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Rehabilitation of Bridge at
Agarwada

Course on Repairs and Rehabilitation
Faculty: Prof R.J Shah
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THE SITE
The bridge was constructed across river Mahi on SH-2 at Km 107, near
village Agarwada. It about 31 Km downstream side of Panam dam.


This bridge connects North Gujarat and adjoining states of Rajasthan and
Madhya Pradesh
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The Bridge
SUBSTRUCTURE:
The sub-structure consist six 1.0 m diameter solid R.C.C. columns resting on
R.C.C. well cap of 10.77m height.

Spacing of columns in transverse direction was 2.63 m and in longitudinal
direction was 6.86 m c/c .

There was a tie beam of 0.76 x 0.3 m at a height of 6.33 m from the top of well
cap and three columns were connected in transverse direction.
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The Bridge
FOUNDATION:
single circular R.C.C. well foundation of 7.93m external diameter.

The depth of well varies from well to well.
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SUPER STRUCTURE:

Precast - prestressed post tensioned three girder and stab system on

R.C.C. frame of 6 no.
1.0m diameter Column.

Spans are simply supported on cantilevered hammer head.
Loading was anticipated as two lane of class A' and single lane of class AA,
having 7.0 m width of carriageway.

Length of the bridge was 439 m, consist of 6 central spans of 56.4m and
end spans of 50.3m.
The Bridge
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Schematic diagram Showing The bridge in details
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The girders are spaced at 2.36m c/c with depth of 3.04m.

The bottom bulb was of 0.49m and the top flange was of 1.14m and the web
thickness varies from 0.49m to 0.61m.

Thickness of the web stab is 0.15m.

Thus the overall depth of super structure is 3.2m .

The 9 no. 0.23m thick diaphragms are provided at equidistant.
The Bridge
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BEARING
Under each girder over the hammer head the elastomeric bearings are
provided on both the ends.

WEARING COURSE
The average thickness of 75mm, R.C.C. is provided as wearing course.

EXPANSION JOINT

The sliding plate type expansion joint is provided at each junction, it
consists of 50 x 50 x 6 mm angle and 100 x 6 mm plate.

RAILING
R.C.C. H type vertical members and top hand rails have been provided.
The Bridge
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River flow data:
Catchment area: 11815 miles^2
Design discharge: 15,00,000 cusecs
Design HFL: RL 246.25 ft
Rock Level: RL 280.50 ft
The Bridge
Contractual details:
Commencement Date: 4th Aug. '73
Completion date: 29th Feb. '84
Construction cost: Rs. 1,55,00,000/-
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The bridge was distressed due to certain reasons but the major cause was
that, in 1990 there was a high flood in which the discharge was measured as
much as 8 lakh cusecs though it was not so high as compared to designed
discharge of 15 lakh cusecs.

With in the short span of one hour discharge was increased from 5 lakh to 8
lakh.

Due to this the distress observed in foundation/pier P6, link in super
structure of span 6 and span 7 due to shifting of well P6.

Distress noticed in concrete such as cracking, spalling, Leaching, honey
combing, exposed reinforcement, damage to railings, damage to bearings,
improper functioning of expansion joints and cracking of wearing coat.

As per the reports there was the abnormal scour observed around well.
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Photograph Showing The bridge in distress
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The distress observed in structure are:

1. Pier P6 was tilted / shifted on downstream side, which resulted in the
shifting of the column and hammer head was also shifted from actual
position in the same direction, resulting the shifting of centre tine by
0.60m on the deck level and 0.36m at well cap level.

2. This dislocation of the members affected the sliding plate type expansion
joints between P6 and P7. The upstream side parapet on P6 was crushed
and separated the downstream side parapet apart by 0.11m.
The other expansion joints are also not functioning property.

3. As per the report of Department of Roads and Buildings there had been
considerable scour around all the wells due to tremendous increase in the
discharge and in some cases the scour had traveled below the cutting
edge of the well.
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4. There was heavy spalling, cracking and exposure of reinforcement in
steining walls.

5. There were vertical cracks in column, maximum width of 1.11 mm.

6. The tie between the column at P6 was cracked at the intermediate level.

7. From the report of department and the video photography, it been found
that P6 was not resting on the rock uniformly and the cavities shown were
about 53%, the same is been observed that other piers but tilting / shifting
was observed in P6 only.

8. The elastomeric bearing was damaged under spans 6 and 7.

9. The wearing coat had been cracked and damaged.

10.Some water spouts were missing due to which, the concrete was badly
affected.
There was some vegetation is grown in some places an debris were
accumulated in expansion joints and spouts.
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Schematic diagram Showing Locations of Rebound
hammer testing points.
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TESTS CONDUCTED FOR CONDITION SURVEY

The consultant for condition survey of the bridge conducted the test and
visual inspection.
They accessed the position with help of trolley, for inspection of main girders,
diaphragms, soffit of deck slab, bearings, expansion joints and sub structure
elements.

