SQP For Launching of Span Truss

HCC-DSD-VNR Consortium Management System
Segment Quality Plan For The Launching Of Span Truss

HCC N 097 17 007
I. History of Revisions
Revision No. Revision date Chapter/clause no. & text Reason for
affected revision
R-0 07-07-13 First Issue
R-1 30-08-13 Revised as per client 2nd Issue
comment
R-2 20.11.13 Ch.4-Span Lowering 3rd Issue
deleted from scope, is
covered in separate SQP.
Ch- 4, 7, 14, 15.2, 15.3,
15.6, 15.7, 15.11 Updated
Revision No.: 2; Revision Date: 20.11.2013 Page 2 of 134

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INDEX
CHAPTER PAGE NO.
Construction of Composite welded steel truss girders having span of 34 x
125m + 2 x 32.6m for the Super-structure of Bogibeel Rail-cum-Road Bridge
over the river Brahmaputra near Dibrugarh, Assam in India .......................... 1
1 PURPOSE ..................................................................................................... 8
2 NAME OF PROJECT .................................................................................... 8
3 PROJECT LOCATION .................................................................................. 8
4 SCOPE .......................................................................................................... 9
5 ENVIRONMENTAL & CLIMATIC CONDITION OF PROJECT SITE ............ 9
(a) Climate ............................................................................................... 9
(b) Temperature....................................................................................... 9
(c) Hydrology ......................................................................................... 10
(d) Design Limitation & Consideration ................................................... 10
6 TERMS, DEFINITIONS & ABBREVIATIONS ............................................. 11
7 DESIGN & DRAWINGS REFERENCES ..................................................... 12
8 DESIGN REPORTS ..................................................................................... 13
9 CROSS REFERENCES .............................................................................. 14
10 RESPONSIBILITIES ................................................................................... 14
11 PERSONNEL .............................................................................................. 14
12 ASSUMED DURATION OF THE OPERATION........................................... 15
13 MATERIALS ................................................................................................ 16
14 MOBILIZATION OF EQUIPMENTS ............................................................ 17
15 METHODOLOGY FOR THE LAUNCHING OF FBARICATED TRUSS ...... 19
15.1 Introduction ......................................................................................... 19
15.2 Proposed Launching Method (QAP Clause: 4.1.1) .......................... 19
15.3 Installation of Enabling Structures for Launching .......................... 23
15.3.1 Assembly / Launching Yard.............................................................. 24

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15.3.1.1 Typical Sequence of work at Assembly Yard................................... 24

15.3.2 Launching Track (At Assembly Yard 3 & 4)...................................... 26
15.3.2.1 Purpose .............................................................................................. 26
15.3.2.2 Installation......................................................................................... 26
15.3.2.3 Check Point ....................................................................................... 27
15.3.3 Launching Sledge ............................................................................ 29
15.3.3.1 Purpose .............................................................................................. 29
15.3.3.2 Installation of Sledge ........................................................................ 30
15.3.3.3 Check Point ....................................................................................... 32
15.3.4 Foundation for Camber Check ......................................................... 33
15.3.4.1 Purpose .............................................................................................. 33
15.3.4.2 Installation of Camber Foundation ................................................... 33
15.3.4.3 Camber Checking Procedure ............................................................ 35
15.3.5 Launching Bearing at P-31(v)........................................................... 37
15.3.5.1 Purpose .............................................................................................. 37
15.3.5.2 Installation of Lunching Bearing ...................................................... 37
15.3.5.3 Check Points ..................................................................................... 39
15.3.6 A-Struts (For temp. strengthening of truss) ...................................... 43
15.3.6.1 Purpose .............................................................................................. 43
15.3.6.2 Installation of A - Struts .................................................................... 43
15.3.6.3 Check Points ..................................................................................... 44
15.3.7 Temporary Connection of Span Truss ............................................. 45
15.3.7.1 Purpose .............................................................................................. 45
15.3.7.2 Installation of Temporary Connection .............................................. 47
15.3.7.3 Check Points & Tolerances ............................................................... 48
15.3.8 Launching Nose & Tail ..................................................................... 50
15.3.8.1 Purpose .............................................................................................. 50
15.3.8.2 Installation of Launching Nose ......................................................... 51
15.3.8.3 Corrosion Protection System for Launching Nose and Tail ............. 54
15.3.9 Pulling System ................................................................................. 55
15.3.9.1 Pulling Arrangement (At Vertical Assembly Yard) ......................... 55
15.3.9.2 Pulling arrangement at pier location ................................................. 60
15.3.10 Launching Bearing at Pier ............................................................. 66
15.3.10.1 Purpose .............................................................................................. 66
15.3.10.2 Installation......................................................................................... 70
15.3.11 Bracket at Pier P10, P20 and P30 ................................................. 73

