VOCATIONAL TRAINING REPORT STUDY ON CONSTRUCTION OF FLYOVER OF BRPNNL, PATNA Under guidance of: Er. Arvind Kumar Project engineer BRPNNL, Patna

1. VOCATIONAL TRAINING REPORT
STUDY ON CONSTRUCTION OF FLYOVER
OF BRPNNL, PATNA
COSTRUCTION OF FLYOVER FROM
MITHAPUR TO CHIRIYATAND
Submitted by- Under guidance of:
Vishal Prakash Er. Arvind Kumar
Enrol no.-CIV/93/13 Project engineer
Reference no.- NIT/T&P/15/159 Dt.01.10.15 BRPNNL, Patna
National institute of technology, Srinagar

2. ACKNOWLEDGEMENT
I would like to express my deepest appreciation to all those who
provided me the possibility to complete this report . A special
gratitude I give to project manager Er. Arvind Kumar,( BRPNNL) ,
whose contribution in stimulating suggestions & encouragement,
helped me to coordinate my project especially in writing this report.
Furthermore I would also like to acknowledge with much
appreciation the crucial role of Er. Tanweer siddique(Bridge), Er.
Rishu Singh(Q.S), Er. Ashish Kumar (Survey) and S.P. Singla
construction Pvt. Ltd. Staffs for best possible guidance regarding the
Project.
Lastly, I would like to appreciate the efforts made by BRPNNL, Patna
for providing the professional experience to the us.
Date: 22/01/2016 VISHAL PRAKASH
Place: Patna

3. BIHAR RAJYA PUL NIRMAN NIGAM
LIMITED, PATNA
CERTIFICATE
This is to certify that the project named “Study on
construction of Flyover from Mithapur to chiriyantand”
submitted by Mr. VISHAL PRAKASH Enrol no.- CIV/93/13 in
partial fulfilment of the requirement for Bachelor of
Technology Degree in Civil Engineering at National
institute of technology, Srinagar
And this work has not Plagiarized from elsewhere to best of
my knowledge.
Date: 22/01/2016 Er. Arvind Kumar
Project Engineer

4. CONTENT
S.NO TOPIC PAGE NO.
01. INTRODUCTION 05
02. CONSTRUCTION
DETAIL
06
03. EXECUTION OF
PROJECT
07
04. SURVEYING 08-09
05. FOUNDATION 10-13
06. SUBSTRUCTURE 14-26
07. SUPERSTRUCTURE 27-34
08. SPECIFICATIONS 35-36
09. CONCLUSION 37
10. REFERENCES 38

5. INTRODUCTION
BIHAR RAJYA PUL NIRMAN NIGAM LIMITED, PATNA(BRPNNL)
was established on 11th June 1975 as Govt. Company.
The recent project , flyover from “mithapur to chriyantand” is
also in construction under BRPNNL .
It will reduce the Traffic problems . In Patna due to excess
vehicles and poor traffic system and poor road space i is
necessary to construct flyovers.
The Flyover is 2x2 lane of carriage way 5.5m from Mithapur
R.O.B to chiriyantand via station road (854m. Elevated +207m
ramp) in Patna.

6. CONSTRUCTION DETAILS
Project title Construction of flyover (2 lane and
1 lane) carriage way (5.5m) from
G.P.O golembur to Chiriyatand
flyover via station road
Project estimated cost 150 crores
Contractor S.P. Singla constructions Pvt.Ltd.
Consultant Stup Association with treetek
Client BRPNNL, Patna
Site Location Station Road

7. EXECUTION OF PROJECT
 Sequence of construction:
1. Surveying
2. Analysis and design of the structure
3. Piling
a. Drilling
b. Pile cap Construction
4. Construction of Pier shaft and Pier cap
5. Construction of Pedestal and seismic stopper
6. Construction of segments and/or girders
7. Launching and gluing of segments
8. Construction of road over bridge

8. SURVEYING
TOPOGRAPHICAL SURVEY:
Topography is used to determine the position or any point in
both the horizontal and vertical coordinates( Latitudes,
Longitudes, Altitudes).
Survey includes Reconnaissance. Then
various maps are studied and then detailed
is done by Total station and layouts are
given on AutoCAD.
With the help of this total space for the
construction of the flyover ,no. Of lanes and
total carriage are decided.

