RESEARCH, DESIGN & DEVELOPMENT SOME RECENTACHIEVEMENTS New Initiatives in Design and Fabrication Design of Bow string Arch ROB's for NHAI with special class loading for span 42m, 48m, 54m, 60mand72m Side Pathway for plate girders: Design of Side pathway forplate girdersissued ROB bow string steel girder for zone V for span 48m, 60m & 72m, Design of Side Pathway for composite and open web girder forall spanissued Temporary substructure: Design of temporary substructure enhanced speed of 40 kmphissued. Redesign of composite girder for 25t loading of spans 12.2m & 18.3m with HSFG bolts Steel Bridge Code has been reprinted incorporating 22 correction slips after a gap of nearly 40 yearsin Sept. 2017 IRS Code for Earthquake Resistant Design of Railway Bridges (Seismic Code) has been prepared and issued on 27.10.2017 for adoption on Indian Railways. IRS Code for Earthquake Resistant Design of Railway Bridges (Seismic Code) has been prepared and issued on 27.10.2017 for adoption on indian Railways, Revision of Provisions related to crack width in IRS-Conerete Bridge Code (CBC):- The provisions regarding crack width were very stringent nearly 80% additional reinforcement were required to be provided, to comply the instructions as compared to reinforcement required for moment/load considerations. With revision in crack width requirements there will be saving of Crores of Rupees on year to year basis. (BMRC projected saving of 2.5 crperkm of, Metro construction), Deletion of para 14.9 and 15.9.9 of IRS-CBC having provisions regarding Shrinkage and Temperature reinforcement in contradiction to distribution reinforcement, Nearly 2-3 tonne additional reinforcement were required to be provided to follow these provisions in each RCC BRIDGES & STRUCTURES Box (for two line). These being redundant have been deleted, RCC Box designs have been modified. A&C 5 to IRS-CBC (reprint 2014) dated 13.06.2017 issued. Clause 16.4.4.4.5 modified ‘and maximum spacing of shear stirups in PSC. increased as per reference code i.e. BS: 5400. This wll reduce congestion of shear links as well as ‘quantity of shear reinforcementin PSC, Newly designed PSC U slab for 12.2m span. weighs only 89t against existing PSC slab of 163t,, requires about 30% less height above bed block level, economical, replaceable with Plate Girders & shall facilitate continuation of LWR on Bridges. ON-GOING RESEARCH PROJECTS Corrections Slips issued/ proposed in IRS:CBC- 4 A&C-1 to IRS-CBC (reprint 2014) dated 16.12.2014 issued. Provision of crack width in IRS-CBC were examined in relation with provisions in other codes. Existing provisions were considered too stringent and accordingly, modified. 4 A&C 2 to IRS-CBC (reprint 2014) dated 14.01.2015 issued. Clause 5.4.7 of IRS- CBC. Provision of coating for concrete bridges re-introduced. + ABC 3 to IRS-CBC (reprint 2014) dated 20.01.2015 issued. Clause 4.5.1, 14,9, 15.9.4.1, 15.9.4.2 & 15.9.9 of IRS-CBC modified to permit use of Fe-500 grade or higher grade stee! for reinforcement. ‘ABC 4 to IRS-CBC (reprint 2014) dated 15.11.2016 issued. Clause 14.9, 14.9.1 & 15.9.9 pertaining to provision of shrinkage and temperature reinforcement deleted. + ABC 5 to IRS-CBC (reprint 2014) dated 13.06.2017 issued. Clause 16.4.4.4.5 modified and maximum spacing of shear stirrups in PSC increased as per reference codei.e. BS: 5400. + ABC 6 to IRS-CBC (reprint 2014) dated 27.07.2017 issued. Clause 7.1.5 modified and use of Stainless Steel Reinforcement as UTES Ta OuatdBridges & Structures per IS 16651:2017 permitted in unavoidable circumstances/exireme cases. Modification in clause No. 7.26.4.2.4.1, on Properlies of HDPE Sheathing. (Modified draft A&C Slip No. 7 to IRS CBC sent to Board vide letter no. CBS/PCB dated 17/02/2017). Draft A&C No. 8 to IRS CBC (reprint 2014) dated 01.11.2017 sent to Railway Board for approval. Clause 15.9.3.1.1 proposed to be Modified regarding Ductile Detailing in line with new IRS Seismic Code. 4 Draft A&C No. 9 to IRS CBC (reprint 2014) dated 10.05.2018 sent to Railway Board