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15.3.11.1 Purpose .............................................................................................. 73

15.3.11.2 Installation / Assembling .................................................................. 74
15.4 Operation Method of Pulling Device @ Pier Location ..................... 77
15.5 Operation of Launching Bearing ....................................................... 84
15.6 Operation Method of Launching Nose .............................................. 90
15.7 Operation Method of launching tail .................................................. 97
15.8 Launching Procedure ......................................................................... 98
15.8.1 Sequence of Launching (QAP Clause: 4.1.1)................................... 98
15.8.1.1 LAUNCHING PHASE 0: ................................................................. 99
15.8.1.2 LAUNCHING PHASE 1.0 ............................................................. 105
15.9 Dismantling of Nose for Launching train 2, 3 and 4 ...................... 113
15.10 Dismantling of Tail ........................................................................... 118
15.11 Removal of Launching Bearing and Cutting Connection Joints .. 119
15.11.1 General........................................................................................ 119
15.11.2 Jacks required for Operations: .................................................... 120
15.11.3 Weather Conditions during cutting and lowering of Trusses........ 120
15.11.4 Bearing axis ................................................................................. 120
15.11.5 Operational Procedure: ............................................................... 121
16 CORROSION PROTECTION .................................................................... 128
17 GRINDING OF BOTTOM CHORD WELDING .......................................... 129
18 CHECKING SETTLEMENT ....................................................................... 130
19 QUALITY CONTROL PROCEDURES ...................................................... 131
19.1 Inspection & Testing Plan:............................................................... 131
20 OHS & ENVIRONMENT MANAGEMENT PLAN: ..................................... 131
21 EMERGENCY PLAN ................................................................................. 131
22 ATTACHMENTS: ...................................................................................... 132
22.1 Attachment A: Extracts from Structural Analysis ......................... 132
22.1.1 A1 Bearing Forces Launching Phase 2 Page A1/1 – A1/8 ............. 132
22.1.2 A2 Bearing Forces Launching Phase 0-1 Page A2/1 – A2/15 ........ 132

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22.1.3 A3 Launching Yard Single Truss Page A3/1 – A3/10 ..................... 132
22.1.4 A4 Launching Yard Sledges Phase 0 Page A4/1 – A4/30 .............. 132
22.1.5 A5 Launching Yard Sledges Phase 1 Page A5/1 – A5/28 .............. 132
22.1.6 A6 Deflections Launching Phase 2 Page A6/1 – A6/12 ................. 132
22.2 Attachment B: Methodology Sequence Drawings ......................... 132
22.3 Attachment C: Inspection Plan ........................................................ 132
22.3.1 C1 Inspection Plan Launching........................................................ 132
22.4 Attachment D: Emergency Plan ...................................................... 132
22.4.1 D1 Emergency Plan ....................................................................... 132
22.4.2 D2 Bracing Nose ............................................................................ 132
22.5 Attachment E: Bolts - Torque Moment ........................................... 132
22.5.1 E1 Torque Moment ........................................................................ 132
22.6 Attachment F: Strands Scheme ...................................................... 132
22.6.1 F1 Strands Scheme ....................................................................... 132
22.7 Attachment G: Table of Level .......................................................... 132
22.7.1 G1 Tip of Nose Phase 0 and 1 ....................................................... 132
22.7.2 G2 Connection Piece Phase 0 and 1 ............................................. 132
22.7.3 G3 Tip of Tail Phase 1 ................................................................... 132
22.8 Attachment H : Specification of Major Equipments ...................... 133
22.9 Attachment I : Erection Scheme of Launching Nose..................... 133
22.10 Attachment J : Erection Scheme of Launching Tail ...................... 133
22.11 Attachment K : Erection Scheme of “A” Strut ............................... 133
22.12 Attachment L : Erection Scheme of Connection Member ............. 133
22.13 Attachment M : Erection Scheme of Launching Bearing .............. 133
22.14 Attachment N : Erection Scheme of Pulling Device ...................... 133
22.15 Attachment O : Scheme for Camber Check at Assembly Yard .... 133
22.16 Attachment P : Erection Scheme - Pulling Device Anchor Beam 133
22.17 Attachment Q : Erection Scheme of Brackets ............................... 133

