Multilevel Flyover Case Studies

J. S. JadhavChief Executive

B. G. Shirke Const. Tech. P. Ltd.

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AbstractCASE STUDY: Flyover at Nashik Junction, Pimpri-Chinchwad

1. Construction at crowded junction of two national highways NH-04 and NH-50.2. Completion of project with GOAL OF ZERO ACCIDENT.3. Traffic Management.4. Restriction of use of Mobile Cranes.5. Working at 22 Mtr. height at main junction.6. Concerting of Pier in a single pour.7. Boring for Piles of 1.2 M Diameter in hard rock by Hydraulic Rig.8. Construction at Complex Junction of second level flyover/first level flyover.9. Working in river Pavana – Completion of river bridge in eight months. Launching of Girders of ROB in 18 hours over a very dense traffic of CR.

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Multilevel Flyover Case Study – MULTILEVEL FLYOVER AT NASHIK JUNCTION IN PCMC, PUNE

Presented by: Mr. K. B. Lawand, Dy. General Manager (Projects)B. G. Shirke Const. Tech. Pvt. Ltd., Pune

B. G. SHIRKE CONST. TECH. PVT. LTD., PUNE HAVING ISO 9001, 14001 & 18001, ESTABLISHED IN 1944 IN THE FIELD OF CIVIL ENGINEERING CONSTRUCTION PROJECTS. EXECUTING INFRASTRUCTURE, RESIDENTIAL, INDUSTRIAL AND COMMERCIAL PROJECTS FOR LAST 72 YEARS IN INDIA AND ABROAD. TODAY, SHIRKE GROUP IS AT THE COMMANDING HEIGHTS IN CIVIL AND INFRASTRUCTURAL FIELDS OFFERING UNIQUE CAPABILITIES TO INDIGENOUS AND OVERSEAS CLIENTS--------------------------------------------------------------------------------------------------------------------------------------------------------Project : Design & Construction of Flyover, ROB, River BridgeClient : Pimpri Chinchwad Municipal Corporation, Pune – 411018Consultant : Consulting Engineering Services (I) Pvt. Ltd.Contractor : B. G. Shirke Construction Technology Pvt. Ltd. – Vijay M. Mistry Construction Pvt. Ltd. (JV)

Preamble:

• This has a unique structure, complex in nature

comprising of Railway Over Bridge (ROB), Flyover and

Bridge over River Pawana.

• It is located at crowded junction of Old Mumbai Pune

Highway NH-4 and Pune Nashik Highway NH-50 within

PCMC area.

• The junction has a very dense traffic of 120 Nos. vehicle

per minute.

• Construction of 2 tier flyover within 30 months at such

junction having maximum height of 22 Mtr. was a very

challenging work.

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Major Components:

2nd Level Flyover : Height -22 Mtr. Length - 1110 Mtr. (27

Spans)

1st Level Flyover : Height -16 Mtr. Length - 1800 Mtr. (36

Spans)

ROB (Rail Over Bridge) : 110 Mtr. (6 Lane + FOB)

River Bridge (Pawana) : 206 Mtr.

Ramps & Loops : 1030 Mtr.

Service Roads : 2000 Mtr.

ACTIONS TAKEN IN ADVANCE AT MOBILIZATION

STAGE TO ACHIEVE THE CHALLENGING GOAL OF

COMPLETION IN 30 MONTHS

• MOBILIZATION PLAN AND CO-ORDINATION WITH

VARIOUS DEPARTMENTS

• GEOTECHNICAL INVESTIGATIONS, SURVEY AND

PRELIMINARY DESIGNS AND DRAWINGS

• PLANNING OF MANPOWER / MACHINERY /

MATERIALS / FINANCE

• PLANNING OF FORMWORK / STAGING

• Q U A L I T Y A S S U R A N C E , S A F E T Y A N D

ENVIRONMENTAL ASPECTS

• TRAFFIC DIVERSION PLANS AND RELOCATION

OF UTILITIES

ACTIONS PERFORMED IN VIEW OF EARLY

COMPLETION

Considering the scope of work / complexity / site

conditions and topography, work breakdown structure is

prepared and six teams were deployed simultaneously to

achieve the planned targets.

• Team 1 & Team 2 were deployed simultaneously from

both ends of 2nd level flyover progressively towards the

part of junction.

• Team 3 & Team 4 for 1st level flyover.

• Team 5 for Ramps & utility relocation.

Maintaining constant pace of work with ZERO accident

was one of the major challenge. Following measures

were taken for flawless the traffic management.

• Proper traffic management for smooth / safe / easy

movement of traffic having density of 120 vehicles per

minute during peak hours at junction of 2 national

highways.

• Traffic diversion plans prepared stage wise – for

hindrance free, smooth and safe movement of traffic.

• Close co-ordination and liaising with traffic police.

• IRC Standard barricading were fixed.

• ]Traffic wardens and dedicated safety cell to guide

traffic were deployed.

• Road furniture like blinkers, cat eyes, bollards, etc.

were used for safety of traffic.

Following main challenges were faced during

execution:

1) Identification & relocation of existing utility services.

2) Traffic diversions at various stages.

3) Completion of entire River Bridge within a period of 8

months.

4) Construction of intersection of 1st & 2nd tier flyover at

highly dense traffic movements.

5) Construction of tall pier (20m Height) in single pour.

6) Erection of temporary supporting structure for 20 Mtr.

Height at a junction.

7) Obtaining approvals from Railway Authorities and

construction of ROB.

8) Launching of girder in specified time of block.

9) Construction of entire bridge / flyover / ROB with

ZERO accident.

10) Environmental Aspects.

