SUMMER TRAINING PRESENTATION

MUNGER RAIL CUM ROAD BRIDGE SUMMER TRAINING PRESENTATION MADE BY : JAIVEER & VIKAS

CONTENT Gammon Construction limitedBasic Intro: Bridges Types of BridgeTruss BridgeMunger Rail Cum Road BridgeUse of specification in Munger BridgeScope of workCivil Work Steel Work

GAMMON CONSTRUCTION LIMITED, INDIA The company originated from a construction business founded in India in 1919 by John C. Gammon. Later, branches in Asia, the Middle East and Africa formed subsequently, and while these companies became largely independent, there was frequent interchange of staff, plant, finance and technology between them. In 1955, a branch was engaged to build a new runway at Kai Tak Airport in Hong Kong. In 1958, Gammon Construction Limited ("Gammon") was formed to establish a permanent presence in Hong Kong.

GAMMON INDIA HAS EXECUTED SOME NOTABLE CIVIL ENGINEERING PROJECTS

Foundations of the Gateway of India. India's first cable-stayed bridge at Akkar, Sikkim The longest railway tunnel in Asia for Konkan Railway at Ratnagiri, Maharashtra. Mahatma Gandhi Setu spanning the river Ganges, between Patna and Hajipur in Bihar. Terminal building for Sharjah International Airport, UAE Elevated viaducts for Delhi Metro Rail Corporation. India's first second-generation nuclear reactor Prototype Fast Breeder Reactor at Kalpakkam. Gammon have built the largest number of bridges in the Commonwealth region.

BRIDGES

A structure built to span and provide passage over a river, chasm, road, valley or any other physical hurdle without closing underneath way such water bodies or any physical obstacle. The function required from the bridge and the area where it is constructed decides the design of the bridge. Designs of bridges vary depending on the function of the bridge, the nature of theterrainwhere the bridge is constructed and anchored, the material used to make it, and the funds available to build it.

TYPES OF BRIDGESThere are various types of bridge use all over the world such as:Beam bridge Truss bridgeCable-stayed bridgeSuspension bridgeCantilever bridgeArch bridgeMovable bridge

BEAM BRIDGE

SUSPENSION BRIDGE

CABLE STAYED BRIDGE

ARCH BRIDGE MOVEABLE BRIDGE CANTILEVER BRIDGE

Truss Bridge Truss Bridges are structures built up by jointing together lengths of material to form an open framework - based mainly on triangles because of their rigidity. They are very strong and can support heavy loads.FORCES: As with a Beam Bridge the top of a loaded truss is placed in compression and bottom in tension. These forces are shared among the angled members.ADVANTAGES: They are very strong and make efficient use of materialsDISADVANTAGES: They are more complex to construct and need a high level of maintenance.

Types of Truss Bridges

MUNGER RAIL CUM ROAD BRIDGEMunger Ganga Bridge is a rail-cum-road bridge under construction across the Ganga River at Munger in the Bihar. The bridge will connect Munger and Jamalpur twin cities to various districts of North Bihar. Bridge is connected by Beam Bridge in both sides for rail.The 3.692 km long bridge costing Rs. 180 crore. The bridge will form a link between NH80 on the southern side of the Ganges and NH 31 on the northern side of the Ganges. The Bridge connects districts of Begusarai and Khagaria to the Divisional headquarters Munger city.Construction work on the bridge was inaugurated by Atal Bihari Vajpayee, Prime Minister, through video conference system, in 2002. A railway has set the deadline for completion of these two mega bridges during 2015-2016

INTRODUCTIONProject Name - Construction of Steel Superstructure for Rail-cum-Road Bridge Across River Ganga at Munger in BiharLocation - Between Munger & Khagaria in BiharImportance -To provide a long awaited connectivityDescription -Two lane Road & single Railway track Bridge Length - 3.690 KmSuperstructure - Welded Steel Truss (riveted joints)Total dimension of Awarded bridge - 1782 Mtrs long ,12.25 Mtrs wide & 18.5mtr height

EMPLOYER - East Central Railway, PatnaCLIENT - BBJ Construction Co Ltd, KolkataCONTRACT VALUE - Rs 375.19 CroresSPAN ARRANGEMENT- 1 x 32.6 + 29 x 125 + 1 x 32.6QUANTITY OF STRUCTURAL STEEL - 24770SITE JOINTS - RivetedANCILLARY WORKS - RCC Deck, Bearing Pedestals, Exp Joints