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22.18 Attachment R : Scheme for Removal of Connection Piece .......... 133

22.19 Attachment S : Checklist Format .................................................... 133
22.19.1 CHECKLIST FOR SLEDGE ERECTION & PRECAMBER .......... 133
22.19.2 CHECKLIST FOR RESIDUAL-CAMBER .................................... 133
22.19.3 CHECKLIST FOR LAUNCHING NOSE ERECTION ................... 133
22.19.4 CHECKLIST FOR TEMPORARY CONNECTION PIECE
ERECTION ................................................................................................ 133
22.19.5 CHECKLIST FOR INSTALLATION OF PULLING DEVICE &
LAUNCHING BEARING ............................................................................ 133
22.19.6 CHECKLIST FOR INSTALLATION OF LAUNCHING BEARING 133
22.19.7 CHECKLIST FOR LAUNCHING AT P31(v) ................................. 134
22.19.8 CHECKLIST FOR DEFLECTION - LAUNCHING PHASE-0 ........ 134
22.19.9 CHECKLIST FOR DEFLECTION - LAUNCHING PHASE-1 ........ 134
22.20 Attachment T : Inspection Scheme for Bottom Chord and A Strut
During First and Second Truss Launching. .............................................. 134
23 DISTRIBUTION ......................................................................................... 134
24 RECORDS ................................................................................................. 134

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1 PURPOSE
The purpose of this document is to establish the specific methods and

procedures that shall be followed for the execution of Launching of pre
fabricated Span Truss of the bridge structure and its related Quality,
Inspection, Health, Safety, Environmental and Resources deployment
procedures in accordance with the Contract ref. No. CON/Bogibeel-
Super-str./180 dated 28.02.12 (hereinafter called as the “Contract”)
Clause No. 4.6, all corresponding sub-clauses (Page 150) and all other
relevant clauses in the Contract, along with the Good for Construction
drawings (hereinafter called the GFC drawings”) provided by the Railway
as per the said contract and approved QAP (HCC-DSD-VNR/BS/QAP/01-
R5, Clause No 4.0) submitted by Consortium.
2 NAME OF PROJECT
Construction of Composite welded steel truss girders having span of 34 x

125m + 2 x 32.6m for the Super-structure of Bogibeel Rail-cum-Road
Bridge over the river Brahmaputra near Dibrugarh, Assam in India
3 PROJECT LOCATION
• State : Assam
• District : Dibrugarh
• River : Brahmaputra
Geographical Location:
• Longitude 94°45′46″,
• Latitude 27°24′22″ and
• Axis 315°07′05″.

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4 SCOPE
The Scope of this methodology covers the following activities:

• Construction/Installation of enabling structures for Launching of
Span truss.
• Construction Methodology for the Lunching of Span truss.
• Deployment of Plants, Equipments and Machinery etc.
• Quality Assurance and Quality Control during Launching work and
post checks, tests etc.
• Total numbers of Span to be Launched from South bank by
incremental launching method are as follows:
o Normal Span (125m c/c of Pier) : 39 Nos.
• Two numbers of End span shall be erected by crane with

supporting arrangement.
5 ENVIRONMENTAL & CLIMATIC CONDITION OF PROJECT SITE
(a) Climate
The climate of the project area is humid and tropical. A hot and humid pre-
monsoon from March to mid May, a prolonged southwest monsoon or
rainy season from mid May to September, a pleasant post-monsoon or
retreating monsoon from October to November and a cold pleasant winter
from December to February are the characteristics of the general climate.
(b) Temperature
The hottest months are May to September with mercury reaching 42ºC
during June. The coldest months are December, January and February
when temperature drops to 5ºC. The months, November and March, can