•IDENTIFICATION & RELOCATION OF EXISTING

UTILITY SERVICES:

Project site was located at very crowded traffic Junction

and residential locality along OLD Mumbai Pune (NH-4)

as well as Pune Nashik Highway (NH-50).Network of

utility services were congested and it was difficult to

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identify since laid long ago.

Following measures were taken to overcome

issues in identifying & relocating utilities:

• Close liaising with all concerned Authorities.

• Cross cuts at specified intervals.

• Identification by using ultrasonic equipment.

• Scheduling of relocation through available space.

• Relocation of utilities in time without disturbing its

serviceability and maintaining progress without

stoppage.

* TRAFFIC DIVERSION:

Traffic diversion during the construction of obligatory

spans of first level flyover through the center span of

second level flyover at Junction and Piers of first level

flyover fouling below the girder of second level flyover

was a difficult task.

Actions Performed:

• Staging of second level girder at intersection is

designed considering obstruction of two piers.

Accordingly, it is erected at site.

• Traffic is diverted from both sides of staging

arrangement and maintained well.

• Obligatory staging is designed for spans of first level

flyover and deployed at site.

* CONSTRUCTION OF TALL PIER (20 MTR.

HEIGHT) IN SINGLE POUR

:: Aesthetical appearance of Pier:

• Form finish concreting in single pour

:: Challenges accepted during execution:

• Controlling heat of Hydration.

• Compaction of concrete at bottom of Pier.

• Sustainability of formwork to withstand hydraulic, wind

pressure as well vibration stresses during concreting.

• Continuous Pouring up to height of 20 Mtr. without

segregation of concrete.

• Constraint of constant moving dense traffic at junction

hence safety of road users and workmen.

• Time management for supply of concrete.

::Actions performed:

• Formwork for starter of pier up to 600 mm height was

accurately aligned with Geodimeter (GPS).

• Reinforcement fixing and tying was completed in

stages of 4.8 Mtr. height progressively with specialized

formwork to have working platform for safety of workmen

and stability of reinforcement.

• Specialized, water tight formwork having modules of

2.4, 1.0, 0.8 Mtr. height was used to have joint less finish.

• Chilling plant is used to maintain the temperature of

concrete below 200 C at the time of pouring.

• The rate of pouring of concrete was maintained at 7 to

8 m3/Hr.

• Formwork of Pier / Pier Cap was wrapped with Hussein

cloth and kept wet by continuous sprinkling of water to

reduce heat of Hydration.

• To ensure compaction of concrete at bottom, high

frequency of vibrators of equivalent shaft length along

with surface vibrators for every 4 Sqm. were used.

• Immediately on completion of initial setting time, the

curing with sprinkling of water was started on the top and

sides of Pier / Pier cap, already wrapped with Hussein

Cloth.

• All Quality Control measures were taken during

concreting to achieve desired strength and form finish of

concrete.

* Temporary supporting structure for 20 Mtr.

height at junction

::Planning of formwork / staging of 96 nos. of spans for

maximum height up to 20mtr. was a challenging task,

since it was to be completed within 26 months

• Formwork of box girder was designed to utilize flexibly

for both first and second level flyover.

• Considering of cycle of 40 days of each span, no.

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• of sets derived so as to complete all spans in 26

months.

• 6 sets of Formwork & Staging consisting of total 2200

MT. Steel structure was to be repeatedly used more than

6 times as per planned scheduled, hence, total staging,

erection & de-erection quantity was more than 13200 MT.

TOWER CRANES:

• The movement of heavy formwork sets as well as

shifting of construction materials, the tower cranes were

preferably used to avoid movement of cranes at ground

level.

*ROB: APPROVALS OF RAILWAY AUTHORITIES

IN TIME

• There were 31 stages to get the approval from Railway

Authorities. This was challenging task to obtain approval

of Railway Authorities within 6 months. We have listed out

all the stages, prepared bar chart considering estimated

time and obtained approval in record period of 6 months.

* ENVIRONMENTAL ASPECTS

::ENVIRONMENTAL MANAGEMENT PLAN (EMP):

EMP consists of the set of mitigation, monitoring and

institutional measures was to be taken during

construction of project for eliminating any adverse

environmental and social impacts, offset them, or reduce

them to acceptable levels. The plan also included the

actions needed to implement these measures

Activities/Stages considered for EMP are listed

as below:

* Mobilization Stage:

• Movements of materials & Equipment to site

* Site Preparation Stage :

• Site Cleaning & Control of Surface Erosion

* Construction Stage:

• Generation of Environmental Pollution

• Dust Emission

• Water Pollution,

• Handling & Control of Construction Wastes, etc.

* ENVIRONMENTAL MONITORING

::Environment Monitoring was done for 3 seasons,

1. Summer Season

2. Post-monsoon Season

3. Winter Season

* “ENVIRONMENTAL FRIENDLY INITIATIVES”

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*ACHIEVEMENTS

• Safety Aspect: - Entire construction activities with

ZERO Accident.

• Architectural Aspect: - Construction of Pier / Pier Cap

in a single pour to have joint less concrete appearance.

• River Bridge: - Completion of Bridge in 8 months.

• ROB: - Obtained approval from Railway Authorities in

shortest possible time of six months.

• Junction Development with modern amenities.

*RESULT OF SAFETY MEASURES EXERCISED

AT SITE

• “First Construction Safety Award 2011-12” on 12th

January 2012 at “International Fair CONSTRO 2012''

• This project is awarded with “Gold Trophy & Certificate

of Merit” under Infrastructure Category.

• Mr. Vikram V. Shenvi, Sr. Engineer- Environment &

Safety has been awarded with special “Certificate of

Appreciation for Special Jury Award for Best Safety

Management Team”

• Zero accident till completion of project.

WE ARE COMMITTED TO DELIVER QUALITY

PRODUCTS WITH SPEED, SAFETY &

SUSTAINABILITY

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