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MUNGER RAIL CUM ROAD BRIDGE
PROJECT
PRESENTATION
17.01.2014
INTRODUCTION
Project Name Construction of Steel Superstructure for Rail-cum-Road Bridge Across River Ganga at Munger in Bihar
Job code No. 8802
Location Between Munger & Khagaria in
Bihar Similar Bridge Across river Brahmaputra in Assam
Importance To provide a long awaited
connectivity Description Two lane Road & single Railway track Bridge Length 3.690 Km
Superstructure Welded Steel Truss (riveted joints)
LOCATION MAP
Munger Bridge
SALIENT FEATURES Employer East Central Railway, Patna
Client BBJ Construction Co Ltd, Kolkata
Contract Value Rs 375.19 Crores
Completion Period 30 months
Span Arrangement 1 x 32.6 + 29 x 125 + 1 x 32.6
Type of Superstructure THROUGH TYPE WELDED STEEL TRUSS
Weight of 125m Span 1885 MT/Span
Width/Depth of 125m Span 13.35m/18.5m
Gammon Scope 12 x 125
Quantity of Structural Steel 24770
Site Joints Riveted Ancillary Works RCC Deck, Bearing Pedestals, Exp
Joints
ERECTED SPANS
Khagaria end
Munger End
P 29
P28
ERECTION IN PROGRESS
Typical 125m Span elevation
Top Chord Members
Bottom Chord Members
Diagonals
Verticals
End Raker
Road Deck
Rail Track
Matching point of North and Sounth End
Key Technical Features
Item Features
Type of span Welded girder with riveted connection at joints
Height / Width of span 19.68m / 13.0m outside dimension
No of members in one span 417 members
No load & Dead Load camber 181.35 mm & 112.5 mm at center
Weight of one span 1885 MT
Max weight of single lift 25 MT (1st Bottom Chord after assembly)
Type of welding in members Submerged Arc Welding / MIG Welding
Type of steel being used E 250B, E 350Cu, E 450Cu (Normalized, Fully Killed)
Key Specifications
Item Code no. Item covered Steel supply IS :2062: 2006 Steel plates / Rolled section
Fabrication IRS:B1 - 2001 Fabrication
Welding IRC: WBC Metal arc welding in steel
IRS: M-39/M-46/M-28 SAW 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:4225 UT of plates
IS:4260 UT of butt welds
Riveting IS:1148 /IS:1149 Steel rivet bars / HT Steel rivet bars
IS: 1929 Hot forged steel rivets
Painting IS:9954 Surface preparation (Sand Blasting)
IS: 5666 Etch primer
IS:104 / IS:2074 Zinc chrome Primer (Yellow) /(Red Oxide)
IS:2339/IS:2590 Aluminum paints /Aluminum for metalizing
Erection IRS- B1 :2001 Erection of steel members
SCOPE OF WORK - STEELWORK
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
WORKSHOP
SCOPE OF WORK - STEELWORK
B ERECTION
Transportation & Pre-Assembly Erection of Truss by Cantilever
Method Field Riveting Alignment & Lowering on Bearings Grouting of Bearings Final Painting
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
ENABLING WORKSA FOR FABRICATION Camp Establishment at Khagaria End Fabrication Workshop – 3 nos Layout Platform Establishment at Munger End (BBJ
Yard) Trial Assembly & Stacking Yard Sand Blasting & Metalizing Enclosure Feeding track
ENABLING WORKSB FOR ERECTION Fabrication of Heavy Duty Trestles Piling for Anchor Span Supports Erection Cranes Design/Manufacture Fabrication of Links/Pins Fabrication of Strengthening Members Staging for Erection/Site Joints Scaffolding for Riveting/Painting Access Ladders/Platforms/Walkways
SALIENT CONTRACTUAL FEATURES
MOBILISATION ADVANCE STAGE I
5 % of CV against BGB - 18 % interest
MOBILISATION ADVANCE STAGE II
5 % of CV against BGB - 18 % interest
PLANT ADVANCE 10 % of CV. Max 75 % of Plant cost. Hypothecation/BGB for full value of plant.
SECURITY DEPOSIT 10 % of each Bill. Max 5 % of CV.
LIQUIDATED DAMAGES
Entire amount levied by Railways if contractor is solely responsible. OR proportionate to their value of work to total value.
FAILURE IN EXECUTION OF THE CONTRACT
Performance guarantee will be encashed & SD will be forfeited.
SITE FACILITIES TO BE PROVIDED TO RAILWAY
Furnished Office, Codes, manuals, 2 vehicles, 6 computers, software, 2 printers, maintenance personnel, motor boat, walkie talkies etc.