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also be quite cold in some years. During the other months, temperature is
more or less moderate and pleasant to bear.
(c) Hydrology
Brahmaputra is a perennial river with maximum discharge of around
73000cumec during monsoon. In the off peak seasons, some part of the
river bed remains dry but it is not possible to identify which part as the
stream changes its course after every monsoon.
• Design Discharge : 73000 cumec
• Design HFL
o With Aggradations : 106.52m
o Without Aggradations : 102.92m
• Low Water Level : 98.30m
Note: The Hydraulic data is an extract from DPR of the project and
provided by NFR. The return period of the highest HFL is taken as 100
years in the DPR.
(d) Design Limitation & Consideration
Maximum wind speed 15 m/s [54km/hr] has been considered during
launching operation if wind speed goes more than the consideration,
launching operation should be stopped and truss will be anchored if wind
speed goes more than 20m/s[72 km/hr].[Detail anchorage arrangement is
elaborated in this SQP in later chapters].
During launching process, weather forecast shall be maintained at site

office. Before each launching process a weather forecast shall be
obtained and 5 more days starting from the day of launching operation
shall be reported.

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6 TERMS, DEFINITIONS & ABBREVIATIONS
The words like Contract, Consortium, Contractor, Engineer (Synonymous

to Engineer’s representative), Drawing, Employer, Government, Works,
Worksite used in this methodology shall be considered to have the
meaning as understood from the definitions of these terms given in the
General conditions of the contract. All terms, definitions & abbreviations of
ISO 1090, ISO 12944 (all sections) and their referred ISO codes shall also
apply.
Terms and Definitions
SUB-CONTRACTOR The firm selected by the Contractor on the

basis of its past experience about work,
Equipment availability, Financial ability and
competent manpower to carry out a part of
work.
CONSORTIUM HCC-DSD-VNR Consortium
ENGINEER/CLIENT Northeast Frontier Railway
Abbreviations
PQP Project Quality Plan

QAP Quality Assurance Plan
SQP Segment Quality Plan
CEMG Construction Engineering & Methodology
Group of HCC
IMS Integrated Management System
MTC Manufacturer’s Test Certificate
QA Quality Assurance
QC Quality Control
ITP Inspection Test Plan
QMS Quality Management System
QHSE Quality & Health, Safety & Environment

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7 DESIGN & DRAWINGS REFERENCES
Document
Index Name of the document
No.
Launching - General Arrangement Drawings
D M-001 Launching Scheme
B M-011 Launching Phase 0.1 - Yard
A M-012 Launching Phase 1.0 - Yard
A M-013 Lowering Truss
A M-021 Launching States Phase1 – 9
A M-022 Launching States Phase 10 -19
A M-023 Launching States Phase 20 -39
A M-024 Launching States Phase 40 + Phase II/29..30
A M-025 Launching States Phase III/1..20 + Phase IV/8..9
Reinforcement Superstructure
B M-101 Reinforcement - Normal Span
B M-102 Reinforcement - Span 40,31,30,21,20,11,2
C M-103 Details Connection Truss Girder
A M-104 Temporary Vertical Truss Member (A-Strut)
A M-105 Temporary Vertical Truss Member (A-Strut) – Alt.
Pulling Device
C M-200 Pulling Device - Overview
C M-201 Pulling Device - Anchor Beam
B M-202 Pulling Device - Const. Pier
0 EW97FS-07 Pulling Device – Construction of Piers - GA (Alt.)
0 EW97FS-08 Pulling Device – Connection Details – (Alt.)
0 EW97FS-09 Pulling Device – Connection Details – (Alt.)
Launching Bearings
B M-300 Sliding Bearings - Overview
E M-301 Sliding Bearings - Detail
Bracket Pier Axis 10,20,30
B M-400 Bracket Pier 10;20;30 - Overview
A M-401 Bracket Pier 10;20;30 - Details
Launching Nose
E M-501 Launching Nose - Side View
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Document
Index Name of the document
No.
E M-502 Launching Nose - Top and Bottom Chord
E M-503 Launching Nose - Sections
0 M-504 Launching Nose – LN to Low
Launching Sledge & Track
A M-600 Launching Yard - Overview
A M-601 Launching Sledge - Overview
C M-602 Launching Sledge - Details
A M-603 Launching Track (Steel Girder and Temp. Guiding)
B M-604 Launching Track - Pulling Device
0 BB/97/MC/100 Pulling device on Yard Details
C M-605 Launching Track - Pier P 31(v)
0 M-606 Block Foundation 4,50 x 4,50 m – Camber
A M-610 Launching Track - Reinforcement
All Launching work shall be done as per approved GFC Drawing.
8 DESIGN REPORTS
• Design Report M 151-A - E Structural Analysis Superstructure
• Design Report M 250 Structural Analysis Pulling Device Pier
• Design Report M 251 Structural Analysis Pulling Device Yard
• Design Report M 350-B Structural Analysis Sliding Bearing