for approval. New Clause 4.5.1 (e) proposed to be added for Addition of stainless steel reinforcement also as a type of reinforcement & Clause 7.1.5 (a) is proposed to be modified regarding Deletion of provision for application of cement slurry coating tothe reinforcement. ™ Corrections Slips Issued/Proposed in IRS-Bridge Substructures and Foundation Code Modified Draft A&C No. 7 to IRS BS&FC (Revision- 2013) dated 15.06.2017 sent to Railway Board for approval. Clause 6.14.3, 5.16.22 & 5.16.2.93 proposed to be applicable to Bridge Arches too. ™ Corrections Slips Issued/ Proposed in Arch Bridge Code * A&C 8 to Arch Bridge Code dated 28.01.2015 issued for Clause 5.3.3 Pertaining to Arch Load Testing. With issue of this A&C, Arches of smaller spans (between 1m to 4.5m) have also been covered under tis. 4 Draft A&C 9 dated 02.03.2015 to Arch Bridge Code sent to Railway Board to incorporate changes due to changes made in IRBM regarding distressed bridges. Thereafter, the Arch Bridge Code will be reprinted incorporating A&C up to 9. ‘> 84” BSC recommended for allowing upto 200% overstress in arches also similar to provisions of IRS: Substructure & Foundation code vide item 2.2 above Annual Report 2017-18 ON-GOING IMPORTANT DESIGNPROJECTS: ™ Design of 106.6 m Span Open Web Girder * * 106.6 m span open web girder is required for important ridges. Design work has been completed. Drawing isunder preparation. Steel proposed is E350 B0, with K-type truss. Design of 30.5m Span Ballasted Deck through type: * * irders ‘The through girder drawings are all with steot channel sleepers. For better riding and for permitting laying of LWR on bridge, ballasted deckis preferred. Design of 30.5 m span with RCC deck over stringers has been taken in hand, ™ — 12.2m Post-tensioned PSC Girder for DFC Loading Standards PROGRESS OF ON GOING RESEARCH PROJECTS (EXTERNAL) = Development of Crite: Analysis of St. * for Dynamic 1 Railway Bridges Benefits Expected > Optimization and extension of impact values to be considered in bridge design for speeds upto which dynamic analysis snot required (~ 200 KMPH). The existing codal values are for 41251160 KMPH only. > Criteria for dynamic analysis of bridges for higher speeds (Upto 350 KMPH) where CDAValues cannot be used nt Features > — Sanctioned cost -%43,22,640.00 > — Yearofsanction - 2012-13,DF-3,PH18 > Agency - IITRoorkee > MOUDate - 09.10.2012 > — Expenditure till 31.03.2016- €40.01 Lakhs. > — Budget Grant 15-16 -%1.12 Lakhs. > Expenditure in currentyear-Nil Objective / Deliverables > — DynamicAnalysis ofall types of Girder and Truss bridges including Comparisons of Dynamic AnalysisTit fel mL UK with CDA based normal analysis, for Passenger speeds 160 Kmph to 300 Kmph and Freight 125 Kmph to 450 Kmph for MBG, HM, 25t and 32.5tloading. Procedure (step by step) to conduct DynamicAnalysis. Draft Provisions for Bridge Rules/ Steel Bridge Code along with design implications Current Status > > This work was awarded with a clear cut, requirement of development of “Criteria for Dynamic Analysis of Stee! Girder Bridges for High speed loading’. The current practice of using the CDA values for evaluating the impact load is limited to the speed of 160 Kmph. Beyond 200 Kmph speed for some frequencies the Dynamic analysis of Bridges becomes necessary as per Euro Code, The Indian Railways does not have provisions to deal with high speed loading on bridges. ‘The Project is complete IIT-Roorkee: ‘submitted Final Report on March, 2018 The report is not yet complete in ‘required format and ameeting was held ‘0n01-06-2018in IIT/Roorkee with HOD of Earthquake Department and they have agreedto correctthe report. ‘The revised final report is expected to be complete by October, 18 = Evaluation And Management of Longitudinal Force on Substructure of Railway Bridges Scope and Objectives > To evaluate the longitudinal force coming on the sub-structure of railway bridges. Formulation of guidelines for design provisions regarding longitudinal loads ‘on steel and prestressed concrete