Munger ganga bridge

Presentation on Steel Fabrication work and Erection of girder by Cantilever erection method.

1. MUNGER RAIL cum ROAD BRIDGE PROJECT PRESENTATION 17.01.2014

2. INTRODUCTION Project Name Construction of Steel Superstructure for Rail-cum-Road Bridge Across River Ganga at Munger in Bihar Job code No. 8802 Location Between Munger & Khagaria in Bihar Similar Bridge Across river Brahmaputra in Assam Importance To provide a long awaited connectivity Description Two lane Road & single Railway track Bridge Length 3.690 Km Superstructure Welded Steel Truss (riveted joints)

3. LOCATION MAP Munger Bridge

4. SALIENT FEATURES Employer East Central Railway, Patna Client BBJ Construction Co Ltd, Kolkata Contract Value Rs 375.19 Crores Completion Period 30 months Span Arrangement 1 x 32.6 + 29 x 125 + 1 x 32.6 Type of Superstructure THROUGH TYPE WELDED STEEL TRUSS Weight of 125m Span 1885 MT/Span Width/Depth of 125m Span 13.35m/18.5m Gammon Scope 12 x 125 Quantity of Structural S teel 24770 Site Joints Riveted Ancillary Works RCC Deck, Bearing Pedestals, Exp Joints

5. ERECTED SPANS Khagaria end Munger End P 29 P28

6. ERECTION IN PROGRESS

7. Typical 125m Span elevation Top Chord Members Bottom Chord Members Diagonals Verticals End Raker Road Deck Rail Track

8. Matching point of North and Sounth End

9. Key Technical Features Item Features Type of span Welded girder with riveted connection at joints Height / Width of span 19.68m / 13.0m outside dimension No of members in one span 417 members No load & Dead Load camber 181.35 mm & 112.5 mm at center Weight of one span 1885 MT Max weight of single lift 25 MT (1 st Bottom Chord after assembly) Type of welding in members Submerged Arc Welding / MIG Welding Type of steel being used E 250B, E 350Cu, E 450Cu (Normalized, Fully Killed)

10. Key Specifications Item Code no. Item covered Steel supply IS :2062: 2006 Steel plates / Rolled section Fabrication IRS:B1 - 2001 Fabrication Welding IRC: WBC Metal arc welding in steel   IRS: M-39/M-46/M-28 SAW welding /MIG welding/MMAW   IS:9595 Metal arc welding in carbon steel   IS:7307 (Pt-1) Approval test for welding procedures   IS: 7310 (Pt-1) Approval test for welders Ultrasonic Testing ASTM (SA 578/ 578M)/ IS:4225 UT of plates   IS:4260 UT of butt welds Riveting IS:1148 /IS:1149 Steel rivet bars / HT Steel rivet bars   IS: 1929 Hot forged steel rivets Painting IS:9954 Surface preparation (Sand Blasting)   IS: 5666 Etch primer   IS:104 / IS:2074 Zinc chrome Primer (Yellow) /(Red Oxide)   IS:2339/IS:2590 Aluminum paints /Aluminum for metalizing Erection IRS- B1 :2001 Erection of steel members

11. SCOPE OF WORK - STEELWORK A SUPPLY, FABRICATION Supply Steel of Grade Fe 410W & Fe 490 Unloading, Stacking Fabrication of Members at Site Workshop Trial Assembly & Dismantling Shop Riveting, where necessary Sandblasting & Metalizing/Painting Span wise Stacking

12. WORKSHOP

13. SCOPE OF WORK - STEELWORK B ERECTION Transportation & Pre-Assembly Erection of Truss by Cantilever Method Field Riveting Alignment & Lowering on Bearings Grouting of Bearings Final Painting

14. SCOPE OF WORK – CIVIL WORK For Entire Bridge Length Concreting of Bearing Pedestals Concreting of RCC Deck of Bridge Installation of Crash Barriers Installation of Expansion Joints Road Surfacing Road Marking