9. TRAFFIC SURVEY:
Is done carry out design improvement traffic system and
management. Traffic forecasts predicts the future traffic levels
on the road. In this flyover design is so made to meet for next
25 yrs.
TRAFFIC MONITORING:
Traffic control includes CCTV and other means for monitoring
traffic by local and state roadways to manage traffic flow and
providing advice concerning traffic congestion.
TRAFFIC CONTROL:
Traffic controllers(T.C) usually known as Lollipop men shows
the their Stop/Slow sign known as STOP. A camera is also
installed to detect the traffic rule violations, including
speeding of vehicles.

10. FOUNDATIONS:
Foundations are the structures which are constructed below
existing ground level. It sustains the loads coming from the
sub structures and superstructures.
Bridges had to carry a big load so PILE FOUNDATION are
preferred.
It is a type of foundation which where good soil are at the
depth of 10-15m or soil having low bearing capacity.
In this flyover Group of piles drilled for piling:
for P1 to P14- 10 Piles (140 nos.), for P21, P23, P24, P26, P27,
P29, P30, P32,33& P21A- 4 Piles(40 nos.), for P22, P25, P28,
P31, P22A- 6 Piles(30 nos.), P16 to P19 – 8 Piles(32 nos.)
Total nos. Of piles =242 piles

11. PILE FOUNDATION
All piles have Dia. =1200mm
Depth =25m (except for P1A, P1B, P1D which have 30m piling)
M35 Grade of concrete
Piles are structure that are made up of steel, concrete, timber.
They are used to build pile foundation, and use of piles is
necessary to ensure safety.
• PILES are divided
in given category:
Steel
piles
Concrete
piles
Wooden(
Timber)
piles

12. CONCRETE PILES
In this flyover ,Piles used are Concrete cast in-situ piles.
Types of Concrete Piles:
PrecastPiles
These are
prepared by using
ordinary
Reinforcements &
they can be
octagonal
These Piles are
casted to any
Length& cured.
Precisepiles
These are
Prestressed by
use of high
strength steel
cables. Ultimate
Strength= 260ksi.
After curing ,the
cables are cut,
thus producing
high compressive
force on piles.
Castin-situpiles
Piles are built by
making hole in
the ground and
then filling it with
concrete.
Two types – a)
Cased, b)
Uncased

13. PILE BORING:
Digging in ground for strong foundation is Pile Boring. For
excavation on top soil 2-3 m an instrument named AGAR is
Placed on the top of the digging machine.
Liner is used to maintain the stability of the soil.
SOFT GROUND DIGGING HEAD:
It is being made for digging clay and it is made of heavy duty
high carbon. It is being is done in 3 phases:
A) EXCAVATION- Digging is done by Auger Machine( MAT) up to
28m. After digging flushed Bentonite to prevent the bore hole
from collapse and installing the bottom section of temporary
casing in ground by oscillating and jacking.

14. B)CONCRETE PLACEMENT:
Concreting is done by transit Mix Truck and it has got ability
to take 7 cubic m of concrete which are casted in foundation
and settled by TREMIE Pipe.
The pile shaft will be concreted by underwater Tremie
technique the pipe is inserted to the bottom of pile leaving
cover of “500mm”. Concrete will be poured by tremie pipe by
using concrete skip.
C) INSTALLATION OF REINFORCEMENT:
After completion of concreting, dowel bars of required length
and nos. Will be installed to pile shaft and down to the
predetermined level before extraction of bottom steel casing.
Reinforcements is done by steel, cage and Liner.

16. SUBSTRUCTURE
Substructure Pier cap
Pier shaft
Pile cap

17. Pile cap:
• Formation of pile-
pile cap= R.L of existing ground level-cut off
level
Pile cap is formed by combination of pile and
then binding the steel followed by shuttering
• Dimension of pile caps-
for P1 to P15:
length= 16m, breadth=5.2m, height=1.8m
for P16 to P19:
length= 12.4m, breadth= 5.2m, height= 1.8m
for P21, P23, P24, P26, P27, P29, P30, P32,
P33, P21A, P20A, P23A, P20
length=breadth= 5.2m, height=1.8m
for P22,P25, P28, P28, P31, P22A
length= 8.8m, breadth= 5.2m, height= 1.8m
After piling
completion, soil is
excavated for
construction of pile
cap.
For proper pile cap
P.C.C. Is provided for
separation from
mud. At site 75mm
thick PCC is carried
out for control over
seepage.

