Port Connectivity ROB-II Cable Stay Bridge on NH-566

LOCATION MAP
First of Its Kind The NH-566 ROB-II Bridge is the first cable-stayed Railway Over Bridge (ROB) in India
on a curvature, with a radius of 180 meters.
 DESCRIPTION OF BRIDGE
Center Span 78 m Foundation
Back Span 2*46 m (Pile Foundation)
Total Length 170 m Pile Dia. 1m
Radius of curve 180 m Nos of Pile 14 each
Super Elevation 3.8% Pile cap Shape Octagonal
Height of Pylon 35 m

Pile Cap Size

Length 23.55 m
Width 9.3 m
Depth 2.5 m

Sub-Structure
RCC Concrete M60
Tie Beam Size(L*W*H) 28.7*3.8*2 m
Main Girder 60 Nos
Cross Girder 114 Nos
Stay cable 52.5 MT.
Total Concrete Quantity 5200 Cum
Total HYSD steel for ROB-II 900 MT
Total Structural Steel 1750 MT
 SOIL INVESTIGATION AND TESTS
Standard Penetration Test Dynamic Pile Load Test

Pile Integrity Test

FOUNDATION DETAILS OF STAY CABLE PORTION AND BACK
SPAN PIERS.
Two Parallel foundations with central span 78 mtr
and 46 mtr back spans.

Main Foundation Backspan Foundation

The bridge's foundation The back span

consists of 14 friction piles foundations consist of 12
with a diameter of 1.0 piles of 1m diameter with
meter and an average depth average depth of 18 mt
of 18 meters for each pylon. for each from the pile
cap.

Additional strap beam was provided on the top of

pile cap to tie both inclined pylon at bottom to
distribute the load to sub-strata safely due to its
unique design.
Pile Cap and strap beam at Pylon Cross section of Pylon
Locations
Pile foundation:
 CONSTRUCTION MATERIAL
Concrete Steel
M-60 (Corrosion Incubators) Fe 500D (CRS Steel ) Max 32 mm Diameter
SUMMARY OF CONCRETE MIX DESIGN OF M-55 FOR PILE
Water Cement Ratio 0.30
Admixture % by Weight of Cement 0.45 (2.43 Kg)
Water Content (Kg/m ) 3 184.51
Cement (Kg/m3 ) 270 (as per MORTH book clause no 1715 , for high
performance concrete , the maximum cement
content with mineral admixture such as GGBS or fly
ash is 380kg/cum , hence the 50% works out to 190
kg/cum whereas cement content used is 270
Kg/cum thus suffices the conditions)
GGBS (Kg/m )3 270 ( 50% )
20 mm (Kg/m3 ) 626.56
10mm (Kg/m3 ) 491.56
Sand (Kg/m )3 683.52
Corrosion Inhibitor (Kg/m3 ) 3.00
20 mm : 10 mm 56:44
CA : FA 61:39
Cement Brand Bharathi OPC 53
GGBS Brand CMPPL
Admixture Brand FOSROC AURAMIX 402
Bipolar Corrosion Inhibitor Krishna Conchem EPCO-KP-200
 CONSTRUCTION
Lower Pylon Tie Beam Upper Pylon Saddle Structural Steel Works

•Economical •Prestressed Tie •Specially •The upper pylon

formwork for •Procurement- E350 BR Grade
beam having designed has cast along structural steel size varying from 50 mm
lower pylon was length 28.70 M, lightweight RMD with saddle with to 12 mm used for fabrication of main
specially width 3.80 M and (Turkish material) proper girder, cross girder and anchorages
designed to depth 2.0 M. was orientation and conforming to IS 2062.
support the 150 designed to in mm accuracy.
MT reinforcement • Scaffolding •Fabrication-The fabrication of
support the
in inclined material was used structural steel girders posed
superstructure.
position. to carry out the •Due to dense significant challenges due to their
work, which was 5 reinforcement in curved design; however, 100%
•A total jacking times safer and the pylon, it was accuracy was achieved in both
• The outer angle force more than light in weight. very challenging
of 73 degree in the girder and anchorage
51000 KN has to fix the saddle
which the applied on each fabrication.
with accuracy in
designed frame tie beam. X, Y, and Z •The process was carried out at an
was kept holding plane. RDSO-approved fabrication
the reinforcement •Specially facility in Dharwad.
till the concreting. designed light •Protection - After sandblasting, a
weight RMD protective coat of paint was
(Turkish material ) applied to safeguard the
scaffolding segments from corrosion and
material was rusting, ensuring the durability and
used. longevity of the structures.
 Erection Works

• Prior to erection, all segments, girders, and

anchorages were thoroughly inspected to
prevent any unforeseen complications.