Analysis Load Transfer Launching Bearing –
• Design Report M 351 Superstructure
Analysis Load Transfer Launching Bearing –
• Design Report M 352-A Superstructure – FEM
• Design Report M 450 Structural Analysis Brackets Pier 10,20 and 30
• Design Report M 550-A Structural Analysis Launching Nose
• Design Report M 650 Structural Analysis Launching Track

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9 CROSS REFERENCES
This Methodology shall be read in conjunction with the following

documents:
• Tender Document Specification

• Good for Construction Drawings for Bogibeel Bridge.
• QAP : HCC-DSD-VNR/BS/QAP/01-R5
• Welding Plan : HCC N 097 17 08
• Segment Quality Plan for Fabrication : HCC N 097 17 02
• Segment Quality Plan for Erection : HCC N 097 17 06
• Segment Quality Plan for C.P System : HCC N 097 17 05
10 RESPONSIBILITIES
Personnel responsible for execution and quality control for enabling and
permanent works shall be as per the responsibilities Matrix laid down in
the Project/Segment Organization Chart.
11 PERSONNEL
It shall be ensured that supervisory personnel at all level and workmen

carrying out each of the Launching process are adequately informed and
well trained. They shall have the overall understanding of the process and
the consequent loss of quality & loss in the service life of the Bridge due to
inadequate adherence to the procedures.
Manpower required for the critical activities are as follows.
• Senior Launching Manager: 1

• Launching Manager: 1
• Launching Engineer: 2

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Skilled workers shall be positioned on each pier during launching for

feeding of the launching pads on launching bearings.
At each pier, following skilled workers shall be deployed:
- 6 workers for feeding and taking the sliding plates out (2x2
infront of each launching bearing for inserting sliding plates and
1x2 on the back of launching bearing for taking out the plates )
- 2 workers as a handyman
- 1 supervisor
Following skilled workers shall be deployed at pulling pier [i.e. P11, P21,
P31 and P40] for pulling arrangement
- 2 Hydraulic operators
- 1 Electrician
- 1 Lunching Supervisor
The supervisors will be in contact with walkie-talkies to the launching

operator at the hydraulic equipment. Assistance from skilled workers shall
be given for placing installation of strands and stressing.
12 ASSUMED DURATION OF THE OPERATION

Activity Description Duration
Launching of a regular span 125 m from One Pier to Other 15 h
The launching process for one span (Incl. pre & post activities)will be done in 3 days
Launching from assembling bed 3 to connection point 15 h

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13 MATERIALS
• Elastomeric Bearings:
a) Launching Bearings:
• 900 x 150 x 60 mm,
• Spring stiffness 360.00 kN/m,
• Allowable compression >= 15 N/mm2
b) Sledge:
• 400 x 200 x 40 mm,
c) Pulling Device:
• 4 Nos. x [400 x 300 x 30 mm],
• PTFE-Plates:
• t = 5.5 mm,
• Allowable compression >= 15 N/mm²,
• Stainless Steel:
• Yield stress >= 170 N/mm²
• 12MM/GR.SS304L//EN 10088-1/X2CRNI19-11/1.4306
• Strands Type:
• 15.2mm dia uncoated stress relieved low relaxation seven-ply
strand as per IS 14268
Documents supplied with the material shall be checked which includes
material test certificate and suppliers declaration of conformity.

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14 MOBILIZATION OF EQUIPMENTS
Equipment List For launching

S.
Description Quantity Remarks
No
1 Crawler Crane (Groove/Kato 40t 1 Nos. For nose erection
)
2 Crawler Crane ((P&H 1 Nos. For nose and tail
KOBALCO 5100 100t ) dismantling and
launching bearing
placement.
3 GMAW, Welding Equipment As per req. for welding of temp
(set) connection
4 250 T Barge 1 Nos. For Nose and tail
dismantling
5 Tug Boat [250HP] 1 Nos. For barge movements
6 1000 T Capacity multi strand 4 Nos. Pulling arrangement at

