The document outlines the construction project of a new broad gauge railway line between Obulavaripalle and Venkatachalam Road junction, addressing transportation challenges from Obulavaripalle to Krishnapatnam. It details the substructure and superstructure elements, including various structural components like pile foundations, girders, and bearings, as well as the testing methods applied to ensure structural integrity. The project is managed by Delta Construction Systems Private Limited, with detailed references to engineering standards and tests conducted throughout the construction process.

1. Presented By
Harish Korutla
ID No. B111804

2. Contents
 Introduction
 Substructure
 Superstructure
 Miscellaneous Items
 Conclusion
 References

3. Introduction
 As the transportation of goods become too difficult from
Obulavaripalle to Krishnapatnam, Government had proposed new
Broad Gauge (BG) line between Obulavaripalle and Venkatachalam
Road junction-Construction of Rail and Road over Rail Bridge between
Km. 93-95 near Venkatachalam Road junction Railway station
between Guduru and Nellore crossing NH-5 at NH Km. 154/148 and
Railway Km. 155/22-24 in Nellore district in South Central Railway.
 And it is undertaken by Delta Construction Systems Private Limited
Hyderabad.

4.  This project is an extract of new Railway line from Obulavaripalle of
Cuddapah district to Krishnapatnam Port of Nellore district.
 An existing South Central Railway line crossing Obulavaripalle Railway
station is shown in the figure below:

5.  More precisely an overview or key plan can be plotted as follows:

6. Substructure
 Substructure can be defined as the union of structural elements
which are in contact with the ground. The Structural elements of
Substructure are listed and explained below.
 Pile Foundation
 Pile Caps
 Piers
 Abutments
 Pier Caps/Trestle Beams
 Pedestals
 Bearings

7. Pile Foundation
 Noticed that the soft rock exists after two or three layers of soil which
explains the selection of foundation for transfer of super structural
loads coming from the bridge onto the ground safely.

8. Pile Identification

9. Tests on Piles
 To assess the carrying capacity of the casted piles and to ensure the
homogeneity, various advanced tests have been conducted.
 A third party GEOTIES INFRATECH PVT. LTD. have conducted three
tests on the test pile.
 They are listed below:
 Initial Pile Load Test/Kent Ledge Load Test
 Dynamic load Test
 Pile Integrity Test

10. Initial Pile Load Test/Kent Ledge Load Test
 Loading applied on the pile head was measured by volumetric method.
In this method sand bags were arranged on top of the platform which is
made with 8mm thick MS plate. The plate rests on the secondary
beams of ISMB 300. These 27 No’s ISMB 300 was resting on 7No’s of
ISMB 600 and supported by solid bed on either of the pile. The total
dead load available for the pile load test was about 1100MT.

11. Initial Pile Load Test/Kent Ledge Load Test

12. Dynamic load Test
 The basic purpose of high strain dynamic pile testing is to
evaluate pile static capacity and its structural integrity using
measurement of both force and velocity.
 Strain transducers and accelerometers are attached to the test pile.
 Strains induced under the impact of a heavy falling hammer from a
pre-determined height are measured with the help of strain
transducers attached to the pile, whereas accelerometers record the
accelerations generated in the pile. The Pile Driving Analyzer(PDA)
converts strain to force, and acceleration records are converted to
velocities.
 By using measured velocities, they performed trial and error process in
CAPWAP Software and computed forces in order to plot the graph
between measured and computed forces.
 And subsequent results have been found out and assured by the Chief
Engineer or Engineer In charge.

13. Pile Driving Analyzer

14. CAPWAP Software

15. CAPWAP RESULTS OF PILE: P4/8

16. Test results of Pile: p4/8

17. PILE INTEGRITY TEST
 The low strain Integrity testing is a Non-Destructive Integrity test
method for foundation piles for the assessment of potential problems
like cross sectional changes, honeycombing, Physical dimensions,
continuity of pile and concrete quality.
 This testing requires the attachment of the highly sensitive
accelerometer to the pile top with viscous material.
 After hammer impact downward compressive wave is generated
travelling with wave speed “c”.

18. Pile Caps
 Design of Pile Cap is based on the code of practice IS: 2911 (Part 1/Sec2)
– 1979.
 Clear cover 75mm was maintained for Pile Caps by following the notes
specified in drawings. Plan of the Pile Cap is shown below:

19. Piers
 Piers are compression members built as a major part of the bridge to
carry the super structural loads coming from various structural
elements like pier caps, pedestals, girders, deck slab and wearing coat,
wheel axle loads etc.
 Piles are designated as P1, P2, P3, P4, P5, P6, P7, P8. P3, P7, P8 carry
composite girders. P1, P2, P4, P5, P6 carry PSC girders. P2 lies in the
median of the National Highway – 5.
 P2 details are shown in below figure

20. Abutments
 Abutments are the structural elements function for the load distribution
onto the ground and backfill material or earthen embankment with the
help of approach slabs.
 In this project, Abutments are designated as A-1 & A-2.
 While concreting return walls and abutment walls, they’ve provided weep
holes with an arrangement of PVC Pipes covered with geotextile material
at one end to counteract clog formation.

21. Pier Caps/Trestle Beams
 Pier Caps generally treated as platforms for supporting pedestals,
bearings, girders over it.
 Pier Caps are also known as “Trestle Beams”.
 P1, P2, P3 trestle beams carry NH-5 composite girders. Similarly P7, P8
trestle beams carry Railway Span composite girders.