• The erection process presented significant

challenges due to space constraints, the
presence of a live railway track, and the need to
minimize disruption to train operations.

• Method involved erecting temporary staging for

each girder sequentially, launching the girder
over the staging, and then moving backward to
repeat the process for subsequent girders. This
method of placing girders is known as End-on
launching.
 Erection Challenges

Space Constraints Crane Operations

The limited space between piers P124 and P125 Two 80 MT cranes were used for launching the
required the use of the end-on method for erection main girders. In areas with tighter space limitations,
and launching. This involved erecting temporary a 250 MT telescopic crane was utilized. The
staging for each girder sequentially and then erection activities over the existing ROB were
moving backward to repeat the process. conducted during late-night hours to avoid
inconvenience to road users & railway movements
and safety standards were thus met.

Safety at work
Erection challenges were met without LTA in
the construction of complex structure.
9 Million safe working hours were achieved
without any accidents.
STAY CABLE INSTALLATION PROCESS
 STRAND PREPARATION
 Strands cutting was carried out in factory with anti-slip keys fixed on the strands.
Strand cutting length formula:
L= L0+2*(A1+L1) in which
L0——Center line distance between bearing plates of stressing and fixed end (mm),
offered by design.
A1——Length of anchor head (mm);
L1——Length for stressing operation, normal it's 1.5m;

 PE sheath at both anchoring ends were removed to calculated length, which will be satisfied
stressing requirement.
PE sheath cutting length calculation：
LS=A1+A2+L1-L2
A2——Length of sealing socket
L2——Length of PE sheath in sealing socket
 Strand Cutting Procedure
A) Cautions to strand cutting work:

I. In case of PE sheathing damage occurs, repair were carried out immediately, severe
damaged strands were rejected.

II. Careful check was essential to ensure cut length was accurate.

B) PE sheath at both ends were removed by using special tools.

C. After removing PE sheathing, unwind the stranded steel wires, clean off the wax at
both ends. The galvanized layer was carefully protected from damage during
cleaning. Steel wires was winded back after cleaning.

D. Cutting the out ring 6 wires of strand in 12cm, keeping the center wire and head
button by Head button device LD10K (for strand towing).
 Strand Threading and Installation
Preparation of Strand Threading Installation of Stressing Jack Chair
 Under 100 meters cables , manual pushing by the workforce is
 For Individual strand stressing operation, the
typically sufficient, for cables exceeding 100 meters, methods such
Jack Chair was installed before cable installation.
as cyclic threading or continuous threading are more efficient and
 The Jack Chair has screw to connect with the
reduce labor requirements.
anchor head.
 The selection of the lifting equipment should account for the initial
stressing force of the first strand and the weight of the strands to be
cyclically threaded.
 Winches or strand-pushing machines should be positioned
strategically for safe and efficient operation.
Installation of Stressing Anchorages
 Anchor holes should be aligned with holes of sealing plate. Deviation in Holes position is not allowed, trial thread should be
through with a strand.
 Anchor holes should be clean to assure its anchoring performance
 Fix the sealing plate with stretch tube which is socketed by dot welding to avoid loose contact and corresponding potential
risk during installation.
 Adjust the nut at stressing end during stressing.
 Before positioning the anchorage ,clean the guide pipe and drainage outlet at lower end.
 Anchorages shall be set at top surface of bearing plate at outside pylon. Three centering blocks shall be temporarily welded
on bearing plate, which shall be removed after the first strand be stressed. Use chain block to let anchorage into guide pipe.
During installation, have the grouting port at a lower position and avoid damage on the thread.
 Anchorage holes array of both ends shall be horizontally placed and aligned identically by aligning Centerline of both ends
anchorage with that of embedded bearing plate, the deviation shall not be more than 5mm.
 The hole of anchorage and saddle should be aligned with each other.
HDPE Pipe Installation
Strand Threading and Stressing