pulling jacks (at pier location) pier location
7 200 T Capacity multi strand 2 Nos. Pulling arrangement at
pulling jacks (at Yard location) assembly yard and P1
Location
8 Power Pack (EOHP), 80LPM 3 Nos. For pulling Jacks
discharge
9 600T Single acting Hydraulic 4 Nos. For span lowering
jacks, (with tilt saddle and fixing
collar)
10 600T Single acting Hydraulic 4 Nos. For load transfer during
jacks, (with tilt saddle and fixing stress releasing
collar)
11 Hydraulic Jacks (500T Capacity) 4 Nos. For Camber check
(Single acting with tilt saddle
and fixing collar)
12 Hydraulic Jacks (400T Capacity) 8 Nos. For launching bearing @
(with tilt saddle and fixing collar) P31(v)
13 Power Pack (EOHP) 8 Nos. For 600T jacks

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Equipment List For launching

S.
Description Quantity Remarks
No
14 Single acting hydraulic jacks 4 Nos. For adjustment and
(20T Capacity) with hand pump alignment of the truss
girder at launching yard
15 Single acting hydraulic jacks 20 Nos. for adjustment and
(50T Capacity) with hand pump alignment of the truss
girder on piers
16 Double acting hydraulic jacks 4 Nos. Below Launching bearing
(50T Capacity) with tilt saddle and nose during
along with hand pump launching
17 Sling [Lifting Belt], lifting As per req. For the lifting of light
capacity ~ 10-20T weight Component
18 6x 36 Steel core wire rope slings As per req. For Launching bearing
,(20 dia to 36 dia) and heavy materials
19 D- Shackles As per req. For heavy lifting
20 D.G Set (125KVA) 1 No. For P11/P21/P31 & For

P1 from assembly yard.
21 D.G Set (30 KVA) 1 No. For standby arrangement
and lighting of the girder
22 PPT & Safety equipments As per req.
Specification of major Equipments is provided in Attachment H.

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15 METHODOLOGY FOR THE LAUNCHING OF FBARICATED TRUSS

15.1 Introduction
A Rail cum Road Bridge is proposed by Indian Railways across River

Brahmaputra near Dibrugarh in Assam. The bridge will carry three lane
road with footpath on both side and also a dual broad gauge Rail with
gang way on either side. The superstructure is a two tier composite truss
with completely welded steel truss and reinforced concrete deck for road
on top.
The span configuration of the main bridge consists of

1*33.4+39*125+1*33.4 making a total bridge length of 4941.4m. All the
spans are designed as simply supported spans with effective span of
121.6m (c/c of bearings). The bridge has a navigational clearance of 10 m
above HFL. The whole bridge is on straight alignment without any vertical
gradient.
15.2 Proposed Launching Method (QAP Clause: 4.1.1)
A brief process of the whole launching method is explained below to get

an overall picture of the launching procedure. Later on a detailed step by
step procedure for launching, along with work instructions, important
parameters to be noted, design validation process, details of various
installations required for launching, etc are elaborated in separate
sections.
The superstructure is proposed to be launched by “Incremental

Launching” from the embankment on A1 side. The components of the
truss like Nodes, Bottom chord, Top chords, Vertical, Diagonals etc are
fabricated in a custom built workshop. These fabricated units are
transported to Assembly Yard (Yard 1 and 2) where in the components
are assembled and welded in Laydown condition to make modules of

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about 30 m each. Each of these modules (weighing about 110 to 135 T)

are transported by two gantries operating in tandem to the Vertical
Assembly Yard (3 and 4) where in all these modules are assembled to
true line and level. The joints between the two modules are welded here
along with other components like cross beam, bracings etc. The whole
truss is assembled on sledges of varying height to consider pre-camber.
These sledges will also facilitate longitudinal sliding of the completed
trusses in the yard. The sledges supporting the truss will slide over the
launching tracks which in turn are supported by specially designed
foundations.
Once the first truss (for span P39-P40) is completed, the truss will
be jacked up on another set of specially prepared foundations (located
behind P31(v)) to verify the camber (when the truss is supported on four
end supports). Once the camber checks are completed a prefabricated
Nose will be fixed to the front end of the truss. The purpose of the Nose is
to reduce the cantilever bending moments and the reaction on bearings
due to cantilever. During this process of fixing of nose, a launching
bearing will be mounted on P31(v). For further operations of launching,
pier P31(v) will be used as support.
After the Nose erection is complete, the truss is pulled forward with the
help of a pulling device. This pulling device is mounted on a Pier P1 and it
will pull the truss and the nose forward. As the truss moves forward, a
sequential jacking of the truss at P31(v) is done to control excessive
reactions on the sledges. Launching is continued till the nose takes
reaction on the launching bearing mounted on A1. In order to negate the
deflection of the nose tip due to cantilevering, the bottom of the nose is
profiled so that the nose lands freely on the launching bearing in spite of
cantilever deflection.