SALIENT CONTRACTUAL FEATURES
MAJOR QUANTITIES
Mild Steel (Fe 410W) Supply – 8249 MT
HT Steel (Fe 490) Supply - 16521 MT
Mild Steel Fabrication/Erection - 7420 MT
HT Steel Fabrication/Erection - 15162 MT
Load Test of 125m Span - 3 nos
RCC M30/M35 - 12900 m3
Reinforcement - 2100 MT Supply of cement - 5779 MT Supply of Reinf Steel Fe 500 - 2205 MT Design, Supply of Exp Joints
Modular Strip Seal 125m Span - 29 nos Modular Strip Seal 32.6m Span - 2 nos
BBJ’S SCOPE OF SUPPLY
AS PER CONTRACT AGREEMENT
APPROVED FABRICATION DRAWINGS WILL BE ISSUED BY BBJ AFTER APPROVAL BY RLYS
MASTER JIGS WILL BE PREPARED AND GOT APPROVED BY BBJ. GAMMON MAY BE ALLOWED TO MAKE WORKING JIGS FROM THEM
BBJ WILL PREPARE AND GET ERECTION SCHEME APPROVED. GAMMON MAY FOLLOW
ESCALATION/STAR RATE PAYMENTSESCALATION FORMULA BASED ON BASE DATES
/INDICES
1. LABOUR R*(l-lo)/lo*0.3 Consumer price index(RBI) 15.07.2008. 143
2. MATERIAL R*(w-wo)*0.25 Wholesaleprice index-All commodities(RBI)
15.07.2008. 240
3. FUEL COMPONENT
R*(F-Fo)*0.15 Wholesaleprice index-Fuel,Power,Light & Lubricants RBI)
15.07.2008. 377.2
4. STEEL Ex works price at SAIL+ ED 01.07.2008
a. Reinforcement bars
Q*(Bs-Bso) 8 mm dia.
b. M.S.Angles Q*(Bs-Bso) 65x65x6 MM IS 2062.E250A SK
c. Plates Q*(Bs-Bso) PM plates 10 – 20 mm IS 2062 E 250A SK
d. Plates Q*(Bs-Bso) PM plates 10 – 20 mm IS 2062 E 350 cu
Not known.
e. Channels Q*(Bs-Bso) ISMC 200x75 IS 2062 E 250A SK
5. CEMENT R1*(Wc-Wco)/Wco)
Wholesaleprice index-Cement (RBI)
15.07.2008 – 222.
R – Gross value Q – cost of steel supplied during month
R1 – cost of cement consumed during month
PENALTY FOR MISSING MILESTONES
MILESTONES KEY DATES REMARKS PENALTY
Submission and approval of erection scheme for 125 M span
D + 90 days
Railways to issue GAD & Stress sheet 15 days from LOIRailways require 30 days for approval
Rs 2 Lakh per day. If contractor makes up the progress within next two key dates, then the penalty shall be reimbursed. Maximum cumulative penalty is @ 3% of CV.
Submission of fabrication drawings for 125 M span with complete Design.
D + 150 days
Railways require 30 days for approval. 50% Drawings shall be submitted from D+60 days and balance 50% drawings within D + 150 days.
Completion of Trial assembly of one 125M span & Pass by Railways.
D + 270 days.
Railways require 21 days for approval. Trial assembly to be offered with all test reports, measurements & relevant doc.
Launching of First span except placement on bearings.
D + 300 days.
Launching of Second span except placement on bearings.
D + 330 days.
Launching of Fifth span except placement on bearings.
D + 390 days.
“D” is issue Date of LOA
MOBILISATION – KEY DATES
Award of Contract by BBJ 09.04.2009 Site Mobilization started on 07.07.2009 Receipt of Shop Drawings 26.02.2010 onwards
Receipt of Steel from SAIL 04.03.2010 onwards Fabrication Agency Finalized 04.03.2010 2 no Fabrication Shops Comp 31.03.2010 Mobilization for Jigs/Fixtures 31.03.2010 Full Mobilization of Agency 31.05.2010 Completion of Piers by Rlys 30.06.2010 Scheduled Completion Date 07.11.2011 1st EOT granted till Date 31.12.2013 2nd EOT applied up to 15.06.2015
PLANTS & EQUIPMENTSEquipment No's
Hydra (8 T to 14 T Cap) 9 nos.Handling cranes 2 nos. (45 MT & 50 MT capacity)EOT cranes 5 nos. (20 MT capacity)Goliath crane 2 no. (50 MT & 20 MT capacity)Generators 7 nos. (40 KVA to 500 KVA)Jacks 10 nos. (100 to 250 MT capacity)
Plate straightening Arrangement 1 nos. (with 2 x 350 MT Jack)Distortion correction Frame 2 nos.Compressors 7 nos.Radial drill machine 15 nos. Magnetic drill machine 37 nos.Pug machine 15 nos. SAW machine for outside welding 13 nos.SAW machine for inside welding 2 nos.MIG welding sets 12nos.MMAW sets 23 nos.Flux baking furnace 4 nos. USFD machine 1 no.Angle Grinding machines 60 nos. Riveting equipment's 3 setsAutomated I-girder Assembler 1 nos. Automated I-girder Straightener 1 nos. CNC Gas Cutting Machine 1 nos. End Milling Machine 1 nos. Calibrated Inver Tape 1 nos.
