ING-IABSE Webinar series in Association with ICE

Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Design and Construction Aspects of Arch Bridge over River Chenab

SHASHANK RAJBHOJ
Afcons Infrastructure Limited

Brief CV
Shashank Rajbhoj has gained Bachelors Degree in Civil Engineering from Government College of
Engineering, Aurangabad and Masters Degree in Structural Engineering from VJTI, Mumbai. He is
having 20+years of experience in Civil Engineering Industry. He is Chartered Engineer and Fellow
Member from Institute of Engineers India.

He has got Experience in Design of Permanent Bridges, Enabling Structures and Construction
Methodologies of Bridges. He is currently working on esteemed projects i. e M.G Setu Patna, Chenab
Arch Bridge and has worked on various other Bridge and Metro projects.

He is currently working as Assistant General Manager (Designs) in Afcons Infrastructure Limited, Head
office in Mumbai.
 Design and Construction aspects of Arch bridge over River Chenab
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
Key Stake Holders
Clients Konkan Railways Corporation Limited
Northern Railways
Contractor Chenab Bridge project Undertaking
U/o Afcons Infrastructure Limited
Clients Consultant Scott Wilson Kirkpatrick & Co. Ltd (England)
Scott Wilson Kirkpatrick India Pvt. Ltd.
Flint & Neill Partnership (London)-JV
(COWI)
Designers WSP Finland Ltd & Leonhardt Andra & Partners
Slope Stabilization IISC, Bangalore
IIT, Delhi
ITASCA (USA)
Name of the Work Design and Construction of Special Bridges Across the
River Chenab at Km 50/800 on the Katra-Leole Section of
the Udhampur-Srinagar-Baramulla Rail Link Project
 Content
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

• Brief about AFCONS

• Details of Chenab Bridge

• Broad methodologies for Bridge Deck Erection

• Erection of Arch – Local & Global Cycle

• Arch Closure

• Proposed Bridge Deck Erection over Arch

 BRIEF ABOUT
AFCONS INFRASTRUCTURE LIMITED
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

• One Of India's Premier Construction Companies involved in Infrastructure Development Segment with
an enviable past experience record of executing varied type of projects .

• Specialist firm in the fields of construction of all types of Marine works, Bridges works, Roads works,
Specialized foundations.

• 1959 - Established as "Rodio-Hazarat”, A Partnership Firm between "Rodio Foundation, Switzerland"

& "Hazarat & Co., India“

• 1976 - Registered as "Asia Foundations & Constructions Ltd. (AFCONS)“.

• 1997 - Renamed "AFCONS Infrastructure Ltd."

• 2000 - Taken over by "SHAPOORJI PALLONJI GROUP”.

 BRIEF ABOUT
AFCONS INFRASTRUCTURE LIMITED
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

• Knowledge Management and Knowledge Services

Most Admired Knowledge Enterprise Award (MAKE) at 3 levels in
2017 from TELEOS UK:
▪ Global Level - as a Global Independent Operating Unit (IOU)
▪ Asian Level- as a Most Admired Knowledge Enterprise in Asia
▪ National Level - as a Most Admired Knowledge Enterprise in India
AFCONS got the same awards from 2017 to 2020 in succession
a) Africa Best Employer Brand Award at the sixth Africa Best Employer
Brand Awards 2019
b) Best Employer in Bhutan at the 14th Employer Branding Awards
c) 17th Construction World Awards – recognised as a Top-Ranked
International Contractor by ENR (Engineering News-Record) and named
the Second Fastest Construction Company (Large Category)
d) Dream Employer of the Year, Top 5 Dream Employers and Dream
Companies to Work (Oil & Gas sector) at the World HRD Congress
Awards
 BRIEF ABOUT
AFCONS INFRASTRUCTURE LIMITED
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Currently AFCONS is executing the following very technically challenging projects:-

• Construction of Railway Bridge across the Chenab River in Jammu and Kashmir – Tallest railway bridge in
the world

• Constructed of 8.8 km long Rohtang Pass Tunnel – Longest tunnel in the world at an altitude above 3 km
Best Construction Project at the CIDC Vishwakarma Awards 2021
National Highway Excellence Award for Outstanding Project in Challenging Conditions (MoRTH)
6th Atal Shastra Markenomy Awards 2020
10th Construction Week India Awards 2020

