TECHNICAL DETAILS OF RAJIV GANDHI (BANDRA-WORLI) SEA LINK PROJECT (PACKAGE-IV)
APPROACH BRIDGE
General:
Bridge is arranged into units of typically five or six continuous spans of 50m.
Length of bridge: 800m + 200m + 1600m
Span: 50m
Carriageway: 15m
Side walk: 2.2m on one side
Crash barrier: 400mm on both sides
Pile:
Load bearing piles socketed into hard rock to a minimum of 4m length.
4 nos. of bored cast in-situ pile of 1.5m dia of length varying from ญญ5m to 36m designed for load carrying capacity of 1000T (approx.).
M50 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 12mm thick permanent steel casing for all piles.
Total nos. of pile: 372
Pile cap:
Hexagonal shape pile cap of size 10m x 9.5m x 3.5m for fixed pier location and 10m x 8m x 3m for sliding & expansion pier location.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Tremieseal (PCC) of M30 grade concrete 1m thick below pile cap.
Cofferdam: Interlocking liner type, Circular type & Sheet pile type.
Total nos. of pile cap: 94
Pier:
Hammer head shape hollow pier of size 4m x 2.5m, height varies from 5m to 18m. Pier is divided as Fixed type, Sliding type & Expansion type.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of pier: 94
Segment:
Fish belly shaped precast segmental concrete box of size 18.1m x 3m x 3m with 3 voids. Segments match cast by short line method.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Segment weight: 110T to 130T
Total nos. of segment: 1554
Erection:
Span by span construction using over head launching truss of capacity 1600T. One span consists of 16 segments.
Epoxy glue is used to join the segments. Temporary post-tensioning is done using 6 nos. stress bars during gluing.
2 nos. cast in-situ wet joints of 200mm width in each span is provided.
Bearings: Disc bearing (fixed & sliding type) of capacity varying from 700T to 1400T.
Post tension: 30 nos. of tendons each having 19 x 15.2mm strands and 6 nos. of tendons each having 4 x 15.2mm strands.
Expansion Joint: Modular type expansion joint with movement range of 320mm.
CABLE STAYED BRIDGE
Bandra Cable Stay
General:
Length of bridge: 600m
Span: 50m + 250m + 250m + 50m
Carriageway: 15m
Side walk: 2.2m on both sides
Crash barrier: 400mm on both sides
Pile:
Load bearing piles socketed into hard rock.
For tower, 52 nos. of bored cast in-situ piles of 2.0m dia of length 30m designed for load carrying capacity of 2000T (approx.). For pier, 4 nos. of bored cast in-situ pile of 2.0m dia of length varying from ญญ22m to 26m.
M50 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 16mm thick permanent steel casing for all piles.
Total nos. of pile: 84
Pile cap:
‘H’ shape pile cap of size 57m x 30m x 6m for tower. Hexagonal shape pile cap of size 10m x 12m x 5m for pier.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Tremieseal (PCC) of M30 grade concrete 2m thick below pile cap.
Cofferdam: Interlocking liner type.
Post tension: 28 nos. of tendons each having 19 x 15.2mm strands.
Total nos. of pile cap: 9
Tower/Pier:
125m height tower above pile cap with varying cross-section. 4 inclined legs of tower meet at 70m from deck level and continue straight for another 30m. The 30m straight portion is provided with anchorages for stay cables. Grooves are provided on the curved faces of the tower for aesthetics.
Hammer head shape hollow pier of size 4m x 2.5m with height 18m.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of Tower: 2
Total nos. of Pier: 8
Segment:
Fish belly shaped precast segmental concrete box of size 22.7m x 3m x 3m with 3 voids. Segments match cast by short line method. Anchorage for stay cables provided in alternate segments.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Segment weight: 130T to 150T
Total nos. of segment: 394
Erection:
Segment by segment erection by balance cantilever method using Derrick system of capacity 150T.
Epoxy glue is used to join the segments. Temporary post-tensioning is done using 22 nos. stress bars during gluing.
Cast in-situ wet joints of 50mm width is provided at every 50m interval.
Stay cable: Parallel wire system with 7mm dia. galvanized steel wires and 2 layers of HDPE. The number of steel wires in stay cable varies from 61 to 121 and the capacity of stay cable varies from 390T to 770T. The length of stay cable varies from 85m to 252m. Dead end of stay cable is anchored to the tower head and the live end is anchored to both sides of deck at 6m interval. There are 33 nos. of stay cables on either side of the tower.
Total nos. of stay cables: 264
Post tension: 134 nos. of tendons each having 19 x 15.2mm strands of various lengths.
Bearings: POT type PTFE bearing (sliding type) of capacity varying from 750T to 1850T.
Expansion Joint: Modular type expansion joint with movement range of 480mm.
Worli Cable Stay
General:
Length of bridge: 350m
Span: 50m + 50m + 150m + 50m + 50m
Carriageway: 15m
Side walk: 2.2m on both sides
Crash barrier: 400mm on both sides
Pile:
Load bearing piles socketed into hard rock.
For tower, 6 nos. of bored cast in-situ piles of 2.0m dia of length 30m designed for load carrying capacity of 2000T (approx.). For pier, 4 nos. of bored cast in-situ pile of 1.5m dia of length varying from ญญ22m to 26m.
M50 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 12/16mm thick permanent steel casing for all piles.
Total nos. of pile: 56
Pile cap:
Hexagonal shape pile cap of size 19m x 12m x 3m for tower. Hexagonal shape pile cap of size 10m x 8m x 3m for pier.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Tremieseal (PCC) of M30 grade concrete 1m thick below pile cap.
