Replacement of existing steel F.O.B.

(31m span) with new steel truss bridge

(single span 41m) without traffic or power
blocks
between
Masjid bunder Sandhurst Road stations
on Mumbai Dadar
section

of

Central Railway




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PRESENTED BY




A. K. Pandey
ADEN / HQ / Nagpur / C.Rly.

A. K Mishra
ADEN / Miraj / C.Rly.

S.R.Gahane
ADEN / solapur / C. Rly.

W.P.Tiwari
AXEN / Porbunder/ W.Rly.

Pawan Kumar
AXEN / Jabalpur/ W.C.Rly.










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Contract agencies



This work was carried out by MS
Simplex Concrete Piles India Ltd. The
drawings were prepared & supplied by the
contractor dully proof checked by IIT Mumbai
& approved by railway.




















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Case Study



This work was carried out in connection
with Laying out 7
th
line between CSTM &
Sand Hurst Road stations of C.Rly. at
km 1/19-20

The old F.O.B. was constructed prior to 1905
with 31m span having hinged joints with top,
bottom members & bracings. The bridge were
built with early steel.

The joints of old F.O.B. became fixed &
immovable due to rusting caused by aggressive
atmosphere of costal area. Hence in place of
functioning hinged joints, the joints now became
fixed.

The span of new F.O.B. was required to be
increased to 41m to accommodate 7
th
line as well
as increasing head way clearance to 6.25 m.




4



Salient features ,obligatory points & construction
procedure

There were 6 main lines running below the
F.O.B. There were minimum space available
within the railway boundary beyond extreme
most tracks. It was not possible to acquire
additional land for laying of 7
th
line because of
densely populated suburbs available just
beyond the railway boundary.

A through survey & rigorous exercise were
carried out to adjust one more track and it was
found that a minimum space for 7
th
track can
be created, if central pier of old F.O.B. is
eliminated and in place of thick old abutments
new sleek & thin RCC abutments are being
constructed.

The work was carried out as per approved
drawings of steel structure & launching
scheme. The stair cases of old F.O.B. were
dismantled and new abutments were
constructed with out disturbing spans of old
F.O.B.



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The galvanized steel structure of new F.O.B.
were fabricated in workshop & transported to
the site in three segments by road.

At the launching stage it was felt that using &
placing Road cranes on the track was not
possible. Hence higher capacity cranes with
longer boom were used to place segment of
new truss bridge just at a top of east side
abutment.

The top members of the existing bridge with
little modification were used to launch new
boxed trusses in three parts by fixing 100mm
dia rollers at top members of the old F.O.B.
However dead load of old F.O.B. was reduced
by removing RCC flooring slabs.

A road crane of 250 T capacity & 60m dia
telescopic boom was placed on outer side of
the east abutment of the F.O.B. All the three
parts of the box trusses were lifted from
ground & placed on top of the old bridge.




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The first truss was pulled out with the help of
chain pulley then 2
nd
& third part respectively.
The truss in three parts were pulled in
position & jointed with H T bolts.

After jointing all parts of the truss it was lifted
with the help of four jacks 20 T capacity to
600mm & mounted on wooden sleeper pile.

The top booms of old bridge were tied with
bottom members of the new truss with M.S.
bolts & clamps and old F.O.B. was dismantled
in parts during corridor blocks.

On removal of old structure new bridge were
lowered & placed on bearings.

Finally RCC flooring slabs were placed ,stair
cases were constructed and bridge was
opened for pedestrian traffic.








7


Requirement of material & equipments



Road crane (200T) - 1 No.
Chain & Pulley arrangement - 4 Nos.
Hydraulic jacks(20T) - 4 Nos.
Crow bars - 10 Nos.
Tommy Bars - 8 Nos.
Black smith equipments - 4sets.
Gas Cutting equipments - 4sets.
Three Phase Generator - 1 No.
Wire ropes (40 m Long) - 4 Nos.
Hydraulic Jacks (15 T ) - 4 Nos.
C.C. Cribs - 200Nos.
Wooden sleepers - 50 Nos.
Rollers (100 mm dia) - 30 Nos.





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MAN POWER PLANNING



Man power for jacks 4x 5 = 20 Nos.
Truss work 2 x 5 = 10 Nos.
Gas cutting batches 2 x 2 = 4 Nos.
Black Smith batches 2 x 2 = 4 Nos.
Miscellaneous 1 x 20 = 20 Nos.
Total = 58 Nos.


















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WORKS CARRIED OUT BEFORE LAUNCHING


Arrangement of all parts of the truss near
the east side abutment fitted with rollers
at bottom members.

Fixing of steel channel ISMC 300 on top
members of the old bridge .

Marking of accurate center line on girder
for exact placement.

Imposition of caution order of non stop
20 kmph imposed, on the day while
launching were carried out.

To reduce dead weight of old bridge
flooring slabs were removed.

To provide additional support and
strength to the old F.O.B. to with stand
load of new truss. The steel pier of old
F.O.B. were provided with racker steel
channels.






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Power & Traffic Block ( 2 Hours corridoor )


No power or traffic block were taken
for launching of new truss bridge.
The launching were carried out
under speed restriction of 20 Kmph .

Only the corridor blocks were
utilized to cut and remove the old
truss bridge members.


















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Precautions take care of


A meticulous planning was done to
ensure 0 failure to avoid any
accident while working with crane
or while sliding truss segments.

Utmost Care were taken during
sliding of trusses from one end to
other on the old F.O.B. above the
running tracks.

Care has also been taken while
slewing the existing trusses so that
no hanging part or loose part may hit
the running trains.

For controlling of alignment two
ropes were also connected to first
segment of the truss.








12


DISCUSSION & CONCLUSION


The Iunchinq wus curried out onIy with
the heIp of roud crune und with simpIe
equipments Iike Chuin puIIeys without
truffic und power bIocks It suved
rescheduIinq & deIuyinq of pussenqer &
suburbun truins AnciIIury works curried
out durinq corridor bIocks of individuuI
Iines However RCC works were carried
out well before, which includes
abutments & precast flooring slabs.


For dismenteIIinq of oId FO uIso onIy
corridor power or truffic bIocks were
used

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Drawings indicating approved launching scheme of
Chinch - Bandar F.O.B.







Sectional Elevation Showing New F.O.B. Launched
above old F.O.B. at same location.






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Drawings indicating Cross Section of existing F.O.B.
loaded with truss-segment of new F.O.B.










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Sectional Elevation Showing Launching of 1
st
segment
of New F.O.B. over old F.O.B.












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Sectional Elevation of New F.O.B. accommodating 7
main line tracks.















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COURSE & PROJECT DIRECTOR


Shri. Manoj arora (PW)
IRICEN / PUNE

We are thankful to our Course
Director, Shri. Manoj arora ( PW ) & our project
incharge Shri Rajesh Kumar(PT-1)
for guiding us to complete this Project and
also for leading and guiding throughout
the course.











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We would like to pay our gratitude
and special thanks to


Shri. SHIV KUMAR, Director, IRICEN

For leading
the Institute
and giving us
the competitive & healthy
environment for the overall
development of all the trainee officers
to become successful officers
of Indian Railways.

















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Staff and faculty



We are also thankful to all the faculty
members who are very helpful and giving
their knowledgeful support to us in all the
subjects at the Institute.

We are also thankful to all staff of
Institute as well as hostel, who were
instrumental in imparting one of the best
available training.










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Actual photograph of work site








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THANKS