• Replacement of Superstructure of Existing 5.585 Km long, 4 Lane MG Setu over River Ganga on National
Highway 19, Patna. This is the biggest rehabilitation work being carried out in India.
Best Construction Project at the CIDC Vishwakarma Awards 2021
National Highway Excellence Award for Excellence in Innovation (MoRTH)
 DETAILS OF CHENAB BRIDGE: Project Alignment
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

BARAMULLA
SRINAGAR

Udhampur to Katra – 25 km
Katra to Banihal – 111 km QAZIGUND
Banihal to Baramulla – 137 BANIHAL
km
Chenab Bridge

KATRA
UDHAMPUR

JAMMU 7
 DETAILS OF CHENAB BRIDGE: General Arrangement
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Deck is 362m above Water Level

Tallest Railway Bridge in the World
 DETAILS OF CHENAB BRIDGE: Scope of Work
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
Total Length of Bridge : 1315 m
Bridge Height at Arch Portion : 359 m
Main Arch Span : 467 m
Civil Works:
➢ Excavation Quantity : 10,00,000 Cum
➢ Concreting Quantity : 65,000 Cum
➢ Rock Bolting : 1,40,000 Rmt
Fabrication and Erection Works:
a) Deck Fabrication:
➢ Approach Span (S10 - 40 & S50 - 180) : 7925 MT
➢ Main Span : 4849 MT
➢ Sleepers and Stools (S10 to S70) : 400 MT
b) Arch : 9213 MT
c) Pier and Trestles:
➢ Approach Span (S20, S30 & S60) : 1400 MT
➢ Main Span (S40, S50, & S41-49) : 3543 MT
 DETAILS OF CHENAB BRIDGE: Salient Features
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

• Geographical Location
• High Altitude in the vicinity of snow-clad Himalayan Mountains
• Close to Near Zero temperatures
• Seismically highly active area - Zone V

• Geological Condition
• Unstable slopes and Erratic Geology
• Very Detailed Geotechnical and Geological Investigations
• Extensive Slope Stability Analyses
 DETAILS OF CHENAB BRIDGE: Salient Features
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Special Considerations in Design

• Blast Loads
Load for Foundations – Pressure generated by explosion
of 100kg (TNT equivalent) occurring at ground level at a
distance of 20m from face of piers/abutments.

For Superstructure – Pressure generated by an explosion

of 40 Kg (TNT equivalent) on the deck of bridge.

• Redundancy
One Arch chords buckles, or one diagonal member of
the arch truss fails due to blast loading. The Railway on
the bridge incidentally can safely travel without the
bridge collapse failure on the mentioned redundant
Redundancy Parameters
location.
 DETAILS OF CHENAB BRIDGE: Salient Features
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Design Influenced by Choice of Construction Methods

• Cantilever Arch Erection using Cable Crane
• Incremental Launching for Viaduct Spans & Main Spans

High Wind Speeds

• Design based on Wind Tunnel Tests
 DETAILS OF CHENAB BRIDGE: Wind Tunnel testing
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Wind Tunnel Tests carried out in Force Technology Lab in Denmark.

11 km diameter “disk” modeled for local topography to link wind
velocity at the structures to basic wind velocity of 39m/s (at 10 m
height, smooth terrain). (1:2200 scale).
The maximum wind speed at deck level is found to be 74m/s
 DETAILS OF CHENAB BRIDGE: Wind Tunnel testing
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Aero Elastic Model of Full Bridge

Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

BROAD METHODOLOGIES OF DESIGN AND EXECUTION

BRIDGE DECK ERECTION

 PLANNING & EXECUTION - SLOPE STABILIZATION AND SUBSTRUCTURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Before Excavation

Making of Approach Roads

 PLANNING & EXECUTION - SLOPE STABILIZATION AND SUBSTRUCTURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

EXCAVATION : 6.1 LAKHS Cum

ROCKBOLTING: 33,100 RMT
SHOTCRETING: 50,000 SQM S10 ABUTMENT

S20 FOUNDATION

S30 FOUNDATION

S40
FOUNDATION

BEFORE EXCAVATION AFTER EXCAVATION

 Bridge Deck Erection by Incremental Launching Method
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

P120-
Arch Crown
P10 P40 P130 P180
P50 P70

Launching S70 to Launching S180 to

S120-S130 S120-S130

Launching S10 to Launching S70 to

Arch Crown Arch Crown

Launching on Arch Portion – 785m Launching on Viaduct Portion – 530m

 Bridge Deck Erection on Viaduct Spans by Incremental Launching Method
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Part 2 - Straight Viaduct Spans Part 1 - Viaduct spans with curve of varying
S70 to S120 Radius S180 to S120

Incremental launching of Viaduct Spans

 PART 1 – Bridge Deck Erection on Curves of Varying Radius S180 to S120
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

The Deck is fabricated as

per the bridge alignment
and launched on a
designed Launching
Circular Curve.

