PROJECT REPORT On REPLACEMENT OF BED BLOCKS ON BRIDGE NO. 23 ( BANAS BRIDGE) ON JAIPUR – SAWAI MADHOPUR SECTION (NWRAILWAY) (30x18.29 meters SPANS)

OUR HEARTEST THANKS To Project Guide: SHRI AJAY GOYAL Sr. Prof OUR HEARTEST THANKS To Project Guide: SHRI AJAY GOYAL Sr.Prof.Bridges, IRICEN, PUNE & SHRI V.B. SOOD, Professor Bridge, IRICEN, PUNE PRESENTED BY R. C. MEENA ADEN LINE JP NWR MOHAN RAO ADEN/SW.SC/SCR RAJU SOLANKY AXEN/CON./NWR

HIGH LIGHT OF THE PRESENTATION IMPORTANT DETAILS OF BANAS BRIDGE BRIEF HISTORY OF BRIDGE Derails of the defects observed REASON FOR REPLACEMENT OF BED BLOCK SCOPE OF WORK INVOLVED LIST OF THE TOOLS PLANTS & man power PRELIMINARY ARRANGEMENTS BEFORE EXICUTION OF WORK PLANNING FOR THE REBABILITION REQUIREMENT OF MAN POWER SAFETY MEASURES TAKEN DURING EXECUTION OF WORK ACTIVITIES INVOLVED IN THE WORK CONCULUSION

BRIDGE NO.23 (BANAS RIVER)

IMPOTANT DETAILS OF THE BANAS BRIDGE Name of the River :- BANAS RIVER No.of Spans : :- 30 X 18.29 Section :- Jaipur – Sawaimadhopur Between Station :- Chothkabarwara- Isarda Location km from 33/8 to 34/4 Year of construction:1905 Type of sub structure: Stone Masonry. Type of super structure: Plate Girders.

BRIDGE No.23 ON BANAS RIVER BETWEEN JAIPUR – SWAI –MADHOPUR SECTION

BRIEF HISTORY OF THE BRIDGE Bridge No. 23 (BANAS) is about 100 years old and stone bed block in 14 pieces were laid during construction of the bridge cracks developed in the bed block. This bridge was declared distressed Permanent SR of 50 kmph speed imposed on the bridge.

DETAILS OF THE DEFECTS OBSERVED Initially stone bed block provided in 14 pieces on MG track & Gauge conversion done in 1992-93 without changing the bed blocks. Strengthening of sub structure has been completed during GC & after long life in service vertical & diagonal cracks observed in bed blocks during detailed inspection.

REASON FOR REPLACEMENT OF BED BLOCK Inadequacies of design of existing bed block to carry heavier axle load & higher speed. Speed restriction of 50 kmph had to be removed which was already imposed on the bridge. Replacement of bed blocks was necessary for safety of bridge and increasing the speed up to 110 kmph.

SCOPE OF WORK All deficiencies in sub-structure removed before replacement of bed block. (Jacketing of piers other sub structure works). Casting of new RCC bed block done in advance on each pier with SR of 20 kmph & stop dead if required. Removed old stone bed block in phases under traffic block. Insertion of RCC bed blocks (which were casted on piers/abutments) including bearings.

LIST OF THE MACHINARY, TOOLS & PLANTS Road vehicle for transportation of man & material Surveying equipment such as thodolite, Leveling instrument, tape etc. Air compressor

Contd.. Pneumatic tools, Drilling machine, chiseling machine & breakers Gas cutting equipment Generator Jacks Hydraulic & Mechanical Capacity 30 Tons 8 Nos. ( 4 in working & 4 stand by) & 50 Tons 4 nos. (2 in working & 2 stand by ) Wire rope Ordinary pulley block Manila rope Crow bars. Steel brackets of cantilever type for creating extra working space. wooden planks & blocks for packing .

Cont.---- Other men & material required Labour : staff deputed to do heavy nature of work. Skilled labour has been arrange & deputed at site for safely execution of work in timely. Highly skilled artisan and supervisor staff have been deputed at site. Timely Supply of Gas for cutting, Fuel & other consumables.

PRELIMINARY ARRANGEMENT BEFORE EXECUTION OF WORK Traffic work order (TWO) for Speed restriction 20 kmph & stop dead if required for 60 days & 2 nos traffic block of 1 hour each for 15 days daily sanctioned from Division with consultation of operating Deptt. RCC bed block (in two pieces) already cast on each pier as per approved drawing. (CE/C/JP/221) Arrangement for curing has been done on each pier by providing of pipe line. Arranged highly skilled staff who has already executed such type of works. Procured all necessary tools & plants including all consumables as required for the work. Meticulous planning is paramount importance for completion of any task.

Protection during replacement of bed block

Protection during replacement of bed block

WORK DURING BLOCK LIFTING OF GIRDERS WITH JACKS. DISMANTALING OF CRACKED BED BLOCKS PIECES IN DIFFERENT PHASES. INSERTION OF CASTED BED BLOCKS AND BEARINGS. LOWERING OF GIRDERS. PROVIDING EPOXY FOR THE COLD JOINT FOR ALL SIDES OF NEW PRECASTED BED BLOCKS IN PIECES. BINDING OF REINFORCEMENT WITH NEW RCC BED BLOCK. FOR CASTING BALANCE PORTION TO MAKE COMPOSITE BED BLOCK.

