Presentation about Under-construction Mahakali Bridge Project in 3 days Training Program on Construction and Quality Control of PSC Bridges चैत्र ११,१२,१३ ,२०७७ organized by Federal Road Supervision and Monitoring Office, Surkhet

2. LOCATION PLAN

3. 1.Name of the Project
Ministry of Physical Infrastructure and Transport
Department of Roads
Road Improvement Project
Mahakali Bridge project
2. Objective
Transportation of People and Goods from Mahakali
Motorable Bridge
3. Project Cost
Approximate 4300 Million
4.Funded by
Nepal Government
5. Contractor’s Details
M/s Kumar – CFEC JV, Mahendranagar-18, Kanchanpur
Nrs. 3,279,334,491.40 including VAT

4. 6. Date of Start
06th September 2017
7. Date of Completion
27 February 2022
8.Location
5.6 KM Downstream from Sharada Barrage
2.6 KM Upstream from Suspension Bridge
9. Approach Road Details
Left Bank – H01 (E-W Highway)
Right Bank – Across Indian Boarder upto NH125 (Target)
10. Classification of Road
Asian Highway, Class I (Four Lane) Standard
11. Total Length of Bridge
800 M
12. No. of Span
16
13.Bridge Width
23.87 M
14. Width of carriageway
7.5 m*2
15. Cross slope
2.5%(Unidirectional)

5. 16. Foundation
Pile Foundation(408 Piles)
17. Substructure
Abutment –Rectangular
Pier-Circular
18. Superstructure
Pre-stressed Concrete Box Girder (Double Cell Box)
Box Girder Depth 2.75m
19. Type of Bearing POT/PTFE
20.Grade of Concrete
In Superstructure M45
In SubStructure M35
In Foundation M35
21.Grade of Reinforcement Steel
Fe 500

6. 22. Present Status
(a) Mahakali Bridge
- 408/408 Piles Completed
- 17/32 Deck slab completed
- Substructure All (Except Abutment A1/Chadani side)
-15/32 Prestressing /Grouting work completed.
23. Physical Progress
- 60.22% upto 21th February 2021

7. Agenda
Layouting
River Diversion
Construction of Different components of Bridge
Piles ,Pile caps, Pier , Pier caps ,Deck slab
Quality Control & Tests
Concrete Mix Design
PIT &PLT
Prestressing and Grouting Works
Photographic Presentation

8. Layouting
After the Construction Survey , required Control
points are established with reference to Master BM
within permissible error limit.
The location of each structures are worked out in the
XYZ co-ordinate format
Control of
Horizontal position -By TS
Vertical position- By Level Machine

9. Layout Coordinates for Piles @MRB
Layout Points are always verified
with Measuring Tape as well
Layout Co-ordinates from Cad

10. Construction Survey

11. During Work

12. Control Station

13. Boys! Take
care about
Prism
Constant

14. River Diversion
Very important for works in River like Mahakali
Effective diversion can make the work very easy
Helps in Reducing water current nearby piling and
other structures to be constructed
Need to be very careful during site selection for
diversion

15. Diversion works(3 km u/s of Bridge
alignment

17. Fluctuation in water level at Mahakali River due
to unnoticed opening of Barrage gates

19. Construction of Different
components of bridge
A. Piles
 Type (Bored Cast Insitu)
Diameter=1200 mm
Length = 28 m Pile
20 m Pile

20. 1.Pile Boring
 After the proper layout Pile Driving Starts

21. Insertion of Casing(Temporary)
As per Dor Specification for Road and Bridges,2073

22. Pile layout Drawing Adopted

23. Bentonite
tank
•Bentonite be soaked for 24 hrs before use
•Level of driling fluid to be maintained 2 m above water level
•Bentonite consumed at MRB piling : For 1400 l=15 bags of Each 50 kg wt
Bentonite suspension for Stabilization of Bore holes

24. Checking Density of Bentonite at Site
•Density of of bentonite suspension shall be 1.03 to 1.10 g/ ml
•Density may rise to 1.25 g/ml
•To be brought down below 1.25 g/ml before concreting

25. Depth Confirmation
1. By Piling Rig Meter
2. By Insertion of Rope
attached with metalic
plate

26. 2.Rebar Cage Installation
•Staggered Lap splices for avoiding
more than 50% lap at the same section
•Master ring(16 mm) at required
spacing
•Sufficient Cover blocks

27. Rebar cage for Piles
Cover block maintaining 75 mm cover
Spacing : Vertical=100 D(D=dia of vertical bar)
: Horizontal: 25d(d=dia of horizontal bar)
Is 2911/Part 1-Sec 1
1.5 m

28. Rebar cage making

29. Shifting of Cage to Piling Location

30. 3. Concrete works
•After proper cleaning of Bored hole and
bentonite density brought down to 1.25
g/ml, Concrete works done.