Incremental Launching – Combined Circular and Transition Curve - Principle

 PART 1 – Bridge Deck Erection on Curves of Varying Radius S180 to S120
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Implementation Innovations – Launching Curve

 PART 1 – Bridge Deck Erection on Curves of Varying Radius S180 to S120
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Side Guidance Arrangement

Pushing of Segment Arrangement @ S180 Abutment

 PART 1 – Bridge Deck Erection on Curves of Varying Radius S180 to S120
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Incremental Launching completed view on

Combined Transition and Circular Curve
 PART 2 – Bridge Deck Erection on Straight Spans S70 to S120
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Actions taken for Straight Viaduct Launching

• Segment Joining Platform at Deck Level

• Lifting arrangement for Segments on Platform
• Welding & Sliding arrangement of Segments on platform for
Incremental Launching
 PART 2 – Bridge Deck Erection on Straight Spans S70 to S120
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Segment Platform @ S70-S80 Segment Transportation to Platform

Lifting of Segment on Platform

 PART 2 – Bridge Deck Erection on Straight Spans S70 to S120
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Incremental Launching of Viaduct Span in

Progress
Puling Arrangement @S90

Supporting frame & Strand Jacks added

on Pier S90
 BRIDGE DECK ERECTION ON VIADUCT PORTION (COMPLETED VIEW)
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Incremental Launching completed view on Combined

Transition - Circular Curve & Straight Alignment
 ASPECTS OF ARCH ERECTION
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

PARAMETERS AND PERMANENT STRUCTURES INVOLVED IN ARCH ERECTION

• Cable crane
• Permanent steel pier P40 and P50
• Temporary towers over piers P40 and P50
• Stressing cables (Forestay and Backstay Cables)
• Foundations at S10, S20, S70 and S80
 INSTALLATION OF PYLONS AND CABLE CRANE FOR ERECTION OF ARCH
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Cable crane with tandem

Pylons at each end
 3D VIEW OF S40 FOUNDATION
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Total Concrete Qty .19325 Cum

No. of Pours : 28 Nos.
Biggest Pour : 1570 Cum

46.8 M
 3D VIEW OF S50 FOUNDATION
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Total Concrete Qty .19325

Cum
No. of Pours : 24 Nos.
Biggest Pour : 1482 Cum

38.3 m
46 m
 INSTALLATION OF PIERS FOR ERECTION OF ARCH & BRIDGE DECK
SUPPORT
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

3 D view of Steel pier P40

(TEKLA BIMSIGHT)

➢ Height of pier = 130.9 m

3 D view of Steel pier P50
(TEKLA BIMSIGHT)
➢Base in transverse direction = 40.0 m
➢ Height of pier = 106.9 m
➢Base in Longitudinal direction = 6.0 m
➢Base in transverse direction = 34.3 m

➢Base in Longitudinal direction = 6.0 m

 INSTALLATION OF PIERS FOR ERECTION OF ARCH & BRIDGE DECK
SUPPORT
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Erection of Pier in Progress Erection of Pier Base Erection of Bracing Assembly

Segment
 INSTALLATION OF TEMPORARY TOWER FOR ERECTION OF ARCH &
BRIDGE DECK SUPPORT
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
3 D view of Temporary tower S40
(TEKLA BIMSIGHT)

➢ Height of pier = 24.0 m

➢Base transverse direction C/C = 9.0 m

➢Base in Longitudinal Direction= 3.0 m

Erection of Temporary
tower on Pier in progress
 ARCH ERECTION PROCESS
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

ARCH ERECTION PROCESS CONSISTS OF

➢ LOCAL ERECTION CYCLE

➢ GLOBAL ERECTION CYCLE

➢ ARCH CLOSURE
 LOCAL ARCH ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021
Step 1 – Bottom Chord of the Arch were installed and
connected by snug tight bolts.

Step 2 – Temporary tension element were installed

between top & bottom Chord.