To arrive at the conclusion they have conducted the tests tike:

1) Rebound Hammer test for assessment of strength of concrete.

2) Ultrasonic test for assessment of cracks and quality of concrete.

3) Cover test for checking of quality and adequacy of cover concrete.

4) Corrosion test for checking of depth and the intensity of corrosion.
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SYSTEMATIC APPROACH TO REHABILITATION OF PROJECT
SURVEY OF PROBLEM

From the documented data available related to the problem from the authorities
and the condition survey report of the present status about problem, the
survey was conducted.

LOCATING THE DAMAGES / DEFECTS /DISTRESS

The deterioration of a structure often appears in visible signs of damages.

A detailed inspection provides information about the damages.

An assessment of the structure may become necessary as a result.

Various tests may be conducted to complement the results of the visual
inspection.

Testing techniques and equipment to be determined relative to the extent and
type of the deterioration and the importance of structure.

To the extent possible, nondestructive methods are preferable.
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VISUAL INSPECTION

It is the primary survey that was been conducted, for each component of the
bridge an for at) the spans.

For convenience of identification, the spans were numbered from Thana Swali
side to Agarwada side.

Numbering of pier was also done on the same lines as for the spans.

And the inspection report was prepared, from which the testing positions and
alternatives were decided. TESTING

The tests are conducted for judging proper condition of elements as given in
section.
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ANALYSIS OF CAUSES OF DAMAGES / DEFECTS /DisTRESS

The purpose of evaluating the structure-damage was not only to determine
the effect of damage to its remaining service-life/toad carrying capacity, but
also determination of causes of defects, so as to enable an intelligent
determination of an effective retrofit.

Before a repair-plan is implemented, either the causes of the damages have to
be removed or else the repair-measure have to be so designed as to
accommodate the causes, and build-in protection against them for future.

SELECTION OF METHOD
The evaluation will be as to whether or not an economical and technically
effective repair plan, can limit or contain the damage and thus enhance the
effective life of structure, in this case the degree of urgency required to
implement a repair-plan because of the advance stage of damage. This
preparation includes for structural and non structural elements.
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APPLICATION OF REHAB SCHEME

As per the selected method the specification was prepared, according to that
the work is under execution.
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ALTERNATIVES PROPOSED FOR REHABILITATION
ALTERNATIVE PROPOSAL NO. 1
The existing well will be cover by new R.C.C. steining from out side
and cast a new well cap.
Encase the existing column and hammerhead with R.C.C, to extend it.
Shift the dislocated spans to the proper alignment.
Not suitable because there is no provision for jacking and shifting of
spans.
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ALTERNATIVE PROPOSAL NO. 1
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ALTERNATIVES PROPOSED FOR REHABILITATION
ALTERNATIVE PROPOSAL NO. 2

Dismantle the deck stab and the diaphragms between all the girders of
spans 6 & 7, and shift the girders to the adjoining spans.

Dismantle the hammer head, columns, and well cap.

Empty the dredge hole and provide new reinforcement cage with rock
anchors up to 5m in the rock, and cast new steining.

Reconstruct the well cap, column, and hammerhead.

Replace the shifted girder to the proper position.

Not suitable because it is costlier proposal.
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ALTERNATIVE PROPOSAL NO. 2
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ALTERNATIVES PROPOSED FOR REHABILITATION
ALTERNATIVE PROPOSAL NO. 3

Support the spans 6 & 7 on the boulder crated boulder steel
columns

Proceed same as alt. No. 2 for tackling the old well.

Most suitable solution because it is economical and less
rework involved in it which will reduce the time.
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ALTERNATIVE PROPOSAL NO. 3
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ALTERNATIVES PROPOSED FOR REHABILITATION
ALTERNATIVE PROPOSAL NO. 4

Erect supporting frames on hammer head of P6 and holds the
spans 6 & 7, with the help of it.

Follow the sequence of alt no. 1.

Not suitable because, erection of frame on the distressed
foundation of P6 may cause more distress.
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ALTERNATIVE PROPOSAL NO. 4
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ALTERNATIVES PROPOSED FOR REHABILITATION
ALTERNATIVE PROPOSAL NO. 5

Support the super structure as alt. No. 3;

Dismantle the hammer head, columns, and well cap.

Cast a cluster of piles on both, upstream and downstream
sides of existing bridge and cast new pile cap, column, hammer
head.