bridges. Review and evaluation of suitable methodologies/techniques for rmitigation of longitudinal forces. > Training of RDSO officials and engineers for evaluation of longitudinal force and its mitigation. Activities > Review of existing IRS provisions for dispersion oflongitudinal force. > Literature survey of provisions in international standards for dispersion of longitudinal force. > — Modelling and instrumentation for evaluation of longitudinal force in the case of steel bridges (two span lengths, three types of bearings — total 6 cases; one time measurement testing for each bridge) > — Modelling and instrumentation for evaluation of longitudinal force in the case of prestressed concrete bridges (two span lengths, two types of bearings - total 4 cases; one time ‘measurementitesting for each bridge) > — Review of available techniques! methods such as STU ete for mitigation of longitudinal force. > — Laboratory investigations on the identified techniques/methodologies for mitigation of longitudinal force > Evaluation of efficacy of the identified technique for mitigation of longitudinal force through field testing on selected two bridges. > Development of guidelines for design provisions for estimation of longitudinal force on bridges. > Training for RDSO officials and field engineers (about 40 nos) for longitudinal force evaluation and mitigation methodologies. Deliverables > Development of guidelines for design provision for estimation of longitudinal force on steel and prestressed concrete bridges > Development of guidelines for ‘management of longitudinal force on bridges > Training/advanced course to the offcialsiield engineers of the RDSO UTES Ta Ouatdon the studies carried out and Sosy s wy methodologies developed on evaluation and management of longitudinal forces on bridges, Present Status MOU for taking up the project signed on 06.03.2017 with timeline for competion in3 years. Payment of 1° installment for %2,31,16,0000- released. 4 bridges identified for initial phase of testing. Testing and calibration in SERC lab is undor progress. Instrumentation of Bridge no. 514 (2 spans) of Southern Railway completed in the last m™ One week training imparted to Graduate Trainees week of May, 2018.Analysis of results from of various Engineering Colleges. instrumentation is in progress. = Online training of MIDAS Latest version for SSE/Design of BES Dt = Schdule for training of MIDAS Software related to specific module of Composite, Bow string, Box Girder and PSC Girder =~ 3 days (out of 5 days Full day) basic Training on STAD Pro.VBi software = 2days (out of days Full day)advance training (on Bow String Stee! Arch Road Over bridges with Response Spectrum loading and moving load generator)" Details of Non-Destructive Testing Done = Nondestructive Testing done in four bridges (Bridge Nos 557, 17, 18 and 19) constructed by RVNL near Bhubaneswar in ECoR and reports submitted for further action 1m Reporton Non-destructive testing of Bridge No.325 near Tilagarh, Sambalpur Division, East Coast Railway = Non destructive testing of retaining wall of RUB at RDSO, Manak Nagar, Lucknow = Report on Non-destructive testing of Br. No. 332 near Balasore, Kharagpur Dvision, South Easter Railway. Details of Consultancy Assistance to Railways = Different bridge of zonal railways including RVNL wore analysed for RSI effects for continuation of LWRICWRon bridges. = Span no. 32 & 34, 35, 36, 37, 38, 39 of Bogibeel Bridge 125m span of N.F. Railway has been cleared forlaunching. = Non Destructive Testing of bridge No. 7 & 34 (near Kota) in Bina-Kota doubling project of W.C. Rallway. 