22. Pedestals
 Pedestals act like platforms for the placement of suitable bearings.
 M40 grade of concrete has been used and 30mm of clear cover has
maintained.
 Supports for placing concrete are of special type (Wooden Box type
material) and they were arranged.

23. Bearings
 The bearing is an element of superstructure which provides an interface
between the superstructure and substructure.
 This interface is vital because superstructure undergoes dimensional
changes and deformations due to various factors which are listed as
follows:
 a) Thermal expansion/contraction
 b) Elastic deformation under live load
 c) Seismic forces
 d) Creep and shrinkage of concrete
 e) Settlement of supports
 f) Longitudinal forces – tractive / breaking
 g) Wind loads.

24. Types of BEARINGS
 i. Free Float Bearing of Capacity 248MT
 ii. Pin Metallic Guided Bearing of Capacity 18MT
 iii. Pin Fixed Bearing of Capacity 93-114MT
 iv. Free Float Bearing of Capacity 189MT
 v. Slide Guide Bearing of Capacity 178MT
 vi. Slide Guide Bearing of Capacity 189MT
 Pin Metallic Guided Bearing is shown in below figure.

25. Superstructure
 Superstructure can be defined as the union of structural elements
which are not in contact with the ground, in other words it’s the
structure lies in the space with the support of substructural elements .
The Structural elements of Superstructure are listed and explained
below.
 Girders
 Deck Slab

26. Girders
 Girders are structural members carry super structural loads and
distribute to the substructure, from then, to the ground safely.
 PSC Girders
 Composite Steel Girders
 Cross Girders/Diaphragms

27. PSC Girders
 Firmly, Precast PSC Girders are casted at the site.
 After curing for 15days, stressing has been done and accordingly
evaluated elongation so as to check with the specifications provided.
 Arrangement of the reinforcement and Cable profiling are shown in the
below figure.

28. Composite steel Girders
 Composite girders are manufactured in the workshop namely PMG
Structural’s Limited.
 As per the designed drawings, composite girders are manufactured and
shipped to the site.
 Before going for the manufacture of composite girders, activities
included like materials’ tests such as Physical dimensional check,
Chemical analysis, Mechanical testing and etc.
 For the erection of composite girders, DTI Washer was used in the
process of tightening the bolted connection.

29. Direct Tension Indicators
 The Direct Tension Indicators are special type of washers with
indentations which get pressed when the tension is applied.
 DTIs are very good method of ensuring that the bolts are tightened
properly, and shall be preferred over plain washers.
 Measuring the amount by which the indentations have been pressed
indicate if the bolts have been tightened to the desired tension level.

30. Check for Tightening
Number of Indicator positions Minimum number of Feeler gauge
refusals*
4 3
5 3
6 4
7 4
8 5
9 5
* No more than 10% of the indicators in a connection bolt group shall exhibit full
compression of the indicator.

31. cross Girders/Diaphragms
 Cross Girders/Diaphragms act like tie beams.
 Intermediate Diaphragms
 End Diaphragms
 Below picture is representing reinforcement inside an End Diaphragm.

32. Deck Slab
 Shear studs are provided on composite girders so as to prevent the
sliding away of concrete.
 Ponding method of curing has been implemented for deck slabs, it’s
showed in the following figure.

33. Miscellaneous Items
 Expansion Joints
 OHE Masts
 Drainage
 Walls

34. Expansion joint
Expansion joints are meant for the allowance of thermal changes in the
whole structural elements.
Specifications and achieved conditions are overlapped for assurance.

35. OHE MASTS & dRAINAGE
 Over Head Electrical Masts are provided for carrying electrical wires
and supply power.
 For every pier, there is a provision of OHE Masts.
 For that purpose, an extra cantilever portion is provided to facilitate the
necessity of electricity.
 Drainage: To facilitate the drainage, drain spots are also mentioned in
the drawing. While concreting the deck slab it is ensured that to
provide PVC pipes.

36. WALLS
 Reinforced Parapet Walls
 Reinforced Ballast Retaining Walls

37. Conclusion
 Basically bridge is catalogued into two categories named as super
structure and sub structure.
 Substructure consists of elements like foundation, columns or piers,
pier caps, pedestals, bearings. Whereas Superstructure consists of
structural elements like PSC girders, Composite girders, Cross girders,
Deck Slab and miscellaneous items. As per the drawings, Work has
done in a fully management plan.

38. References
 Maps from Survey of India
 L & T Ramboll Consulting Engineers Limited Designed Drawings
 Sanfield (India) Limited Bearings’ Drawings
 Geoties Infratech Private Limited Pile Test Results
 Contract Agreement for ROR Site Nellore
 Bridge Bearings for Railways Document
 IRC 83 Part 3 – Specifications for Bearings
 International Journal of Current Research of Academic review
 IS 14268:1995 Uncoated Stress Relieved Low Relaxation seven-ply strand for prestressed
concrete
 Clause 8.5.6 of EN 1090-2
 Annexure J of EN 1090-2
 Clause 8.5.4 of EN 1090-2
 Research Development and Standards Organization (RDSO) Guidelines for Railway
Bridge
 Indian Roads Standards Substructure code
 Indian Roads Standards Superstructure code
 www.piledynamics.com
 RVNL Flyover Bridge Final Drawings
 Information from Site Reports
 Site Pictures at different stages of Works

39. THANK YOU