SOUTH WESTERN RAILWAY Office of the Deputy Chief Engineer, Construction/III, HUBBALLI. No: DCE/CN/LC-85 Date: 07.07.2023 Dy CE/CN/Designs/BNC Sub: UBL - BAY Section: - Proposed construction of ROB at km 145/400-500 in liew of LC No.85 as 1x60.0m bowstring steel girder (Railway span) and 8x24.0m PSC girder + 1x9.0mx4.30m and RE panels in approaches between Hosapete and Kariganura stations. RS wall - Reg Ref: (1) This office letter of even No, dated 05.06.2023. (2) Your office letter No. W.352/CN/BNC/JRU-BAY/ROB/LC-85/RS Wall dated 06.07.2023. With reference to the subject work, observations made vide letter under reference No. (2) above the following remarks are offered. (1) GAD vide drawing No. SWR/CN/BNC/BR/170-2018 had been approved by CBE/SWR on 20.06.2019 for the work of Proposed construction of ROB at km 145/400-500 in liew of LC No.85 as 1x60.0m Bowstring stecl girder (Railway span) and &x24.0m PSC girder + 1x9,0mx4.30m and RE panels in approaches between Hosapete and Kariganuru stations. CAO/CN/BNC vide letter No. W.352/CN/BNC/ROB-RUB/Circular/Policy/Vol. Il dated 04.10.2019 has issued guide lines not to adopt RE wall construction in cases of ROBs where tenders are yet to be invited/finalized. Tender has been called on 11-11-2022 for the work of Hubballi - Ballari section- Proposed construction of Road Over Bridge (ROB)at km 145/400-500 in lieu of LC No.85 Between Hosapete and Kariganuru station as 1x60m clear span bowstring steel girder (Railway Span) and 8x24.0m PSC girder & CC blocks with Geogrid as approaches and service road on both sides of ROB, Hence designs and drawings of CC blocks with geogrid for RS wall have been submitted for scrutiny and approval. (2) Agency has submitted design and drawings of RCC box of size 1x9.0mx4.30m with skew angle of 58 degrees on Hosapete end on 27.02.2023. After scrutiny, Dy CE/CN/Designs/BNC vide letter dated 03.03.2023 has suggested for exploration of an alternate proposal instead of RCC box or otherwise to construct the RCC box in square. It is not appropriate to construct the RCC box in square as it will not match with the alignment of Ballari by pass road. Hence it has been proposed to construct 2x24.0m PSC girder instead of RCC box and RE wall in between P10 and RCC box. The same was approved by CE/CN/I/UBL vide note dated 16.03.2028, Accordingly, the Working Drawing has been revised for the subject work with additional 2 spans of 24 m PSC Girder and CC blocks with geogrid in approaches between Hosapete and Kariganuru’ and got approval from CE/CN/1/UBL on 02.04.2023 for situation at site. Hence there is a variation in height and length of RS wall submitted with the old GAD approved. Copy of the Note and revised GAD are enclosed herewith for your reference please. (3) Attended. (4) Instead of RCC box and RE wall between P10 and RCC box, 2X24.0m PSC girder was proposed and the same was approved by CE/CN/I/UBL on 16.03.2023. Hence the RE wall between P10 and RCC box was not shown in structural drawings submitted.(5) In case of ROB in lieu of LC No.72 at km 126/900-127/000 between Ginigera and Munirabad stations, design and structural drawings for CC blocks with geogrid were got proof checked from IIT/Chennai. Hence proof checking for CC blocks with eogrid for this work from IIT/ISC may not be necessary as it is a similar one. Hence designs and structural drawings of CC blocks with geogrjd duly signed in all pages by all concerned are submitted herewith for approval please. Encl: (1) Note approved (1) Revised GAD (2) CAO/CN/BNC guide