31. Daily Pile Record Sheet

33. As per Dor Specification for Road and Bridges,2073

34. Helpful Notes
 Sufficient head to be given during concreting
 Plug to be provided to avoid contact between concrete and
the bentonite fluid in bore hole
 Provision of spherical ball for blocking tremie pipe opening
in the beginning
 Volumetric Check timely ( Gives idea about ht and tremie
pipe removal during concrete)
 Provision of depth checking rope for confirmation of Level
of Concrete
 Ensure the concrete is done at least 1.5 m above cutoff level

35.  Provisions of Longer casing in high current area &
high water table (Here upto 11 m used )
 Use of Anti wash admixture improves the viscosity of
concrete and prevent segregation during pile
concreting( At Mrb 0.5% solid by wt of cement)
 Workability of concrete to be taken into account
 Adopting sequence during piling is very imp(
Vibrations of machines –strata)

36. SomeProblems encounterd
&Solved
 Pile collapsed
 Bucket stuck
 Problem of High water
current
 Redone with bentonite im
Provement
 Gone for redesign
 11 m linear and bentonite
improvement

37. Design Change Pile(P6)
 Bucket Stucked
 Consulted designer

38. Platform for site safety
Platform

39. Construction of Different
components of bridge
B. Rafts & Substructure
 After PIT and PLT , the work
above pile done

40. Pile Breaking

41. Preparation for PCC work

42. Reinforcement/Form work

43. 1st Pile cap Concrete work@MRB

44. Completed pile cap

45. Last Bucket For Pier cap
2077/11/27

46. Helpful Notes
 Control of horizontal and vertical position of Pier Shaf
at each stage
 Workability of concrete
 Ensure Proper compaction

47. Construction of Different
components of bridge
C. Superstructure ( Soffit , Web
Deck slab and other)

48. Section of Box Girder Bridge

49. Falsework & Formwork

50. Design of Falsework is most
 Section of Falsework

51. Result of Poor Falsework Design

52. Approved Falsework Dwg

54. •Proper foundation bed level to be prepared
•Proper compaction of bed

55. Formwork for Soffit slab

56. Cleaning of Formplates

57. Sheathing Duct Profiling work
 The profiling data and
note s mentioned in
design dwg need to be
followed strictly
 As far as possible avoid
joints( If in case use of
coupler need to be
used)
 Avoid damage
sheathing duct
 Profiling affects
Prestressing !!!

58. Ready for Soffit slab concrete

60. Soffit slab concrete on progress!
Be careful at
the end
block region
Vibrators need to be away from Sheathing duct otherwise Puncture takes
place

61. Concreting completed

62. De-shuttering of Web in action

63. Deck slab Formwork being ready
 Ensure
enough props
are used
based on
design load it
needs to bear
above them

64. Deck slab Concrete work(M45/20)

65. Problems Encountered
 Soution???
 Solved!

66. Helpful Notes
 Workability of concrete
 Ensure Proper compaction
 Take care during end block concrete work(Highly
stressed region)
 Adopt falsework design drawing
 Be careful during profiling work
 Bearing and Expansion joint installation

67. Quality Control and Tests
At Laboratory

68. Mix Design
 Based on IS 100262:2009

73. Concrete at Mahakali Bridge

74. At Site

79. HDPE Pipe insertion inside duct During
Concrete

80. Joint Sampling

81. Joint Sampling

83. Third Party tests
 Bearing Test at Manufacturer

85. LRPC Test at GTC Butwal

86. NDT Test at site

87. Calibration of Equipments

89. Pile Load Test
& Pile Integrity Test

90. Pile Load Test
 Carried out with
reference to Is 2911 Part
IV

92. Load test Summary at MRB

93. Pile Integrity Test
SETUP

94. Velocity vs Length Graph

95. Profile Diagram

96. Prestressing Work
 Based on DoR
Specification for
Road and Bridges
 2 Stage stressing

97. Stressing completed
Hogging at Centre

98. Strand cut off after checking of 24
hr slip(not greater than 3 mm)

99. After the successful Prestressing of
1st Bridge @Mrb

100. Grouting Work
 Proportion
22-24 ltr per 50 kg
bag of cement(1
packet grouting
admixture)
 Take care of
temperature

101. Ready for Grouting

102. Problems encountered!
 Sheathing duct of
another bridge choked
due to grout !!!
 Solved at the end
 Adopt Precaution
measures