18. • Reinforcement steel in Pile cap
• Grade of concrete used
M35
S.no. BARS
1. 20mm @140mm c/c
2. 16mm @140mm c/c
3. 32mm @90mm c/c
4. 32mm @180mm c/c
5. 16mm @180mm c/c

19. PIER SHAFT
A pier shaft is a raised structure provided mostly at the centre
of the pile cap which supports the structure and transfer the
several types of load to the foundation.
DIMENSION OF THE SHAFT:
length= 2m, breadth= 2m, height=
and length= 1.5m, breadth= 1.5m, height=
REINFORCEMENTS IN SHAFT:
S.no. BARS
1. 4 sides 17 NOS. 32mm
2. 4 sides 10mm @100 c/c
3. 4 sides 10mm @200 c/c
4. 16mm @100 c/c
5. 12mm @200 c/c
6. Links 10mm @200 c/c

20. PIER CAP-
Pier caps are the topmost structure of the substructure. Above
these the superstructures (segments & girders) are placed.
DIMENSIONS OF PIER CAPS:
For P1 to P14: Length= 6m, Breadth= 3.3m
For P23, P26, P29, P32, P33, P20A : Length= 5.4m,
Breadth= 2.8m
For P21, P24, P27, P30, P31, P21A : Length= 5.4m, Breadth=
1.9m
For P15, P19 : Length= 11.4m, Breadth= 2.8m
For P16 to P18 : Length= 11.4m, Breadth= 2.4m
GRADE OF CONCRETE FOR CASTING
M 35 Except pier 17 ,where M 40 is used.

21. REINFORCEMENT USED IN PIER CAP
S.no. BARS
1. 12mm @150 c/c
2. 25 nos. 32mm ,top bar
3. 2*5 16mm
4. 12mm @150mm c/c, LV bar
5. 17 nos. 20mm, hunch bar
6. 25mm @125 c/c, Loop
7. 5 nos. 16mm @125mm c/c, Ring
8. 3 nos. 16mm @200mm c/c, Ring
9. 12mm @150mm c/c, bottom bar
10. 24 nos. 20mm @435 c/c in four layers, 6 in each layer

23. BEARINGS, PEDESTALS, SEISMIC STOPPERS
After the accumulation of all the reinforcements in pier cap a
surface is formed over which Bearings, Pedestals and Seismic
stoppers are provided as per the design.
Seismic stopper: The current designs of seismically designs
as a second line of defence. These structures allow
development of in-service moments of the deck, without
transmitting loads on pier and foundation, while during
earthquake they resist the entire seismic action.
Height of stopper= 1.2m
LV bars are used of 400mm
& 700mm ,16mm dia.

24. PEDESTALS AND BEARINGS

25. DIMENSIONS :
• Pedestal: Length= 700mm, Breadth= 700mm, Height= 500mm
• Bearing: Height= 137mm
A bearing is an element of superstructure which provides an
interface between superstructure and sub structure. This is
important because of the deformations and dimensional
changes in superstructure due to Thermal expansion, seismic
forces, wind loads etc. & here use POT PTFE bearing
REINFORCEMENTS :
A mesh of dimension 750mm*850mm is used inside pedestal at
20mm and 100 mm from the top.
8mm @75mm c/c and12mm @100 c/c

26. MAKING OF PILE AND PIER CAP
PROCESS-
 Messing of Pile caps, pier shafts & pier caps by different
reinforced steel bars.
 Welding by Arc welding method.
 Shuttering and then casting(concreting).
CONCRETING OF STRUCTURES
Concrete is a composite material made up of mainly cement,
water and aggregates in definite proportion as per the grade
of the concrete to achieve the desired physical properties.
After casting of the structures curing is done.

27. CURING OF THE STRUCTURE:-
For attaining the full strength of the concrete i.e.
Compressive strength curing with water is properly done on
the casted structure. It takes almost 28 to 30 days for a
concrete structure to attain its strength and durability.

28. DIA. AND DEPTH OF THE BORE HOLES:
• Diameter of the pile =1200mm
• Depth =25m (foundation level)
• Lap length =50D
• Reinforcements : 18 nos. 20mm dia.
& 18mm @150c/c
The 25m of depth consists of following
4 layers:
 clay(7m)
 Gravel & clay mixes(6m)
 Clay(3m)
 Sand gravel mix

29. SUPERSTRUCTURE
Structures which are above the pier cap and placed on
the bearings are superstructure. Roads are further
constructed over it.
SEGMENTS
• TWO TYPES: A) PIER
SEGMENT, B) NORMAL
SEGMENT
GIRDERS
• Used I –girder in this
project

30. SEGMENTS:
Placed on the bearing plate. These are used to make a span
of the flyover. Segments are precast made up of M45 GRADE
concrete and FE 500. These structures are posses both
Tension and Compression members, so designs are made by
taking in account both forces on it.