ItemFeaturesType of spanWelded girder with riveted connection at jointsHeight / Width of span19.68m / 13.0m outside dimensionNo of members in one span417 membersNo load & Dead Load camber181.35 mm & 112.5 mm at centerWeight of one span1885 MTMax weight of single lift25 MT (1st Bottom Chord after assembly)Type of welding in members Submerged Arc Welding / MIG WeldingType of steel being used E 250B, E 350Cu, E 450Cu (Normalized, Fully Killed)

Item Code no. Item covered Steel supply IS :2062: 2006Steel plates / Rolled sectionFabrication IRS:B1 - 2001Fabrication Welding IRC: WBC Metal arc welding in steel IRS: M-39/M-46/M-28SAW welding /MIG welding/MMAW IS:9595 Metal arc welding in carbon steel IS:7307 (Pt-1) Approval test for welding procedures IS: 7310 (Pt-1) Approval test for welders Ultrasonic Testing ASTM (SA 578/ 578M)/ IS:4225UT of plates IS:4260 UT of butt welds Riveting IS:1148 /IS:1149Steel rivet bars / HT Steel rivet barsIS: 1929 Hot forged steel rivets Painting IS:9954 Surface preparation (Sand Blasting)IS: 5666 Etch primer IS:104 / IS:2074Zinc chrome Primer (yellow/red oxide)IS:2339/IS:2590 Aluminum paints /Aluminum for metalizingErection IRS- B1 :2001Erection of steel members

Works Involve In Making Of Munger BridgeIn the making of Munger Rail Cum Road Bridge various work are involve but for getting basic knowledge two type of work are involve. Those works are:The scope of wok: Civil work The scope of Steel work

SCOPE OF WORK: CIVIL WORK For Entire Bridge Length Concreting of Bearing Pedestals Concreting of RCC Deck of Bridge Installation of Crash Barriers Installation of Expansion Joints Road Surfacing Road Marking

Civil . . works

Construction of bearing pedestal & the railway tracks

Civil workConstructionOf :Roads Expansion joint Crash barrier

THE SCOPE OF STEEL WORK A SUPPLY, FABRICATION Supply Steel of Grade Fe 410W & Fe 490 Unloading, Stacking Fabrication of Members at Site Workshop Trial Assembly & Dismantling Shop Riveting, where necessary Sandblasting & Metalizing/Painting Span wise Stacking

STEEL WORK : ERECTIONB ERECTION Transportation & Pre-Assembly Erection of Truss by Cantilever Method Field Riveting Alignment & Lowering on Bearings Grouting of Bearings Final Painting

ISSUE OF STEELPROCESS OF STEEL WORK FLOWCHART FOR BUILT-UP SECTIONS

Cutting Plan Marking GrindingCuttingCheck for StraightnessStraighteningFit Up & Tack WeldFinishingGrindingRemove JigPlace Job on FixtureSandblasting/Metalizing/PaintAPPROVAL BY RDSOTack with JigDrilling End Milling SAW WeldingStraightness checkStraightening

PLATE STACKING YARD

PLATE ARE KEPT THICKNESS WISE AND GRADE WISE AND WILL BE ISSUED ON ISSUE SLIP FROM STORES ON APPROVAL OF PLANING ENGINEER.

PLATE CUTTING AFTER MARKING INSPECTION AS PER CUTTING PLAN WILL BE CHECKED THEN ONLY CUTTING WILL BE CARRIED OUT

CNC CUTTINGPUG CUTTING

FITUP MEMBER IS BEING CARRIED OUT AS PER B1-2001

BOTTOM CHORD FITUPBOTTOM CHORD FITUP COMPLETE FITUP OF BOX DIAPHARAGM

I GIRDER FITUP

WELDING OF MEMBERS

3 TYPES OF WELDING CONSUMBLES ARE BEING USED FOR SAW. 1 :W1 & F1 FOR IS 2062 E-250.2: W2 & F2 FOR IS -2062 E-350.3: W4 & F4 FOR IS 2062 E-450.MIG WELDING MIG WELDING OF VERTICLE POST DAPHARAGMTACK WELD BY SMAW

ULTRASONIC TESTING OF N-CROSS GIRDER OF SPAN 4

ULTRASONIC TESTING

SAND BLASTING

SAND BLASTING OF BLB SA-2.1/2SAND BLASTING OF DIAGONAL SA-2.1/2

METALIZING

METTALIZING OF ROAD STRINGERINSPECTION OF DFT BY ELCOMETER

PAINTING

PAINTING OF MEMBERS BY SPRAY GUN

FINESHED MATERIAL

MEMBERS READY FOR ASSEMBLY

ERECTION OF STEEL WORK

DISPATCH

RIVETING OF JOINT

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