lines for RE panels. Copy to: CE/CN/1/UBL for kind information.ay Sub: Ref: with 12.1 Date: 16.03.2023 NOTE Hubballi Division - Hubballi ~ Ballari section. Proposed construction of Road Over Bridge (ROB) at km 145/400-500 in lieu of LC No.85 between Hosapete and Kariganuru stations as 1x60m clear span bowstring steel girder (Railway span) and 8x24.0m PSC girder & CC blocks with geogrid as approaches and service road on both sides of ROB. Approval for additional spans 2x24m PSC girder ~ Reg. (1) LOA No. SWR-CONST-HQ-ENGG/UBL-BAY-LC-85-R/00836080069734 dated 13.01.2023. (2) [Link]/Design letter No.W.352/CN/BNC/UBL-BAY/ROB/LC-85 dated 3 3-2023. The subject work was awarded to the above agency vide LOA under ref-1 @ completion period of nine months from the date of issue of LOA i.e. up to 0.2023. The GAD for the subject work (Drg No. SWR/CN/BNC/BR/ 170-2018) has been approved. GAD contains a box of 1x9.0mx¢.30m in skew angle of 38 degrees ‘on Hosapete end of ROB. Agency has submitted designs and drawing for the box through consultant on 27.02.2023. After scrutiny, Dy CE/CN/Designs/BNC vide letter under ref-2 has suggested for exploration of an alternate proposal instead of RCC box or otherwise to construct the RCC box in square. As per site conditions it is not appropriate to construct a RCC box in square as it will not match with the alignment of by pass road. instead of RCC box and CC blocks wall on b this Hence it is proposed to construct two additional spans of 24m PSC girder oth sides in triangular portion. With arrangement of spans only 3.20m vertical clearance will be available due to more construction depth of 24m span PSC girder. Existing road level is required to be lowered by 1m and ramping on both sides of approach road to get the required vertical clearance of 4.0m. 1x9, Difference in cost between 2x24m PSC girder span and RCC box of Omx4.30m with CC blocks has been worked out. Difference in cost is Rs (-) 1382876 1.00 (-4.04%). Hence, CE/CN/I/UBL is requested to accord approval for change of span arrangements please. Dy cx/owrSpruBt . : ae Oot s{ at so Fhe ahr ben groper setbeod of REC Set At, onde E and Aoppd ht alias OT 0 pi ee eh at lerut ut A ‘ ferononrht ge She Pd Bestia. Gy caepty Udit) 2 bid'm O56 gta a er obo propel mg 4 of : [ees Ha tee we tk wad os celenp Aco. ® ae pyce(enlspiuses 7 efeaf oat 32 OF PROPOSED ROB AT KM:145/400-500 IN LIEU OF LC No. 85 (MANNED ENGINEERING) 1xé0.0m BOW 7 | STRING GIRDER (RAILWAY PORTION) AND 8x24.0m PSC GIRDER+1x9,0mxd.30m RCC BOX+RE PANELS BOW STRING GIRDER AS PER eee RDSO/B-1041 1/R (SH-ITOTO) TO HOSAPETE TO HAMPI @ @ for) ® EXPANSION JOINT. ® Or Nom EXPANSION JOINT 40mm, 40mm 3 497.885 3 PRHPOSED ROAD LE EXPANSION JOINT N 40mm) ® pmo © expansion som 4mm © expansion sont TO HOSAPETE © CRASH BARRIERS EXPANSION JOINT 40mm 11N 30 SLOPE VERALL SPAN 24 PSC GIRDER 27AZe XP ANSION JOINT ‘40mm )VERALL SPAN PSC GIRDER 10776 sk APPROACH SLAB AS PER IRC-6 OF 2000 VERALL SPAN 24000 © 16992 2arieisx) 16992 PSC GIRDER VERALL SPAN 2. sono 11200(8@) 1501680) 8200(8Q) " PSC GIRDER Foundation | indation Level:485.287 m Foundation Level:485.235 EXG. RAILWAY EXG. RAILWAY a LAND BOUNDARY 1000 LAND BOUNDARY Oe 1000 a ®s | SECTIONAL ELEVATION X Foundation Level: Sq Ay, Mo 35'46,90" ‘8200 Mey HALF PLAN AT TOP HALF PLAN AT BOTTOM (OF PROPOSED ROB AT KM:145/400-500 IN LIEU OF LC No. 85 (MANNED ENGINEERING) 1x60.0m BOW STRING GIRDER \SED RCC BOX OF SIE 1 (RAILWAY PORTION) AND 8x24,0m PSC GIRDER+1x9.0x4.30m gor pRoro ean ton eA PROPOSED ROAD LEVEL 497.885m | RCC BOX+RE PANELS (APPROCH PORTION) | ed ea ATICH 168m FOR BALLARI fan) " | 2) TAND BOUNDARY CAND BOUNDARY (tay ore. = TN 20.3, | TO HAMPI a ms rae ‘am CLEAR SPAN 60.0m_ | ert = | MERGING on “ | POINT | | | RE PANELS | | TO HOSAPETE - . 