31. TYPES OF SEGMENT USED:
• Pier segment(P.S)- These are placed at the end of the span on
the pier cap. Length of P.S is smaller than the normal segment
and the anchor hole are inclined. Two P.S are used in making
of the span.
• NORMAL SEGMENT- These are placed in between two P.S for
making the span and anchor hole are straight. Total 9
segments are used in between two pier.
Total length of span= 2*2.35+9*3.25=33.95m
S.NO. SEGMENTS LENGTH
1. PIER SEGMENT 2.35m
2. NORMAL SEGMENT 3.25m

32. GIRDERS:
Individual beam like structure which are separately placed on
the bearings. These structures are shorter in length than
segment and stressing are done precast by using cables
certain in nos. Depends on the design.
In this project I-girder of 3 and 6 span are used.

33. LAUNCHING OF SEGMENT:
The segments are launched by launching girder or
gantry girder. Beam are connected both end of the
segment and pressure are applied in segments. All
the segments are joined to each other by gluing.
LAUNCHING OF DECK BY LAUNCHING
MACHINE:
Launching machine is used to uplift the segment of
the bridge all the segments are lifted at once by the
use of lifter.
Number of segment between two pier:
no. Of segment= 11
weight of one segment =600T
After placing of the segments Stressing is done by
use of high tensile cables, so that loads came to the
cable & bridge should be stable.

34. JOINTING OF SEGMENT:
Mixing of both type of chemical (Nitobond Pc base thixotropic
epoxy adhesive& Nitobond Pc 30 harder) is done and every
time two segments are compressed(glued) to each other.
After 24 hours the process checked by flushing water and
leakage in anchor hole.
ANCHOR HOLE-
These are present in entire segment to for stressing of it. 6
nos. Of hole are present at one side of segment. Parabolic
shape.
TENSILE WIRE-
It is a high tensile steel wire inserted in all 11 segment for
stressing. No. Of wire depend on the design(12, 19,25etc.).
Grade of the wire is 19T15.

35. PRESTRESSING:
Pre-stressing means creating a permanent stress in the
structure. In this process dead end are fixed with life wedge to
hold the tensile wire. And the free end is fixed with hydraulic
jack and force are applied approximately 369 T.
GROUTING:
Grouting involves injection of cemented material in a certain
ratio of cement and water for isolated pore or void space is
often called Simple grouting.
Quantity of material:
o Cement :1 bag
o Water: 22 litres
o Admixtures: cibex 100

36. SPAN:
The distance between two span is 500mm.
Total span length between two pier varies in this project
P1-P5 =34m, P6-P19=37m and rest have distance= 20m
PRECAUSTION TO BE TAKEN DURING PLACING
CONCRETE
o Water should not be added to concrete during its passage
from mixer to form work.
o The form work(surface) which has to receive the fresh
concrete should be properly watered(cured).
o Concrete should be placed in single thickness.
o Concrete should be tapped in such a way that no honeycomb
surface appear on the surface.

37. TECHNICAL SPECIFICATION
1) Chiriyatand to Gandhi maidan:
OTHER SPECIFICATION:
o Pile group -4 and 6
o A1-P1- 33.25m, P1-P17- 34m, P17-A2- 33.25m
o Length of flyover= 612 m elevated , approach(RE Panel)= 147m fill.
Diameter of pile 1200mm
Vertical & horizontal loads 250T & 30T
Depth of pile cap 1800mm
Number of Piles 110
Number of pile cap 19
Number of segment 198

38. 2) Station to Mithapur
DIAMETER OF PILES 1800MM
VETICAL& HORIZONTAL LOADS 230T& 20T
CONCRETE USED M35(EXCEPT P17: M40)
DEPTH OF PILE CAP 1.8m
NUMBER OF PILES 267
NUMBER OF PILE CAP 38
NUMBER OF SEGMENT 182
NUMBER OF SHAFT 40
NUMBER OF HAMMER HEAD 37

39. CONCLUSION
The project report involves construction of flyover and shows
concern over every written word.
Bridges break down separation and foster connectedness
across gulfs and rivers, between people and countries. As far
back as we can see in history, human beings have used new
technology to solve problem and ease their physical burdens.
The distinctiveness of humans as a species is defined by their
use of tools, and bridge are technological tools that aims to
solve the problem of crossing and obstacle in such a way as to
cut down the efforts and time needed to do so.
As the traffic problem arises in the cities due to more vehicles
in the cities because of big population. This flyover change the
face of the city Patna and Paved the way to progress.

40. REFERENCES:
• Indian bureau of standard and meteorology.
• IS Indian standards.
• IRS Indian road congress( i.e. Recommended code of
practise by IRS)
• ASTM American society of testing and materials.