Stressing Overstressing Force Equation

i) Cable force = Design cable force

Nos. of strands – 1 +Young’s modulas
+Area of strand X Deformative value X
No. of Strands
No. of strands -1
Length of cable

ii) Wedge Draw in = (Young’s modulas X Area of strand

X Wedge draw in ) / Length of Cable in mm

iii) Cable Sag effect = (Young’s modulas X Area of strand

X Effect of cable sag) / Length of cable (m)
 Factors Affecting Strand Force Uniformity

A. Temperature change - Complex structures such as Cable-stayed bridge, it is sensitive to

environment temperature, and strand threading is a long operation
B. Duration, environmental factors such as temperature variation and wind may cause
deformation on the pylons and main girders, so there may be deviation between the instant
force of the installing cable and the calculated cable force.
C. Wind load factor.
D. Temporary load factor.
E. Manual operative factor.
 Individual Strand Stressing
• Mono-Jack YCDS160-150 was applied for strand stressing.
• Ends are stressed first without anti-slip keys, thus the anti-slip keys fixed to
the bearing plate of saddle.
• Then both ends stressed together according to design force and elongation.
Isotonic Tension Method was used to control all forces to be equal.
• The Individual strand stressing was controlled by the pressure sensor,
which was installed on the third strand, fixed by tool anchorage and
dismantled after completion of the stressing.
• During strand installation, the stressing force deviation of every strand in
Individual strand stressing Sensor meter same cable between actual elongation and theoretical elongation was
controlled within ±5%.
• Record the first elongation when force goes to 5MPa, when stressing force
goes to 1MPa record the change of the sensor value which is less than
former strand.
• Calculate the controlling force of the strand base on the sensor meter,
according to calculated stressing value.
• Record all the forces in gauge, sensor reading, elongation etc.
• Record the final elongation after stressing. Fix the working wedge by
Load sensor Principle of Isotonic tightening.
tension method
• Check the draw-in when force release to 3MPa.
• Restress the 1st and 2nd strand to the required force in the same way.
Restress the 3rd strand after removing the sensor.
• Calculate the actual elongation of every strand and compare with the
theoretical value if it's in the required deviation, if not, stop the work and find
the reason.
 Strand Stressing Procedure
• After temporary anchoring working wedge, install the YDCS160-150 Jack,
tool anchorage, tool wedge and Mark the Measurement basis points on
the strand.
• Stressing is done according to the design force.
• Recording the first elongation every time when force goes to 5MPa.
• Recording the change of the sensor value when stressing force goes to
1MPa less than former strand, calculate the controlling force of the strand
base on the sensor change value, then stressing according to this
calculate value.
• Recording the final elongation after stressing. Fix the working wedge and
Sensor meter
tightening.
• Checking the draw-in when force release to 3MPa.
• d. Restress the 1st and 2nd strand to the required force in the same way.
• e. Restress the 3rd strand after removing the sensor.
• f. Calculate the actual elongation of every strand to check with the theory
elongation if it's in the required deviation, if not, stop the work and find the
reason.
 Technical Requirements and Key Points

Technical Requirements Key Points in Mono Stressing Work

a. During the stressing process, both anchor ends of the a. Both anchor end of cable was simultaneously
cable should be tensioned simultaneously to ensure stressed. Working wedge was tightened.
that the uneven forces remain within permissible b. When stressing is up to 100% of controlled force, fix
limits. and tighten the wedge manually with a special tool to
b. After stressing, the deviation of each wedge level assure uniformity in draw in.
should be maintained within 0.5 mm. c. Record the force at the load cell to prepare for the
c. The applied force during stressing should not exceed next strand.
0.5 MPa. d. Uniformity of strand force was related to the
d. The cable force should remain within ±5% of the installation quality as well, so it is very important to
design force, with the force difference between have the wedge out of anchor hole uniformly and the
strands in the same cable limited to ±5%. gap between two wedge half uniformly.
e. The deviation between actual elongation and e. Force input was slowed down when final force is
theoretical elongation should be controlled within reached then record the force.
±6%. f. Make sure the working wedge was tightly fixed
before force releasing and Check the wedge quality
after releasing force.
 Installation of Protecting Parts
Installation of the Installation of the Damper
Wedge Pushing
Anti-Sliding Anchor Device