Step 3 – Install Diagonals 2 & 3 and connected by

snug tight bolts.

Step 4 – Geometry and alignments were checked, and

bolts were fully tightened.

Step 5 – Second set of diagonals 4 & 5 were installed

and tightened using bolts.

Step 6 – Top Chord were installed and connected

using snug tight bolts.

Step 7 – Geometry re-checked and all bolts were fully

tightened for the assembly.
 LOCAL ARCH ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Mockup of arch
Scale = 1 : 10 Full scale trial assembly of Arch

MOCK-UP AND FULL-SCALE TRIAL ASSEMBLY OF ARCH

 LOCAL ARCH ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Segment by Segment Erection of Arch is commenced

from both sides of the Banks according to the Local
Erection cycle as specified in Erection Manual.
 ARCH ERECTION IN PROGRESS
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Inclined lifting of arch segments to accurately match all bolt holes in desired location (Ease of operation) –
Constantly varying inclination
 WIND BRACING ERECTION
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

• Wind bracings – Control wind induced vibrations during

TEKLA snapshot of wind bracings cantilever construction of the arch

• Arch has a width of around 35 m at the abutment and

reduces to almost 9.5 m at the arch crown

• Maximum length of wind bracing is 40 m, consists of pipe

sections and has a gusset connection inclined in all three
directions
 WIND BRACING ERECTION
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Wind Bracing erection

 WIND BRACING ERECTION
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

After Erection of Wind Bracings first stage stressing for Forestay & Backstay cables are carried out
 GLOBAL ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Arch erection proceeds from S40 and S50 ends

Erection of Arch elements are commenced

from both sides till the arch is cantilevering
70m. Hence the First forestay cable is tied to
Laole end Arch to support the Arch Erection and proceed
Katra end further.
 GLOBAL ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Erect Arch upto S41 on Katra end

Erect Arch upto S49 on Leole End

Install forestay cables S41.1 and backstay cables S70.1

Install forestay cables S49.1 and backstay cables S20.1

Katra end Laole end
 GLOBAL ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Proceed with Arch Erection

Install forestay cables S41.2 and backstay cables S20.2

Install forestay cables S49.2 and backstay cables S70.2

Katra end Laole end

 GLOBAL ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Erect Arch upto S42 on Katra end

Erect Arch upto S48 on Laole End

Install forestay cables S42 and restress backstay cables S20

Laole end Install forestay cables S48 and restress backstay cables S70
Katra end
 GLOBAL ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Erect Arch upto S43on Katra end

Erect Arch upto S47 on Laole End

Install forestay cables S43 and backstay cables S10

Install forestay cables S47 and backstay cables S80

Katra end Laole end
 GLOBAL ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Erect Arch upto S44on Katra end

Erect Arch upto S46 on Laole End

Install forestay cables S44 and restress backstay cables S10

Install forestay cables S46 and restress backstay cables S80

Katra end Laole end
 GLOBAL ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Remove Forestay Cables S41.1/S41.2 on the S40 Side

Remove Forestay Cables S49.1/S49.2 on the S50 Side
Proceed with arch erection towards the closure
 GLOBAL ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Proceed with arch erection till closure is reached

Current Status of Bridge

Temporary Cables being de-stressed and removed at
site.
Laole end
Katra end
 GLOBAL ERECTION CYCLE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

STAY STRESSING SEQUENCE

 ARCH CLOSURE
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Tripod-B for adjustment

of Arch tips in Vertical
alignment.

C-Frame for adjustments of

Arch in Plan or Horizontal
Alignment

Y-shaped Strut E for alignment of top

chord for fixing the closure segment
 Proposed Method for Bridge Deck Erection on Arch by Incremental
Launching Method
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

o Erect the permanent Trestle columns on Arch

o Connect top of Trestle columns with Cables for stabilization
o Start main span deck launching simultaneously from both ends
 BRIDGE DECK ERECTION ON ARCH
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Launching over Arch span approaches from both ends

Launching over Arch span is allowed with one span eccentricity from either end
 BRIDGE DECK ERECTION ON ARCH
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Launching over Arch span reaches the crown, launching nose are removed

Launching over Arch from both ends are joint with bolted splice connection

Final view after completion of launching over Arch

Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Marvel

Challenge
Bridge Deck Erection Technology – Best International Practices, Webinar lecture series from 29th May to 3rd July 2021

Thank you