redundancy in case of local failure Chenab Bridge Project Und that can handle loads

46
up to 34 ton (17 + 17) on tandem hook. The height of the cable crane is approximately 130 m and
its span is about 915 m.

6.5 ARCH DESIGN:-

The arch and arch piers of the Chenab Bridge are being made from large steel trusses. In order to
provide minimum wind resistance, it was initially intended to use pipe sections for all members of
the arch. In order to facilitate production on-site, the chords of the trusses and the diagonals were
later modified to become sealed steel boxes. All other members including the secondary members
have been kept circular, which has greatly simplified the connection details. The chord members
will be filled with concrete as it enhances the overall robustness.

In the arch portion, the superstructure is supported on steel piers with a height of up to 120 m.

47
Expansion joints are provided at the end abutments and at Pier S70 that separates the main arch
span from the approach bridge. At this location, there is also a change in the deck height. The
superstructure is a plate girder with a closed deck, where rails are connected. The closed deck
keeps the rainwater out and provides dry environment below the deck.

Construction Innovation

As per AFCONS, bridges all over the world are incrementally launched either on straight
alignment or on curved alignment of uniform radius. Never the bridges are incrementally launched
from one end when the bridge is partly on straight and partly on curve and more so when the bridge
is on transition curve with varying radius. The deck on the viaduct of Chenab Bridge is partly in
straight, partly in circular curve and partly on transition curve.

This is the first time in the world that incremental launching is attempted on a transition curve.
The arch spans will be constructed using cable cranes and derrick moving on the already erected
portion of the viaduct.

Steel Requirement

The bridge will consist of about 25000 ton of steel structures, the main portion of which will be
used for the arch bridge section. The deck of the bridge will be welded in the workshop upside
down in about 8 m long sections, because the welding points in the final structure are mainly
located under the bridge. When the job is completed, the sections are turned around and delivered
to the next stage of the process.

When the long steel columns are ready, the steel deck will be pushed on top of the columns. After
this, a derrick crane, which is capable of lifting about 100 ton, will be placed on top of the deck.
The derrick will crane the arch segments from deck level to the erection front of the arch. Both the
arch and the deck cantilever freely up to 48 m. When the next arch pier location is reached,
temporary cables will be installed to support the arch, and the new arch pier will be constructed on
the free end. The superstructure can then be supported by the arch pier and so forth until the last
arch pier is reached. The very last span of the arch and the elements of the key segment will again
be delivered by the cable crane; closure of the superstructure is done by means of derrick erection.

48
The cable crane built over the valley will move between pylon towers built on both sides of the
valley. The crane can deliver a maximum amount of 34 ton of steel parts.

6.6 CHALLENGES IN CONSTRUCTION METHOD:-

The steel structures of the bridge are being manufactured in workshops built in the mountains. The
workshops have been built in the building site, because there is no proper road network in the
challenging terrain. All steel materials, except for the smallest rolled profiles, are delivered to the
mountains as steel boards. The insufficient infrastructure of the area is causing additional
problems. The river water is not suitable for manufacturing concrete. The water is delivered from
further away in the mountains.

The job is also challenging because the track has curvature in the approach bridge. In this section,
the construction stage bearings have been designed in such a way that it is possible to launch the
steel deck in the curvature portion as well.

6.7 SALIENT FEATURE:-

Name of the Project:

Design and construction of special Bridge across River Chenab at Km 50/800 on

Katra Laole section of Udhampur-Srinagar-Baramulla Rail Link Project (USBRL

Bridge is part of construction of a new Railway line in J&K state from Udhampur to Baramulla.
The alignment crosses deep gorges of Chenab River near Salal Hydro Power Dam, which
necessitates construction of long span bridges. The configurations of steel arches have been

49
REFERENCES

Books:

1. Concrete technology by M.S. Shetty

2. Methodology manuals provided by Afcons
3. IS-codes for Reference
4. IS:516-1959 - Methods of tests for strength of concrete
5. IS:1199-1959 - Methods of sampling of concrete
6. IS:2502-1963 - Code of Practice for bending and fixing of bars for concrete
reinforcement
7. IS:1888-1982 - Method of load test on soils-For general arrangements only.
8. IS:3558-1983 - Practice for the use of immersion vibrators for compaction of concrete.
9. IS:6066-1994 - Pressure grouting of rock foundations in river valley projects
Recommendations.
10. IS:9103-1999 - Concrete admixtures specification
11. IS:4985-2000 - PVC semi perforated pipe code
12. IS:1786-2008,14448-1997 - Rock bolting code
13. IS:1786-2008 - High yield strength deformed steel bars and binding wires for concrete
reinforcement specification.

Websites:

1. http://www.afcons.com/001_about_us.html
2. http://www.engineeringcivil.com/various-lab-test-on-concrete.html
3. www.sciencing.com/types-concrete-testing-68980
4. https://www.qualityengineersguide.com
5. http://www.sciencedirect.com/science/article/pii/S1877705811029997

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