Cofferdam: Interlocking liner type.
Total nos. of pile cap: 12
Tower/Pier:
55m height tower above pile cap 2 inclined legs with strut at top. The tower top portion is provided with anchorages for stay cables. Grooves are provided on the curved faces of the tower for aesthetics.
Hammer head shape hollow pier of size 4m x 2.5m with height 16m.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of Tower: 4
Total nos. of Pier: 8
Segment:
Fish belly shaped precast segmental concrete box of size 22.7m x 3m x 3m with 3 voids. Segments match cast by short line method. Anchorage for stay cables provided in alternate segments.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Segment weight: 130T to 150T
Total nos. of segment: 234
Erection:
Segment by segment erection by balance cantilever method using Derrick system of capacity 150T.
Epoxy glue is used to join the segments. Temporary post-tensioning is done using 22 nos. stress bars during gluing.
Cast in-situ wet joints of 50mm width is provided at every 50m interval.
Stay cable: Parallel wire system with 7mm dia. galvanized steel wires and 2 layers of HDPE. The number of steel wires in stay cable varies from 85 to 139 and the capacity of stay cable varies from 540T to 885T. The length of stay cable varies from 30m to 81m. Dead end of stay cable is anchored to the tower head and the live end is anchored to both sides of deck at 6m interval. There are 10 nos. of stay cables on either side of the tower.
Total nos. of stay cables: 160
Post tension: 70 nos. of tendons each having 19 x 15.2mm strands of various lengths.
Bearings: POT type PTFE bearing (sliding type) of capacity varying from 700T to 1200T.
Expansion Joint: Modular type expansion joint with movement range of 320mm.
LINK BRIDGE
Segmental bridge portion
General:
Bridge is arranged into units of typically three continuous spans of 50m and seven continuous spans of 30m.
Length of bridge: 150m + 210m
Span: 50m and 30 m
Carriageway: 15.65m
Side walk: 1.55m on one side
Crash barrier: 400mm on both sides
Pile:
Load bearing piles socketed into hard rock to a minimum of 4m length.
4 nos. of bored cast in-situ pile of 1.5m dia of length varying from ญญ9m to 11m designed for load carrying capacity of 1000T (approx.).
M50 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 12mm thick permanent steel casing for all piles.
Total nos. of pile: 48
Pile cap:
Hexagonal shape pile cap of size 10m x 9.5m x 3.5m for fixed pier location and 10m x 8m x 3m for sliding & expansion pier location.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Tremieseal (PCC) of M30 grade concrete 1m thick below pile cap.
Cofferdam: Circular type.
Total nos. of pile cap: 12
Pier:
Hammer head shape hollow pier of size 4m x 2.5m, height varies from 8m to 11m. Pier is divided as Fixed type, Sliding type & Expansion type.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of pier: 12
Segment:
Fish belly shaped precast segmental concrete box of size 18.1m x 3m x 3m with 3 voids. Segments match cast by short line method.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Segment weight: 110T to 130T
Total nos. of segment: 128
Erection:
Span by span construction using over head launching truss.
One span (50m) consists of 16 segments and (30m) consists of 9 segments.
Epoxy glue is used to join the segments. Temporary post-tensioning is done using 6 nos. stress bars during gluing.
2 nos. cast in-situ wet joints of 200mm width in each span is provided.
Bearings: Disc bearing (fixed & sliding type) of capacity varying from 400T to 1400T.
Post tension: 30 nos. of tendons each having 19 x 15.2mm strands and 6 nos. of tendons each having 4 x 15.2mm strands in 50m span. 18 nos. of tendons each having 19 x 15.2mm strands in 30m span.
Expansion Joint: Modular type expansion joint with movement range of 240mm.
Girder bridge portion
General:
Bridge is arranged into units of four to seven continuous spans of 24m
Length of bridge: 421m
Span: 24m and 13m
Carriageway: 15.65m
Side walk: 1.55m on one side
Crash barrier: 400mm on both sides
Pile/Pier:
Load bearing piles socketed into hard rock to a minimum of 7m length.
2 nos. of bored cast in-situ pile of 2m dia of length varying from 15m to 20m designed for load carrying capacity of 2000T (approx.).
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Liner: 16mm thick permanent steel casing for all piles.
Total nos. of pile: 30
Pier cap:
Solid pier cap of 1.6m height, 2.4m wide over the two piles with cantilevers at both ends.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Total nos. of pier: 18
Girder:
‘T’ shaped precast girder of 1.1m height, 400mm wide at base and 1.99m wide at the top. Girder length varying from 20m to 22.5m.
Post tension: 3 nos. of tendons each having 7 or 12 nos. of 15.2mm strands.
1.5m wide diaphragm provided to connect girders to make the span continues.
M60 grade concrete & Fe415 grade fusion bonded epoxy coated.reinforcement.
Girder weight: 50T
Total nos. of girder: 162
Erection:
Span by span construction using over head launching truss.
One span consists of 9 girders erected one at a time.
Cast in-situ deck slab of 240mm thick over the girders is provided.
Stitch cable of 9 nos. each having 4 x 15.2mm strand is provided in deck slab at support location.
Elastomeric bearing of size 360 x 360 x 96 mm is provided at expansion joint location. In other location the pier is integral with the deck/girder.
Modular type expansion joint with movement range of 240mm & 160mm. Strip seal type expansion joint with movement range of 50mm.