15Tit fel mL UK Instrumentation of Bridge No. 132 near Rampur Hat, Eastern Railway, Special design and drawing of bearing for bridge No. 283 of Ambala division prepared. = Non-Destructive Testing was conducted on Bridge No. 51 & 52,A between NKE-RXL section of ECR, ‘The reportis under preparation] = Clarification regarding non suitability of 12.2m PSC slab vide RDSO/B-10271 for curved alignment upto 40 given to M/s KRCL along with advice to refer RDSO Drawing No. RDSO/B-10265 for curved alignment upto 2.50, Light weight 915m span PSC slab has been designed. Railway Board vide letter no. 2017/10/CE-IIIBRIPSC Slab, dated 20.08.2017 has directed for replacement of Steel girders up to 9.15m span by PSC Slabs. = Clarification regarding dispensation of provision of uniform bedding layer of cement and cast iron borings in 1:1 proportion undemeath PSC Slabs ‘over properly designed bed blocks of adequate strength given to WR on 22.08.2017, = Examination of cracks in PSC | Girder (RDSO/B- 10262) has been done in Dausa-Deedwana section and Load Testing as perIRS CBC has been advised ™ As desired by CPM/RVNLIR, for clarification Alterations 1 Ato 1 D has been issued in Drawing Nos: RDSO/B-10270/1 & RDSOIB-10270/4 Details of other Recent Activities Inspection of 40643 t of fabricated steel work of triangulated and welded plate girder bridges has been completed in 2017-18 as against target of 180001 importantbridges i.e. Bogibeel, and Chenab. HM Total no. of 94 speed certificates were veltedlissued from bridge point of view and 9 trial reportshave been vetted. Eight girders of 125m span Rall cum Road bridge over Brahmputra at Bogibeel (a national importance project) have been inspected and cleared for launching in 2017-18, making the ‘cumulative total of 39 spans. This is exclusive of the two national Bogibeel Rail-cum-road Bridge on River Brahmaputra (First Fully Welded Bridge of Railways) Total length : 4,940 m Spans : 39 spans of 125m Location : Dibrugarh district, Assam, India Carries : Rallway and Road vehicles Bridge type : Truss Type, Rall Cum Road Bridge Materials : Steel, Concrete Bearings : Spherical Bearings Itis a combined Rail-Cum-Road Truss Bridge in Dibrugarh district at Bogibee! of the north eastern Indian state of Assam over river Brahmaputra connecting Assam and Arunachal Pradesh border. Superstructure of this bridge is composite welded steel truss and reinforced concrete. Itis designed to carry a double line broad gauge railway anda 3-lane road on the lower and upper decks with spherical bearings. Out of 39 spans all spans have been inspected and cleared by RDSO and launched. Chenab Railway Bridge, J & K, India Location : Chenab River between Bakkal and Kauri, J&K State, India Design: Arch Bridge Material: Steel and Concrete Total length : 1,315m (4,314 ft) Height: 359m (1,178 ft) Longest span : 467 m(1,532ft) No. of spans: 17 CorerRDS S The Chenab Bridge is a railway steel arch bridge under construction between Bakkal and Kaur in the Reasi district of J&K in India. This Iconic Bridge is of National Importance connecting Udhampur-Srinagar-Baramula Rail Link Project being constructed by KRCL under the supervision of Northern Railway. The bridge consist of main arch 467m span with approach span of 650m (13 spans) at Kauri end and 185m (4spans) at Bakkal end. It is world's highest railway bridge with the widest span inthe Indian broad gauge railway network. RDSO is carrying out fabrication inspection of the Chenab Bridge and has done the prefabrication requirement like approval of QAP, scrutiny of WPSS and then qualifying the welders to take up the welding works. Till now 650 welding qualification records have been approved and 30 segments of Kauri end viaduct have been inspected by M&C directorate of RDSO. RDSO DESIGNS OF STEEL BRIDGES Plate Girders for 25t Loading Drawings of 12.2m, 18.3m & 24.4m steel plate girder welded type for New Fatigue Criteria and HSFG bolts are available. Plate Girder for DFC Loading (32.5t Axle Load Drawings of 12.2m, 183m & 24.4m steel plate girder welded type for 10 milion cyclesissued. = Open Web & Open Web Underslung Girder for25tLoading Drawings of welded type open web girder for 30.5m, 45.7m, 61.0m& 76.2m, 91.44m and OE cee Bridges & Structures Underslung Girder of 30.5 m for New Fatigue Criteria and HSFG bolts are available, = Open Web Girder for DFC Loading (32.5t Axle Load) Drawings of welded type open web girder for 30.5m, 45.7m, 61.0m &76.2m for 10 