Installation of Collar Sliding piece with lock nut Installation of Damper

• Before installing the damper, the cable
• Use the jack chair as a reaction • After all strands of the cable
should be tightened up at the position of
frame and use the wedge finish stressing, the anti- sliding
the end of guide pipe.
pushing device to push the anchor device is required to be
• If the section of cable is not hexagon,
wedge one by one, to achieve fixed to the saddle bearing plate
some filling strands (1m long each) can
best anchoring performance with bolts, then install the anti-
be used to fill the space of cable to make
under low stress condition. sliding pieces and the lock nut.
it a hexagon section.
• Insert the damper into the pre-embedded
pipe.
• Fasten the bolts to secure the damper in
position within the pipe.
 Anchorage Anti-corrosion Protection

Step 1
Inject special wax into the inner space of the
anchorage.

Step 2
Install caps at both stressing and fixed ends,
filling them with wax.
Wax filling

The Wax filling machine will be used to ensure the anchorage would be completely filled with wax.
 Construction Control

1 Pylon Displacement 2 Elevation Control 3 Cable Force Control

Control

Monitor pylon displacement Control stressing primarily Achieve stressing using a

during stressing using a by elevation, with force as a calibrated hydraulic jack.
displacement monitor. secondary factor.
 Stay Cable Protection

PE Sheath Waxed Strand Repairing Damage

Use PE sheath waxed strand Repair any damage to the PE sheath

for cable protection. using a PE welding torch to prevent
corrosion.
 Protection Solution Inside Anchorage

1 Remove Sheath and Wax

2 Inject Wax/Grease

3 Apply Pressure

4 Check for Leakage

5 Finish Grouting
 Anti-corrosion Measures for Exposed Components

Grease Application Wax/Grease Application Protective Cap

Spread grease on the thread at the outer Spread wax/grease on the surface of Fix a protective cap to the anchorage
sustain socket for anti-corrosion and ease exposed anchorage, wedge, and strand. after stressing is complete.
of fixing.
 Bridge Load Test
1 Purpose
Assess the bridge's behavior under design live load and
check the elastic performance of the superstructure
whether the maximum deflection and percentage recovery
are meets the requirements of permissible limits as
specified in IRC:SP:51-2015 and IRC: SP:37:2010

2 Loading Stages
• Apply load in stages: 25% (60MT), 50%(120 MT), 75%
(180MT), and 100%(240 MT).
• Due to Railway tract below, instead of dial gauges prism
was fixed above top of main girders.
• 8 No. of vehicles having weight of 30 MT each totaling
to 240 MT load were placed on specified location a
shown in the Picture.
3 Deflection Monitoring
• During the entire loading and unloading process the
readings were recorded @ one-hour interval.
• During the 100% loading the maximum deflection w at
critical section was 41 mm against the theoretical
deflection as shown in fig.was 44.1 mm which was
within the permissible limit.
4 Recovery
The bridge successfully completed the load test with a
recovery of 95.84%.
 Challenges Faced During Execution

Dense Reinforcement
Cup-lock system for bar lap was used due to limited space in the pylon.

Inclined Pylon
Separate support system was used to keep reinforcement in an inclined position.

Restricted Area
Carrying out erection work over the existing ROB during late nighttime due to space constraints was a major
constraint.

Curvature Alignment
Carrying out cable stressing in a cross method to stabilize the structure.
 Conclusions

6 95.84%
Cables Stressed Recovery
After stressing six cables, the The ROB II Cable Stay Bridge was
maximum movement in x, y, and z successfully completed with a
directions was 6 mm, 9 mm, and 11 recovery of 95.84%.
mm, respectively.
AERIAL VIEW OF THE PROJECT WITHIN VASCO CITY
AERIAL VIEW OF ROB-2
AERIAL VIEW OF THE PROJECT
AERIAL VIEW OF THE PROJECT
AERIAL VIEW OF THE PROJECT
AERIAL VIEW OF FAÇADE LIGHTING
VIEW OF FAÇADE LIGHTING
Thank You