4 a4 SOUTH WESTERN RAILWAY menyorerweam “aoe [Link]/CN/BNC/ST/ -2023 r CAO/CN/O/BNC SHEET 1 — ion ore —stein HUBBALLI-BALLARI SECTION f . c Z : ; | PROPOSED CONSTRUCTION OF ROB IN LIEU OF LC No. 85 AT 2 & = 3 ¢ & 2 8 2 woor |B «gg 3 5 8 5 § 8 5 g 8 8 5 5 g 3 g g é 3 § a g @ sé g KM:145/400-500 AS 1X60M BOW STRING STEEL GIRDER(RAILWAY ~ PORTION] AND 10X24M PSC GIRDER & CC BLOCKS WITH GEO GRID IN 5 38 g § 8 g 8 8 g § 8 8 8 g g 8 8 g z & § 3 g RB 8) 8 g coke Tae : g é : lz : 3 lg : : : 2 é 3 é z 3 é 3 3 3 i 3 is 3 APPROACHES BETWEEN HOSPETE & KARIGANURU STATIONS. wero | & & 8 8 8 g & g 8 8 g g 8 g g g g g g 8 é 8 & 8 a 8 g = 6S g @ g g g § g § § & 8 g 8g g § g 3 8 8 8 |@ 3 é \8 | 8 g WORKING ELEVATION AND PLAN GHAINAGE t : : H : t ; : : : 5 i 8 | g g i i : | i é | é a e s 5 5 § SSE/DRG/CN/UBL _ (Y RAVINDRA) Y Ko LONGITUDINAL SECTION ALONG PROPOSED ROB SSE/WORKS/CN/UBL (SUDHAKAR SHETTY) ju. VERTICAL SCALE(1:200) Caen AXEN/CN/HVR (y. LAXMINAYARAYANA) 4 DYCE/SPL/CN/UBL (HISAMUDDIN). | CE/CN/I/UBL SS uns (G MURALI KRISHNA) CONSULTANT: NAKSHA INFRA STRUCTURAL CONSULTANTS NO-64, A/1 ROAD NEW TIMBER MARKET UNKAL CROSS, HUBLI-580031 CONTACT:0836-2373091, +91 9916314983 DESIGNER: KUSHAL DAS PATEL ; ; SHEET : 01 Lc. No- HDW/BL/11080/20-21‘SOUTH WESTERN RAILWAY Office of the Chief Administrative Officer, (Construction) 18, Millers Road, Bangalore — 560 043. 080 ~ 23331816 [Link], LR.S.E. Chief Administrative Officer/Constn. Fax. 080 - 23330544 Email ID — caoconstructionbneg@[Link] i Mobile No. 973 No. W.352/CNIBNG/ROB-RUBICirculaniPolicy/VolII Date: 04. AO210 CE(C) East, CE(C) CE(C) CEC) UBL ae ieee cea ) North, CE(C)South, CE(C) Pig BNC, Oy. CE(C)[Link](C) Wiest iVBNG- y CEENCentral [Link](C)Bridges / BNC, Dy. CEICVEast@NC. oy [exe BECEaMienc Dy. CE(C Mente 1/ BNC. Dy: Dy. CE{CYRBUBL, Dy! Dy CEC HVE [Link](CWPPIUBL, [Link]{CY MYS, [Link](CYDVG. ane PE Ree Sub: Guidelines for construction of RE walls for approach portions of ROBs. Recently, we had a case of failure of RE wall of ROB constructed in lieu of LC no.27 between Rajanukunte and Dodballapur stations. Keeping this failure in view, the issues involved have been reviewed and detailed guidelines have been framed which are enclosed for necessary action at your end : SG are, i inalized (Please reter para 1) of the enclosed guidelines). The present tender schedule for RE wall construction shall not be adopted. CE(C)East and [Link](C)Works will take immediate action to prepare and issue revised tender schedule and detailed specifications in consultation with [Link](C) Design which shall be issued separately. Action has to be taken on utmost priorty > — Cases where contracts have been awarded but work is yet to start: Guidelines as given in para 2) of the enclosed guidelines shall be followed. » — Cases where work is already in progress * Guidelines as given in para 3) shall be followed. 't may be noted that maximum height of RE wall should be restricted to 8m to 8.5m above ground level and 10m above the leveling pad in all cases as far as po: cet ([Link]) CAQ(C) SWR DA : 4 (Guidelines for construction of RE panels) Copy to : [Link](C) / Works/BNC, [Link](C) Design/BNC ~ for information and necessary action,18. Resting of RCC panels on pile cap should be avoided at cross wall or abutment face wall or closing wall. (The load on pile cap will be reduced but a portion of approach slab will not rest on fill coil) This needs to be looked into during design of abutments by structural designers. 