Its is the third Model that has been Developed in India.

1. PRECAST SIX LANE FLYOVER
Presented By-
15491A0108
15491A0106
15491A0109
15491A0107
15491A0104
15491A0101

2. CONTENTS
1. Abstract
2. Purpose of the Project
3. Introduction
4. Company overview
5. Site Location
6. Description
7. Quality Lab test
8. Batching Plant
9. Casting Yard
10.Substructure
11.Superstructure
12.Stressing
13.Conclusion

3. Abstract
The Aim of this investigation is provision of spines & wings. Flyover is
high level road bridge .There is a necessity to construct a road over bridge
in ongoing bypass. The Flyover starts at Bhavanipuram Indian oil petrol
bunk &ends besides Rajiv Gandhi park. Since Flyover connecting
Chennai- Kolkata(NH-16) & Vijayawada –Hyderabad (NH-65).Four
laning of NH-9 (1.4km) with NH-5 (3.6km) and 6 lane elevated flyover
(1.975km) from Bhavanipuram to kanaka durga varadhi. Length of the
project is 5.28km. The agreement was signed on 28th December 2015
Contract value is 282.4 cr.

4. Purpose of the Project
• The traffic problem worsens during festival season. The flyover is a solution for the
monitering traffic.Constructing a flyover or bridge over river Krishna or a flyover on the
existing road. Chief Minister N. Chandrababu Naidu has directed the officials to take it up on
priority.
• The main purpose of the project is to control traffic problems.

5. Introduction
FLYOVER:
A grade separated structure connects road at different levels for purpose of
reducing vehicle congestion.

6. To make road easily accessible for day to day life.
The project deals with precast six lane flyover of 2.6km.
It is an elevated flyover of cantilever structure.
It is the third model that has been developed in India.

7. Company Overview
 It is a private incorporated on 27 March 1987.
 It is involved in building of complete construction or parts therefore; Civil
engineering.

8. Site Location

9. Description
Segmental Bridge:
A segmental bridge is a bridge built in short sections called segments.
The bridge is made up of concrete that is precast concrete.
Built at another location & then transfer to final location for placement in the full structure.
Six Lane Flyover:
The design of the flyover is very complicated it has almost 6-8 curves.
The project design includes to vehicular underpasses & pedestrian underpass, besides a
subway infront of the Durga ghat.

10. Quality Lab Tests
BASIC INGREDIENTS OF CONCRETE
• Cement –It is the basic binding material in concrete
• Water- It hydrates cement and also makes concrete workable.
• Coarse aggregate – It is the basic building component of concrete.
• Fine aggregate- Along with the cement paste it forms mortar grout and fills the voids in the
coarse aggregates.
• Admixtures – They enhance certain properties of concrete e.g. gain of strength, workability,
imperviousness

11. VARIABLES IN MIX DESIGN:
• Water/cement ratio
• Cement content
• Relative proportion of fine & coarse aggregates
• Admixtures
QA/QC LABORATORY TESTS
• TESTS ON AGGREGATE:
• Fine aggregates - sieve analysis
• Coarse aggregate – specific gravity test & Impact test

12. TESTS ON CONCRETE:
• Slump cone test
• Compression test
• Compaction test
• Water absorption test
TESTS ON CEMENT:
• Initial setting time test
• Final setting time test
TESTS ON SOIL:
• CBR test
• Compaction test
• Core cutter

13. Batching Plant
Batching plants are machines which mix the different ingredients of concrete homogenously to
produce a perfect mix of concrete. Schwing Stetter India manufactures a wide range of batching
plants that can be broadly classified with respect to their design, batch size, material storage
(Aggregate Storage), and mixer technology

14. COMPONENTS OF BATCHING PLANT
CEMENT SILOS
It is used to store cement with maximum validity for 90 days
The plant has 6 types of silos, 5 silos - 100T capacity and 1 silo - 60T.
WATER JAR
It is used to store water for mixing of concrete
Capacity is about 200lts
ADMIXTURE JAR
Used to store admixtures of both FOSROC and alccofine but in different jars
Capacity is 10 kg

15. CEMENT JAR
• From silos cement is stored in cement jar
• Capacity 500kg
•
AIR COMPRESSOR
• 90% of the work is done by using air compressor
• The motor runs at the speed of 2800RPM
CONTROL CENTER
• The entire plant is controlled digitally
• It requires 2 operators, 6 labour, 4 drivers, 4 helpers
AGGREGATE BINS
• It is divided into 4 parts, 2 for coarse aggregate i.e., for 12mm and 20mm another 2
for fine aggregate

17. MATERIALS USED
Cement : OPC 53 grade cement from KPC
Fine aggregate : Natural sand from Krishna river
Coarse aggregate : 20mm & 12mm from Kondapalli quarry
Admixture
There are 2 types of admixtures
FOSROC
FOSROC is used for quick strength in 24 Hrs
It is of 2 grades FOSROC 400 and FOSROC 550
FOSROC 400 is used in M60 mix and FOSROC 550 is used for M15 to M45 mix.
ALCCOFINE
1203 grade from Ambhuja cements is used for quick setting of concrete
It is used in stitch concrete

18. Casting Yard
A casting yard is a confined place where all concrete structures like segments parapets I – girders etc
recasted or manufactured shifted to there stackyard, cured for the specific period and shifted to the
working site after they required there strength.
Casting is done by two methods
a) Longline method .
b) short line method.
Longline Method:
oAll segments of a span are manufactured on a fixed belt with the form work.
oShows profile of real structure at one time.