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In order to satisfy the strength requirements during launching process, the

members of trusses (like bottom chords, diagonals etc) are strengthened.
For some trusses, “A” struts are installed at specified locations to minimize
the stresses in the bottom chord.
Launching is continued further till the rear end of the first truss
reaches the foundation for camber checking. At this time the second truss
is moved forward and connected to the rear end of the first truss with a
connection piece welded between the two trusses. The process is
continued till the 10th truss reaches at pier P31(v). At this stage a “Tail”
(which is similar to Nose) is attached at the rear end of the 10th Truss.
This is again to reduce cantilever moments at the rear end. Pulling device
of P1 will be disconnected and pulling device of P11 will be activated. Now
the whole system of 10 trusses will be pulled forward till the rear end of
truss 10 reaches at Pier P10. Pulling device of P11 will be de-activated
and further pulling will be done from P21. The process is repeated till the
first train of 10 trusses reaches at P40.
At the end of this stage, the nose is between P40 and A2 and the
tail is between P29 and P30. Nose is dismantled with the help of land
based crane between P40 and A2. Tail is dismantled with the help of a
floating crane/or by other devices like derrick etc operating on the
launched truss and tail.
Simultaneously the second train of trusses T11 to T20 is launched in

similar procedure till the tip of the nose is about 10 mts from Pier P30.
Since the previously launched truss T10 is already in place, the nose
cannot cross beyond P30. To facilitate further launching, a pier bracket is
attached to Pier P30 on A1 side. A launching Bearing is mounted on this
pier bracket. Second train of truss along with nose is launched in stages
over this pier bracket. Part of the nose beyond the launching bearing on

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Pier bracket is dismantled with floating crane (or a similar device operating
from the previously launched truss). After dismantling part of the Nose,
further launching is done in stages and simultaneously part of the nose is
dismantled. This process is repeated till the Truss T11 reaches the final
bearing locations. Repeating the above process, the third and fourth trains
of trusses (10 Trusses for train 3 and 9 trusses for train 4) are launched.
Due to the effect of continuity, there are locked in stresses at the

connection between two trusses. By a systematic procedure of jacking up
and jacking down of some of the supports, the stresses in the connections
are brought to a minimum values. Under such reduced stress level in the
connections, the connections are gradually cut with flame cutting and the
ends of the trusses are finished to the required specification. Since the
launching levels are higher than the required final levels of trusses, all the
trusses are jacked down systematically to lower the trusses on final
bearings.
The first span launching shall be Trial Launching. During first Launching
thorough visual inspection of the Bottom Chords & A-Struts shall be done
when centre of each Chord is at Launching Bearing.
In the following sections all the temporary installations required for

launching and step by step procedure of launching are explained along
with relevant checks, tolerances, etc.

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15.3 Installation of Enabling Structures for Launching
To execute the launching process, following equipment / machine and
temporary steel structures are required.
1. Assembly / Launching yard
2. Launching Track at Assembly yard
3. Launching sledge at Assembly yard
4. Foundation for Chamber Check
5. Launching bearing at Assembly yard i.e. P31(v)
6. A-Struts (For temp. strengthening of truss)
7. Temporary Connection between Trusses
8. Launching Nose / Tail
9. Pulling System
a. Pulling Arrangement at yard
b. Pulling arrangement at pier
c. Hanger for strand during launching
10. Launching Bearing at pier
11. Cantilever Bracket at Pier P10, P20 and P30 for Nose dismantling

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15.3.1 Assembly / Launching Yard
Assembly Yard-1 Assembly Yard-2 Assembly Yard-3 Assembly Yard-4
Fig: 1 Assembly Yard Layout
Assembly of span truss shall be carried out in two phases
a) Assembly Yard (Bed 1 & 2) – Laydown position
In Assembly Yard laydown position, the components will be assembled to

form the modules namely P, Q, R, S & T. The module details are
discussed in Section No. 7.5 of document no: HCC N 097 17 06, Rev 3
b) Assembly yard (Bed 3 & 4) – Vertical position
In Assembly yard (Bed 3 & 4), all assembled modules shall be assembled
in vertical position to make the truss. (For detailed assembly procedure
Ref. document no: HCC N 097 17 06, Rev-3)
15.3.1.1 Typical Sequence of work at Assembly Yard
1) Pre fabricated component will be transported from fabrication shop to

Assembly yard by flat bed trailer.
2) Component shall be unloaded at starting of the shed with the help of 20 T
gantries and shall be kept in its respective position in lay down position in
assembly yard (Bed 1 & 2).