15. ENABLING WORKS A FOR FABRICATION Camp Establishment at Khagaria End Fabrication Workshop – 3 nos Layout Platform Establishment at Munger End (BBJ Yard) Trial Assembly & Stacking Yard Sand Blasting & Metalizing Enclosure Feeding track

16. ENABLING WORKS B FOR ERECTION Fabrication of Heavy Duty Trestles Piling for Anchor Span Supports Erection Cranes Design/Manufacture Fabrication of Links/Pins Fabrication of Strengthening Members Staging for Erection/Site Joints Scaffolding for Riveting/Painting Access Ladders/Platforms/Walkways

17. SALIENT CONTRACTUAL FEATURES MOBILISATION ADVANCE STAGE I 5 % of CV against BGB - 18 % interest MOBILISATION ADVANCE STAGE II 5 % of CV against BGB - 18 % interest PLANT ADVANCE 10 % of CV. Max 75 % of Plant cost. Hypothecation/BGB for full value of plant. SECURITY DEPOSIT 10 % of each Bill. Max 5 % of CV. LIQUIDATED DAMAGES Entire amount levied by Railways if contractor is solely responsible. OR proportionate to their value of work to total value. FAILURE IN EXECUTION OF THE CONTRACT Performance guarantee will be encashed & SD will be forfeited. SITE FACILITIES TO BE PROVIDED TO RAILWAY Furnished Office, Codes, manuals, 2 vehicles, 6 computers, software, 2 printers, maintenance personnel, motor boat, walkie talkies etc.

18. SALIENT CONTRACTUAL FEATURES MAJOR QUANTITIES Mild Steel (Fe 410W) Supply – 8249 MT HT Steel (Fe 490) Supply - 16521 MT Mild Steel Fabrication/Erection - 7420 MT HT Steel Fabrication/Erection - 15162 MT Load Test of 125m Span - 3 nos RCC M30/M35 - 12900 m3 Reinforcement - 2100 MT Supply of cement - 5779 MT Supply of Reinf Steel Fe 500 - 2205 MT Design, Supply of Exp Joints Modular Strip Seal 125m Span - 29 nos Modular Strip Seal 32.6m Span - 2 nos

19. BBJ’S SCOPE OF SUPPLY AS PER CONTRACT AGREEMENT APPROVED FABRICATION DRAWINGS WILL BE ISSUED BY BBJ AFTER APPROVAL BY RLYS MASTER JIGS WILL BE PREPARED AND GOT APPROVED BY BBJ. GAMMON MAY BE ALLOWED TO MAKE WORKING JIGS FROM THEM BBJ WILL PREPARE AND GET ERECTION SCHEME APPROVED. GAMMON MAY FOLLOW

20. ESCALATION/STAR RATE PAYMENTS ESCALATION FORMULA BASED ON BASE DATES /INDICES 1. LABOUR R*(l-lo)/lo*0.3 Consumer price index(RBI) 15.07.2008. 143 2. MATERIAL R*(w- wo )*0.25 Wholesaleprice index-All commodities(RBI) 15.07.2008. 240 3. FUEL COMPONENT R*(F- Fo )*0.15 Wholesaleprice index- Fuel,Power,Light & Lubricants RBI) 15.07.2008. 377.2 4. STEEL Ex works price at SAIL+ ED 01.07.2008 a. Reinforcement bars Q*(Bs- Bso ) 8 mm dia. b. M.S.Angles Q*(Bs- Bso ) 65x65x6 MM IS 2062.E250A SK c. Plates Q*(Bs- Bso ) PM plates 10 – 20 mm IS 2062 E 250A SK d. Plates Q*(Bs- Bso ) PM plates 10 – 20 mm IS 2062 E 350 cu Not known. e. Channels Q*(Bs- Bso ) ISMC 200x75 IS 2062 E 250A SK 5. CEMENT R1*( Wc-Wco )/ Wco ) Wholesaleprice index-Cement (RBI) 15.07.2008 – 222. R – Gross value Q – cost of steel supplied during month R1 – cost of cement consumed during month