millon cycles for DFC loading issued. RDSO DESIGN OF COMPOSITE GIRDERS = Composite Girder for 25t Loading Drawings of composite plate girder for 12.2m, 18.3m, 24.4m and 30.5m spans for New Fatigue Criteria and HSFG bolts are available, = Composite Girder for DFC Loading (32.5t Axle Load) Design and drawings of composite plate girder for 12.2m, 18.3m, 24.4m and 30.5m spans as per NEW fatigue criteria issued (exceptfor slab) STANDARD DESIGN OF ROAD OVER BRIDGES = RDSO Design of Composite Girders for ROB: Drawings of 18m, 24m, 30m & 36m span composite girders for ROBs have been issued including for skew spans upto 20°. The drawings are for 6 different road width configurations. (The drawings have been taken up for revision with revised deck configurations decided by RC.) = Bow-String Girders for ROBs Drawings of 30m, 36m, 42m, 48m, 54m and 60m & 72m span Bow string ROBs have been issued for two-lane road width. = 305m Posttensioned PSC Slab (2 units) for 25t loading standards issued vide drawing no RDSO/B-10277 dated 04.10.2016. Earlier only pre-tensioned PSC slab designs were available for this span. (Railways requested to issue this drawing as for isolated spans it becomes dificult to Use pre-tensioned PSC stabs at site. 366m Post-lensioned PSC Slab (2 units) for 25t loading standards issued vide drawing no RDSO/B-10278 dated 05.12.2016. Earlier only pre-tensioned PSC slab designs were available for this span. (Railways requested to issue this drawing as for isolated spans it becomes difficult to Use pre-tensioned PSC stabs at site. = 4,57m Posttensioned PSC Slab (2 units) for 25tloading standards issued vide drawing no RDSO/B-10280 dated 19.05.2017. Earlier only pre-tensioned PSC slab designs were available for this span. (Railways requested to issue this drawing as for isolated spans it becomes difficult to use pre-tensioned PSC slabs at site). 9.15m Post-tensioned PSC Slab (2 units) for 25t, loading standards in M60 grade issued vide drawing no RDSO/B-10279 dated 11.04.2017. (These are light weight, suitable for replacement of Plate Girders & wil facilitate continuation of LWR). 12.2m Post-tensioned PSC U Slab for 26t loading standards issued vide drawing nos RDSO/B- 10281, RDSO/B-10281/1 & RDSO/B-10281/2 dated 06.10.2017. (These are light weight, suitable for replacement of Plate Girders & will facilitate continuation of LWR), Important Guidelines Issued RDSO issues guidelines for various bridge related activities. important guidelines issued are > NDTofbridges :BS 103, > Instrumentation of Bridges : BS 106 Publication of Technical Handbook on Bridge Inspection and Maintenance by B&S Directorate Inspection and Testing Facilities at RDSO's B&SLab BAS Directorate is having a well fumished laboratory with following facilites. Impact load and static load testing facility for full scale testing of newly developed FRP/Composite sleeper as required by Nodal Directorate. a ee | 18 ‘Arrangement for Static Load Test Concrete Core Cutting and Grinding Machine.RDSS NDT Testing of Concrete Bridges with Ultrasonic Pulse Velocity Meter, Profometer, Rebound Hammer, Resistivity Meter, Corrosion Analyzer, Cut & Pull out test, Permeability Tester, Windsor Probe etc. Corrosion Test by Corrosion Analyzer er ER ES y Cut & Pull out Test on Bridges ROE eee Bridges & Structures Instrumentation Capabilities Available with RDSO RDSO has the following instruments which are used for testing of bridges as per reference received from zonal railways: amt Windsor Probe Permeability Test on PlerTit fel mL UK = Complete Structural Testing System (On loan sed for determining the vibration characteristics from Northern Railway): Can be used for and natural frequency of girders. measuring strains, accelerations, displacements and Residual Life Assessment of Steel Bridges: temperature on steel as wellas concrete bridges. ‘Strain gauges and theoretical SN curve is used for = Vibration Signature Instruments: Can be assessing he Residuallfe ofthe steel Bridges. 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