Measuring Instruments/Gauges As required
Safety equipment's As required
SUPPLY OF STRUCTURAL STEEL
Study shop drawings & make cutting plan
Prepare Steel Indent/obtain from BBJ Send Requisition to HO for P.O. Pursue SAIL for supply of steel Coordinate with SAIL Patna & Fatuha
Yard Authorized Agency to lift steel from
Yard Unloading & Stacking at Yard
Contd….
SUPPLY OF STRUCTURAL STEEL
Identification & Correlation with MTC Visual Inspection & Dimension check Verification of product analysis in MTC Joint Sampling for Testing at NABL lab Verification of Physical & chemical
properties Verification of Charpy V Notch Impact Test Review of Test Results by Railways Acceptance by BBJ/Railways.
FABRICATION Commissioning of plants/equipments Transport steel from GIL Yard to BBJ Yard Make copy of Master Jigs/Fixtures Transport Jigs/Fixtures back to GIL Yard Prepare Lay Out & check with Jigs Issue steel to P&R based on cutting plan Prepare Templates for cutting of Plates Proceed with fabrication as per flowchart
FABRICATION
Broad Classification of Fabricated items
Built-up Sections Requiring Welding (62%) Top Chord, Bottom Chord, End Raker : Box Section Diagonals & Verticals : Channel Type Box; I-
Section Cross Girders, Stringers, Hangers : I-Section
Not Requiring Welding (38%) Gusset/Splice/Pack Plates – Plates Bracings, cleat angle & other Misc items – Angles Bent Gusset/Splice Plates – Plates + Bending
FABRICATION FLOWCHART FOR GUSSET/SPLICE PLATES
Issue of
Steel
Cutting Plan
Marking
Grinding
Cutting
Check for Straightness
Straightening
Tack with Jig
Finishing
Grinding
Remove JigDrilling
Sandblasting/Metalizing/Paint
APPROVAL BY RDSO
FABRICATIONFLOWCHART FOR BUILT-UP SECTIONS
Issue of Steel
Cutting Plan
Marking
Grinding
Cutting
Check for Straightness
Straightening
Fit Up & Tack Weld
Finishing
Grinding
Remove JigPlace Job on Fixture
Sandblasting/Metalizing/Paint
APPROVAL BY RDSO
Tack with Jig
Drilling
End Milling
SAW Welding
Straightness check
Straightening
LAYOUT PLATFORM
FABRICATION
FABRICATION Challenges
Avoid distortion during cutting/welding
Grinding of cut edges of thick HT Plates
Straightening during Fit up & welding SAW Welding inside box sections End Milling of Chord members Accuracy of drilling holes Achieve Camber
FABRICATION
FABRICATION
ERECTION
Cantilever erection as per Scheme by BBJ Involves two customized derrick cranes – 1st
for forward erection and 2nd for follow up work
Some members are strengthened to cater for the erection stresses.
First span (between P30 – P29) will be erected conventionally on trestle supports at all nodes
Once the camber & alignment is accepted, cantilevering of further spans starts.
Feeding of fabricated components will be by trolley at rail level
ERECTION SCHEME
Contd…..
ERECTION SCHEME
CANTILEVER ERECTION SCHEME
RIVETING High Tensile Rivets 24mm dia used at Site Joints Rivets replace temporary fasteners (bolts/drifts) A typical Riveting gang consists of five men All holes in the joint to be made fair Rivets comprise about 1.5% of the Span weight Equipments used
Compressor – Operates the forge, hammer, dolley Forge – Used to heat the rivet by pearl hard coke Tongue – Used to handle red hot rivets Hammer – Used to hammer and prepare rivet head Dolley – Used to hold rivet in position
ALIGNMENT Important to control cantilever erection To start after erection of 3 - 4 spans Involves
Jacking of entire span on Traversing base
Ensure Vertical & Horizontal Alignment
Lowering on Bearings Followed by grouting of Bearings Equipments used
Hydraulic Jacks – 500 T Cap – 9 nos Hydraulic Traversing Base – 9 nos Pack plates – As required
SAFETY CONCERN
Repeated handling of long heavy structural
Sandblasting area close to residential area
Access, staging & walkways on bridge Riveting platforms on bridge Jacking of spans Weather Condition during
cantilevering 1st Span erection on river bed
SAFETY
FINANCIAL STATUS (FORM F3)
DESCRIPTION AS PER TENDER AS PER LATEST CE
CONTRACT VALUE
a) WORK DONE 375.18 376.29
b) ESCALATION - 74.31
c) OTHERS - 0.97
d) TOTAL 375.18 451.57
B. S. EXPENDITURE 269.55 290.50
Y.S. EXPENDITURE 47.20 48.72
B.S. + Y.S. 316.75 339.22
PLANT HIRE CHARGES 6.80 6.93
B.S. + Y.S. + PLANT HIRE CHARGES 323.55 346.15
H.O. OVERHEADS 6.06 9.57
FINANCE CHARGES FOR –VE CASHFLOW 11.26
CONTINGENCIES 3.40 1.61
TOTAL EXPENDITURE 344.27 357.33
MARGINS 30.91 94.24
THANK YOU