21. PENALTY FOR MISSING MILESTONES MILESTONES KEY DATES REMARKS PENALTY Submission and approval of erection scheme for 125 M span D + 90 days Railways to issue GAD & Stress sheet 15 days from LOI Railways require 30 days for approval Rs 2 Lakh per day. If contractor makes up the progress within next two key dates, then the penalty shall be reimbursed. Maximum cumulative penalty is @ 3% of CV. Submission of fabrication drawings for 125 M span with complete Design. D + 150 days Railways require 30 days for approval. 50% Drawings shall be submitted from D+60 days and balance 50% drawings within D + 150 days. Completion of Trial assembly of one 125M span & Pass by Railways. D + 270 days. Railways require 21 days for approval. Trial assembly to be offered with all test reports, measurements & relevant doc. Launching of First span except placement on bearings. D + 300 days. Launching of Second span except placement on bearings. D + 330 days. Launching of Fifth span except placement on bearings. D + 390 days. “D” is issue Date of LOA

22. MOBILISATION – KEY DATES Award of Contract by BBJ 09.04.2009 Site Mobilization started on 07.07.2009 Receipt of Shop Drawings 26.02.2010 onwards Receipt of Steel from SAIL 04.03.2010 onwards Fabrication Agency Finalized 04.03.2010 2 no Fabrication Shops Comp 31.03.2010 Mobilization for Jigs/Fixtures 31.03.2010 Full Mobilization of Agency 31.05.2010 Completion of Piers by Rlys 30.06.2010 Scheduled Completion Date 07.11.2011 1 st EOT granted till Date 31.12.2013 2 nd EOT applied up to 15.06.2015

23. PLANTS & EQUIPMENTS Equipment No's Hydra (8 T to 14 T Cap) 9 nos. Handling cranes 2 nos. (45 MT & 50 MT capacity) EOT cranes 5 nos. (20 MT capacity) Goliath crane 2 no. (50 MT & 20 MT capacity) Generators 7 nos. (40 KVA to 500 KVA) Jacks 10 nos. (100 to 250 MT capacity) Plate straightening Arrangement 1 nos. (with 2 x 350 MT Jack) Distortion correction Frame 2 nos. Compressors 7 nos. Radial drill machine 15 nos. Magnetic drill machine 37 nos. Pug machine 15 nos. SAW machine for outside welding 13 nos. SAW machine for inside welding 2 nos. MIG welding sets 12nos . MMAW sets 23 nos. Flux baking furnace 4 nos. USFD machine 1 no. Angle Grinding machines 60 nos. Riveting equipment's 3 sets Automated I-girder Assembler 1 nos. Automated I-girder Straightener 1 nos. CNC Gas Cutting Machine 1 nos. End Milling Machine 1 nos. Calibrated Inver Tape 1 nos. Measuring Instruments/Gauges As required Safety equipment's As required

24. SUPPLY OF STRUCTURAL STEEL Study shop drawings & make cutting plan Prepare Steel Indent/obtain from BBJ Send Requisition to HO for P.O. Pursue SAIL for supply of steel Coordinate with SAIL Patna & Fatuha Yard Authorized Agency to lift steel from Yard Unloading & Stacking at Yard Contd ….

25. SUPPLY OF STRUCTURAL STEEL Identification & Correlation with MTC Visual Inspection & Dimension check Verification of product analysis in MTC Joint Sampling for Testing at NABL lab Verification of Physical & chemical properties Verification of Charpy V Notch Impact Test Review of Test Results by Railways Acceptance by BBJ/Railways.