Lower the suspended spans to the proper position.
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ALTERNATIVE PROPOSAL NO. 5
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ALTERNATIVES PROPOSED FOR REHABILITATION
ALTERNATIVE PROPOSAL NO. 6

Dismantle the superstructure of span 6 & 7, substructure of P6.

Construct two new wells in the same alignment and cast the
three spans instead of two.

Not suitable because it is costlier proposal.
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ALTERNATIVE PROPOSAL NO. 6
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ALTERNATIVES PROPOSED FOR REHABILITATION
ALTERNATIVE PROPOSAL NO. 7

Same as proposal no. 3, but instead of temporary support
structure, support the spans on two floating pontoon through
steel column structure.

Not suitable because, the water !eve! of the Mahi River is not so
steady, so load heavy bearing pontoon may not stay in required
position though the anchors may tie it in bed.
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ALTERNATIVE PROPOSAL NO. 6
ALTERNATIVE PROPOSAL NO. 7
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STEPS INVOLVED IN REHABILITATION AT P6

. REMOVAL OP SAND
The sand in the working area has to be removed anyhow to concrete the
base and placing of steel sections in the position. For which there are many
method had been tried to arrive the desired optimization, balance between cost
and time. The methods employed were: Demanding pump

For this method the diver has go inside of the water up to the bed level and
put the pipe to suck the sand from bed.

Air lifting pump
Modified sludge pump
Dragger
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. FILLING CAVITY

As stated in distress there are large cavities around the shifted and tilted
well, was filled with concrete of M20. using tremie pipes and funnel from top
of the deck. The concrete was mixed on deck itself with mixer of tilting, 10/7
type.

The divers were used to pour the concrete to the exact location.
. DRIVING OF CASING

The casing was driven in side of the bed by grabing and hammering up to the
hard rock, then after it was taken to the 1.2 m below the hard rock. Temporary
support was given to it to keep it in alignment.
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. FOUNDING Of COLUMN SECTION

The fabricated column sections was towered in side the casing with the help
of crane, from the deck.

The casing was cast in M20 concrete from the same casing and the casing
was retrieved.
. FABRICATION Of TEMPORARY SUPPORT STRUCTURE

The bracing, under water with bolts, will brace at the founded column
sections by divers.
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. LIFTING ARRANGEMENT FOR SPANS 6 & 7
The total dead toad of each span is @ 285 T on each end.
Which is equally shared by 3 longitudinal girders.

Thus the total load on each girder is @ 95T.
So it is proposed to provide flat jacks of caring capacity of 1.25 times the
load, which comes out to be 420 mm diameter, and 170t rated capacity.
With assumption of 80 % efficiency, can take load of 136T.

These jacks are proposed to place under longitudinal girders at distance
from the end.

They will be supported on the steel plates placed over steel joist of isMB
450. After lifting of these spans it will be rested on the packing boxes with
Teflon stainless steel interface.

Than the girders will be side shifted on this least friction surface to the
required alignment by the jacks. After recasting the distressed elements,
and gaining have designed strength spans will be again lifted by same
jacks and place it over new hammer head on the correct position
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. DISMANTLING OF DISTRESSED STRUCTURAL PARTS

Dismantle the deck stab and the diaphragms between all the girders of spans
6 & 7, and shift the girders to the adjoining spans.
Dismantle the hammer head, columns, and well cap.
. CASTING OF NEW WELL FOUNDATION

Empty the dredge hole by clearing of inter/top plug and sand fitting, provide
new reinforcement cage with 80 no. 32 diameter rock anchors up to 5m in the
rock through bottom plug. and cast new steining. Tie them by 12 diameter tor
bar at 300mm c/c.
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. CASTING OF NEW STRUCTURE

To prevent the up liftment of the well it will be anchored in ground by 3m
with ground anchors through bottom plug.

There will be the new layer of R.C.C. of grade M25 in the dredge hole, which
is designed for taking the whole toad of the structure above. New well cap,
column and hammer head will be cast in proper alignment by concrete
grade M40.

The suspended spans will be towered, and shifted to the position after
proving new elastomeric bearings.
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. DISMANTLE SUPPORTING STRUCTURE

After shifting the load of suspended spans to the new hammer head the
erected supporting structure will be dismantled.

The precaution will be taken, not to disturb the existing structure, It will be
retrieved by the same method as of erection, with the help of crane and winch.

. WELL PROTECTION

To restrict scour around the well, the boulders fitted in a weir crate will be
placed all-round the rectified well steining in three layers.

The dimension of crate will be 2000 x 100 x 600 mm. It will be placed at the
depth of RL 63.7m in height of 1800mm and 15500mm beyond outer edge of
steining.
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THANKS
Ernest thanks to Prof. R J Shah for
providing guidance, Slides and
Photographs.
R and B Design circle Gandhinagar for
providing information and details