19. Design submitted by Consultant shall be proof checked by IIT/ISC before submitting to DyCE/Design for approval 20. The density of the soil shall be minimum of 20 KN/m’. 21. Only galvanised ribbed steel strips should be used. 1. The maximum height of the RE wall shall be restricted to 8m to 8.5m above ground level and 10m above levelling pad. 2. Soil properties of back fill material must be checked at the level of [Link] (C) concemed to ensure that back fill being used is as per assumption in the design/ approved drawings. 3. In case height of the RE wall being constructed is more than the limits mentioned above, the structural stability of such RE wall has to be re-checked immediately by re- designing with the parameters of the materials actually being used at site for balance work in consultation with [Link]/CN/Design/BNC 4, The connectors such as bolts and nuts shall be tested for its shear strength, tensile strength, and galvanisation through NABL Accredited Laboratories. 5. All horizontal joints between panels shall be provided with a minimum of two bearing pads of 20 mm thickness. The EPDM {Ethylene propylene diene monomer} bearing pads shall confirm to durometer hardness of 70 IRDH (International Rubber Degree of Hardness). 6. The steel strips shall be tested for its tensile strength, yield strength, galvanisation and elongations through NABL Accredited Laboratories as per QAP. 7. The Quality Assurance Program for procurement of materials, testing of materials and casting of RE panels, erection of RE panels and all other connected processes shall be ensured. & The quality of backfill material and other various parts of RE wall shall be personally checked at the level of JAG officer frequently. 9. At the face of RE wall, 600 mm thick filter media conforming to MORTH specifications shall be provided. 10. The density of the soil shall be minimum of 20KN/m*. 11. Only galvanised ribbed steel strips should be used. 1. The maximum height of the RE wall shall be restricted to 8m to &5m above ground level and 10m above levelling pad.1) GUIDELINES FOR CONSTRUCTION OF RE PANELS FOR APPROACH PORTION OF ROBS WHERE TENDERS ARE YET TO BE CALLED / FINALISED. 1 The present tender schedule for RE construction shall not be adopted till the issue of revised tender schedule and detailed specifications and the same will be issued separately, 2. The maximum height of the RE wall shall be restricted to 8m to 8.5m above ground level and 10m above levelling pad. 2) GUIDELINES FOR CONSTRUCTION OF RE PANELS FOR APPROACH PORTION OF ROBs WHEI YET ‘STARTED. 1. The maximum height of the RE wall shall be restricted to 8 m to 8.5 m above ground level and 10m above levelling pad. 2. In case of locations where height of RE wall is more than height mentioned above, the case shall be reviewed immediately in consultation with [Link]/CN/Design/BNC. 3. The design of the RE wall shall have to be carried out duly taking value as 30° and ‘C’value as 0 (zero). = 4. Before taking up the design, the geo technical investigation and back fil test shall be conducted and reports should be made available to Design Agencies of RE wall These tests have to be conducted in any NABL Accredited Laboratories duly witnessed by contractor's agents and departmental supervisor. 5. In case of weak founding soil suitable ground improvement measures have to be designed and adopted before taking up the RE embankment. 