19. Short line Method:
• In short line method casting of each spine is done by placing in mould.
• The bed of casting spine is placed as per required alignment.

20. Sub structure
Components of Substructure
• Pile
• Pile cap
• Pier
• Pier cap
Purpose of a Pile Foundation:
• To transmit a foundation load to a solid ground.
• To resist vertical, lateral and uplift load.
• The diameter of each pile is 1.2 m.
• Height of pile cap is 1.8m

21. Methodology
• Dredging - Soil pumped from middle of the river to bank
• Auger - Sandy soil
• Tripod (winch) boring - Hard strata
• Pile alignment is maintained by survey techniques ( reference points,
hypotenuse)

22. |Number Nomenclature Dimensions
1 Type 1 2.5x2.1 m
2 Type 2 3.4x2.1 m
3 Expanded piers 4x2.1 m
PIER AND PIER CAP
•There are three types of piers :
•Shape : Ellipse
•Grade of concrete : M60.
•Max. height : 35m
•Min. height : 21.73m
•Reinforcement grade : Fe500
•Extended piers : 6 at P24 & P25, P34 & P35, P40 & P41
•Ht. of pier cap : 1.81m

24. Super Structure
SPINE:
• Spine is one of the segment in the segmental flyover.
• Spine rests on the pier cap.
• In between the two piers there are 16 spines.
• In this 16 spines 12 spines are of same dimensions.
• Spine consists of two lanes having each of width 3m.
• At the top and bottom of spine internal cables are arranged.
• In some of the segments deviating walls are constructed to increase the
strength.

27. PROFILING
• Profiling is done by placing pipes into reinforcement of the spines which allows strands to
pass through them.
• It involves in adjustment of the reinforced bars so that the pipes will accurately fit with
bulkets.
• Dia. of pipes 97mm-124mm.

28. SHUTTERING
• Shuttering is nothing but providing bulkets and side shutters to the spines for concreting
• There are many types of shuttering's, here we use trolley shuttering's
• The bulkets are supported by turn buckles
• Man power -8 workers
• Equipment needed
• Welding machine
• Rod cutters
• Gantry

29. STAGES IN CONCRETING:
• Stage-1 : At bottom of the segment the boom pump is inserted (through the
temporary openings provided on top of the shuttering) for concreting
• Stage-2 : In this stage the concrete is pumped into the side walls
• Stage-3 : Roof concreting is done by closing temporary openings provided
earlier
CURING
• It is done with FOSROC curing compound, which contains 2.6%of wax.
• Curing is done for 3 days before deshuttering

30. DESHUTTERING
• Removing of bulkets and all the side shutters used for concreting is called as
deshuttering.
• It is done for concrete having strength of 30Mpa
• The spine can be lifted, if the concrete strength reaches to 60Mpa.

31. WINGS:
• Wings are also one of the segment in the segmental flyover.
• These wings are connected to the spine at each end.
• These wings are of 4 lanes.
• The width of wing is 8.97m for straight sections and9.87 for curved sections.
• In this HDPE(high density polyethylene) ducts are used in this prestressed steel is used.
• At the end of the wings guide cones are placed to distribute the stress.
• These segments are transferred to site by using girders.

33. PROFILING OF WINGS
• Cable ducts (HDPE pipes) are provided in between the reinforcement.
• The centre to centre distance between the cable ducts is 390 mm.
• The clear cover of cable ducts should not be less than 75 mm
• Size of cable duct is 56mm-90mm

34. WINGS REINFORCEMENT
• Reinforcement is arranged in both longitudinal and lateral directions as per the drawings.
• It takes 1 day to complete reinforcement of wings and the concreting is done on the same day.
• Weight of the reinforcement is 1.6T-2.5T

35. CONCRETING
• It is done in two stages
• Stage-1 : wing beam (tapered)
• Stage-2 : roof
• M60 grade is used in concreting of wings.
• Total quantity of concrete required -7 cum
• For every concreting layer we use needle vibrators to compact the
concrete.
• Grout pipes are also placed near the crash barrier for grouting.
• Concreting of crash barrier is done at site

36. CURING
• Curing is done for 3 days
• Then the wing segments are lifted using 50T gantry gridder and placed in
stacks
• After lifting, the curing is done for 8 days

37. Stressing
STRESSING OF SPINES
• Pre stressing of spines is done after wet matching of spines.
• Stressing is done with multi-jack system.
• Carried out in 2 stages.
• First stage of tensioning is done once after placing all spines.
• Second stage of tensioning is done after attaching wings to spines

38. STRANDS
There are 3 types of strands used for spine ducts
• 22 strands
• 19 strands
• 12 strands
• The diameter of strand is 15.2mm
• Capacity is 8160 N/mm^2
Hydraulic Jacks
• There are 2 types of jacks
Mono hydraulic jack
• It is used for stressing wing segments from S2 to S8
Multiple hydraulic jack
• Used for stressing spines and S1 wing segments

39. STRESSING OF WINGS
• Stressing of wings is done in 2 stages.
• In first stage 5 ducts are stressed, out of which 3 are from one side and 2 from
opposite side.
• After the stitch concreting second stage of stressing is undertaken where 2
ducts (5strands in each) are stressed as per the convenience

40. Conclusion
After the completion of this Project, Flyovers would benefit the commutators
going to Bhavanipuram to Kanaka Durga Varadhi. Anyone can travel from Bhavanipuram
Indian petrol bunk to Rajiv Gandhi Park without facing heavy traffic jam in between. This
Project will prove a great asset to mankind as it will prevent chronic jams.

41. Thank You
For Your Attention…..