26. FABRICATION Commissioning of plants/equipments Transport steel from GIL Yard to BBJ Yard Make copy of Master Jigs/Fixtures Transport Jigs/Fixtures back to GIL Yard Prepare Lay Out & check with Jigs Issue steel to P&R based on cutting plan Prepare Templates for cutting of Plates Proceed with fabrication as per flowchart

27. FABRICATION Broad Classification of Fabricated items Built-up Sections Requiring Welding (62%) Top Chord, Bottom Chord, End Raker : Box Section Diagonals & Verticals : Channel Type Box; I-Section Cross Girders, Stringers, Hangers : I-Section Not Requiring Welding (38%) Gusset/Splice/Pack Plates – Plates Bracings, cleat angle & other Misc items – Angles Bent Gusset/Splice Plates – Plates + Bending

28. FABRICATION FLOWCHART FOR GUSSET/SPLICE PLATES Issue of Steel Cutting Plan Marking Grinding Cutting Check for Straightness Straightening Tack with Jig Finishing Grinding Remove Jig Drilling Sandblasting/ Metalizing/Paint APPROVAL BY RDSO

29. FABRICATION FLOWCHART FOR BUILT-UP SECTIONS Issue of Steel Cutting Plan Marking Grinding Cutting Check for Straightness Straightening Fit Up & Tack Weld Finishing Grinding Remove Jig Place Job on Fixture Sandblasting/ Metalizing/Paint APPROVAL BY RDSO Tack with Jig Drilling End Milling SAW Welding Straightness check Straightening

30. LAYOUT PLATFORM

31. FABRICATION

32. FABRICATION Challenges Avoid distortion during cutting/welding Grinding of cut edges of thick HT Plates Straightening during Fit up & welding SAW Welding inside box sections End Milling of Chord members Accuracy of drilling holes Achieve Camber

33. FABRICATION

34. FABRICATION

35. ERECTION Cantilever erection as per Scheme by BBJ Involves two customized derrick cranes – 1 st for forward erection and 2 nd for follow up work Some members are strengthened to cater for the erection stresses. First span (between P30 – P29) will be erected conventionally on trestle supports at all nodes Once the camber & alignment is accepted, cantilevering of further spans starts. Feeding of fabricated components will be by trolley at rail level

36. ERECTION SCHEME Contd…..

37. ERECTION SCHEME

38. CANTILEVER ERECTION SCHEME

39. RIVETING High Tensile Rivets 24mm dia used at Site Joints Rivets replace temporary fasteners (bolts/drifts) A typical Riveting gang consists of five men All holes in the joint to be made fair Rivets comprise about 1.5% of the Span weight Equipments used Compressor – Operates the forge, hammer, dolley Forge – Used to heat the rivet by pearl hard coke Tongue – Used to handle red hot rivets Hammer – Used to hammer and prepare rivet head Dolley – Used to hold rivet in position

40. ALIGNMENT Important to control cantilever erection To start after erection of 3 - 4 spans Involves Jacking of entire span on Traversing base Ensure Vertical & Horizontal Alignment Lowering on Bearings Followed by grouting of Bearings Equipments used Hydraulic Jacks – 500 T Cap – 9 nos Hydraulic Traversing Base – 9 nos Pack plates – As required

41. SAFETY CONCERN Repeated handling of long heavy structural Sandblasting area close to residential area Access, staging & walkways on bridge Riveting platforms on bridge Jacking of spans Weather Condition during cantilevering 1 st Span erection on river bed

42. SAFETY

43. FINANCIAL STATUS (FORM F3) DESCRIPTION AS PER TENDER AS PER LATEST CE CONTRACT VALUE a) WORK DONE 375.18 376.29 b) ESCALATION - 74.31 c) OTHERS - 0.97 d) TOTAL 375.18 451.57 B. S. EXPENDITURE 269.55 290.50 Y.S. EXPENDITURE 47.20 48.72 B.S. + Y.S. 316.75 339.22 PLANT HIRE CHARGES 6.80 6.93 B.S. + Y.S. + PLANT HIRE CHARGES 323.55 346.15 H.O. OVERHEADS 6.06 9.57 FINANCE CHARGES FOR –VE CASHFLOW 11.26 CONTINGENCIES 3.40 1.61 TOTAL EXPENDITURE 344.27 357.33 MARGINS 30.91 94.24

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