6. Cruci form or T shaped RE panel shall be used to have staggered arrangement of Joints and to avoid continuous vertical / horizontal joints. 7. Thickness of the RE panel shall be of 180mm. 8. The width of RE panel shall be less than 2.0m and height shall be less than1.60m. 9. Preferably the erection of RE panel shall be started from the abutment. 10. The galvanised steel strips shall be tested for its tensile strength, yield strength, galvanisation and elongations through NABL Accredited Laboratories as per QAP. 11. The Quality Assurance Program for procurement of materials, testing of materials and casting of RE panels, erection of RE panels and all other connected processes shall be submitted along with Design so as to verify the entire process in total. It applies for selected back fill materials also. 12, The connectors such as bolts and nuts shall be tested for its shear strength, tensile strength, and galvanisation through NABL Accredited Laboratories; 13. All horizontal joints between panels shall be provided with a minimum of two bearing ads of 20 mm thickness. The EPDM {Ethylene propylene diene monomer} bearing pads shall confirm to durometer hardness of 70 IRDH (Intemational Rubber Degree of Hardness), 14, The Quality Assurance Program for procurement of materials, testing of materials and casting of RE panels, erection of RE panels and all other connected processes shall be ensured. 15, The quality of backfill material and other various parts of RE wall shall be personally checked at the level of JAG officer frequently. 16. At the face of RE wall, 600 mm thick filter media conforming to MORTH specifications shall be provided. 17. Materials can be selected randomly by the Railway and give it to third party lab, x Hye ieee Mee, a SE [Bessa AK Ev [Beeyer/ffime Loh ripe2. In case height of the RE wall is more than the limits mentioned above, thecase be reviewed immediately in consultation with DyCE (C) Design/BNC. 3. Design of RE wall has to be reviewed duly taking value as 30° and ‘C’ value as 0 (zero). 4. If abutment already constructed based on the approved structural drawing, the adequacy of the same shall be checked to suit open PSC/RCC spans and accordingly spanning arrangements have to be decided to retain the abutment already constructed. Review shall be done in consultation with [Link]/CN/Design/BNC. 5. The connectors such as bolts and nuts shall be tested for its shear strength, tensile strength, and galvanisation through NABL Accredited Laboratories. 6. All horizontal joints between panels shall be provided with a minimum of two bearing pads of 20 mm thickness. The EPDM {Ethylene propylene diene monomer} bearing pads shall confirm to durometer hardness of 70 IRDH (International Rubber Degree of Hardness). 7. The steel strips shall be tested for its tensile strength, yield strength, galvanisation and elongations through NABL Accredited Laboratories as per QAP. 8. The Quality Assurance Program for procurement of materials, testing of materials and casting of RE panels, erection of RE panels and all other connected processes shall be ensured. 9. The quality of backfill material and other various parts of RE wall shall be personally checked at the level of JAG officer frequently 10. At the face of RE wall, 600 mm thick filter media conforming to MORTH specifications shall be provided. 11. The density of the soil shall be minimum of 20KN/m?. 12. Only galvanised ribbed steel strips should be used. a sO c oo LN Siem ogre emirolo Wp