EXISTING STONE BD BLOCK TO BE DISMANTLED

DISMENTLING OF EXISTING STONE BED BLOCK OF STONE AT ENDS.

rCC BED BLOCK CASTED AT BOTH SIDE IN PIERS IN ADVANCE

DISMANTALING OF Intermediate PIECE OF BED BLOCK FOR JACKING PURPOSE.

PROVIDING FOUR JACKS 50 TONS CAPACITY FOR LIFTING OF GIRDER

LIFTING OF GIRDER TO REQUIRED HIGHT BY JACKS FOR REMOVAL OF BED BLOCKS UNDER THE GIRDER.

REMOVING OF BEARING & DISTMENTLING OF EXISTING BED BLOCK STONE TO CREATING OF SPACE FOR FIXING OF CENTER JACK CAPACITY OF 50 TONS

Planning, IN CASE BLOCK NOT permitted due to heavy traffic, WORK HAS BEEN DONE IN MARGINE AFTER PASSING OF TRAIN “MINIMUM TIME” 20”

JACKS RELEASED, LOAD TAKEN ON WOODEN BLOCKS & TRAFFIC PASSED WITH EXITING SR 20 KMPH

AFTER PASSING THE TRAIN ,TAKING THE LOAD ON CENTER JACK FOR RELEASING THE SIDE JACKS

LEVELING OF SPACE BY PROVIDING MORTAR & SLEWING OF PRECASTED RCC BED BLOCK FROM BOTH SIDE WITH OR WITHOUT BLOCK

SLEWING OF PRECAST RCC BLOCK UNDER GIRDER MANUALY

INSERTING OF PER-CAST RCC BED BLOCK BELOW THE GIRDER & FIXING BEARING

LOWERING THE JACK FOR RESTING THE GIRDER ON NEW RCC BED BLOCK

BINDING OF REINFORCEMENT & APPLYING APOXY FOR COLD JOINTS

CONCRETING OF IN SITU BED BLOCK & CURING

THE SAME PROCEDURE HAS BEEN ADOPTED FOR BALANCE PIERS (P-2 TO P-29) AND ABUTMENTS(A-1& A2)

AFTER CASTING LAST BALANCE PORTION BED ON ABUTEMENT A-2 & CURING UP TO 28 DAYS . RELAXED SPEED RESTRICTION (IN STAGES) FOR 45 KMPH, 75 KMPH & NORMAL SECTION SPEED (110 KMPH)

TIME TAKEN IN VARIOUS ACTIVITIES AFTER IMPOSITION SPEED RESTRICTION 20 KMPH & STOP DEAD IF REQUIRED (day = D) TILL COMPLETE JOB Sr.No ACTIVITIES PERIOD DAYS remarks 1 Casting of rcc bed blocks both side on each pier. D1 to d8 8 days   2 Curing of rcc bed blocks D2 to d29 28 days Curing started from d2 3 Replacement of rcc bed blocks from piers p1 to p29 & abutment a1to a2 D29 TO D44 15 days Curing started from d30 to d45 after casting of balance portion of bed block on p1 further simultaneously up to p29 & a1,a2 4 Casting of balance portion of bed blocks D30 to d45 5 Curing of balance portion of bed block D31 to d60 15 days (after casted last portion of bed block) 6 Speed relaxed to normal ( 110 kmph) On d61 60 days Note: - work completed with in 60 days including casting, replacement of bed block & curing rcc bed blocks.

ACTIVIES AFTER BLOCK REMOVING OF TEMPORARY STEEL BRACKETS. REMOVING OF WATER PIPE CONNECTIONS REMOVING OF WOODEN PLANKS & BLOCKS. CHECKING OF TRACK PARAMETER ON THE BRIDGE. 22 No. SPANS PRECAST BED BLOCKS HAS INSERTED WHEN BLOCK WAS NOT PERMITTED BY OPERATING DEPT.

AFTER CASTING LAST BALANCE PORTION BED ON ABUTEMENT A-2 & CURING UP TO 28 DAYS . RELAXED SPEED RESTRICTION (IN STAGES) FOR 45 KMPH, 75 KMPH & NORMAL WORKING OF TRATRAIN (SECTION SPEED 110KMPH).

SAFETY MEASURES TAKEN IN EXECUTION OF WORK CHECKING OF TEMPORARY ARRANGEMENTS CHECKING UP OF ALL TOOLS & PLANTS. PROTECTION OF TRACK PROVISION OF SAFETY BELTS PROVISION OF FIRST AID FACILITY AT SITE PROVISION OF ROAD VEHICLE AT SITE PROVISION OF ADEQUATE COMMUNICATION

CONCLUSION THIS WORK IS VERY SPECILISED NATURE IN TRACK WITH HEAVY TRAFFIC DENSITY PROVIDING BED BLOCKS FOR 30 SPANS UNDER TRAFFIC WITHOUT ANY UNUSAL OCCURANCES. THE WORK HAS BEEN COMPLETETD WELL BEFORE THE TARGATED TIME WITH LEAST TRAFFIC BLOCKS.

THANK YOU