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3) Component shall be welded to each other to form Modules as per

approved welding procedures.
4) After testing (NDT) of fabricated module, module will be shifted to Final
Assembly yard (i.e. assembly Bed 3 & 4).
5) Shifting operation will be done in 2 steps
a. Part fabricated component will be lifted in horizontal position from
assembly bed and then it will be shifted to 60° tilter in assembly
yard.
b. At 60° tilter, module shall be kept in horizontal position then it will
be turned in vertical position and shall be shifted to Vertical
assembly yard (Assembly Bed 3 & 4) with 2 nos. of 80T gantry
crane.
6) Final assembly will be done in vertical position at Assembly Yard 3 & 4.
7) After completion of final assembly strip painting work will take place (For
corrosion protection of span truss, Ref Document no. HCC N 097 17 006.
8) A general layout of the launching yard is shown on drawing M 600.

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15.3.2 Launching Track (At Assembly Yard 3 & 4)
15.3.2.1 Purpose
Associated drawings: M – 600 & M – 603
In order to shift the completed trusses to the launching position, launching track
(sliding) shall be provided from the assembly yard (Yard 3 and 4) to the
launching position. (Refer Dwg. No – M600 & M603).
The launching track consists of a steel girder with stainless steel plate on the top.
The steel girder will be supported on concrete
foundations at around 7.8m to 8.0 m c/c. To
account for higher loads during launching
phases, there will be a continuous foundation
for the length of 52 m towards P31(v). The
whole launching track is located in covered
shed. Hence no wind load is acting on the
truss during the launching operation on the
launching track.
Fig: 2-Launching Track
At every anchor foundation of the track, provisions are made for bolting mobile
lateral guiding system. With the help of the guiding system it is possible to push
the truss in lateral direction if necessary (e.g. if the truss shifts out of the centre
line).
15.3.2.2 Installation
The launching level is fixed at 118.156m RL. This level is defined as the level of
the bottom of bottom chord at centre of BJ6. With sledge height of 97.5 mm at
BJ6, the top of sliding track(stainless steel plate) works out to 118.156-
0.0975=118.0585 m RL.

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The pre-fabricated track is kept over temporary shims over the foundation
so as to achieve level of 118.0585 m RL at the top of track. After checking the
top levels accurately, grouting of the base of track shall be carried with non
shrink grout of strength (45Mpa) over the foundations.
15.3.2.3 Check Point
• The completed track for launching will satisfy the following tolerances.
o Horizontal +/-5 mm
o Vertical +/- 3 mm
• Welds in stainless steel of the track must be ground smooth to facilitate
easy sliding.
• During launching operation, the horizontal gap between the horizontal
guide of sledge and the launching track will be monitored by the workers
and the supervisor at the launching yard. If the track touches the lateral
guiding, the supervisor will inform the launching manager who in turn shall
stop launching. The mobile lateral guiding will be installed at the
corresponding sledge location. A hydraulic jack of 50 T capacities will be
installed between the guiding system and the bottom chord. The truss will
be side shifted as required by activation of the hydraulic jack.

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Fig-3: Typical Section of Launching Track with Mobile Lateral Guiding
Fig-4: Typical Section of Launching Track

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15.3.3 Launching Sledge
15.3.3.1 Purpose
Associated drawings: M – 601 & M – 602
In order to slide the completed truss from the Vertical assembly Yard, the truss is
erected on sliding blocks called as “Sledges”.
Due to the pre-camber to be provided to the truss, the sledges shall be made of
different heights. There are in total 22 sledges for each truss. The sledges are
located under every node.
Fig-5: Launching Sledge
Fig-6: Side View of launching Sledge

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15.3.3.2 Installation of Sledge
The sledges consist of a steel girder with PTFE at the bottom. This PTFE will
slide on the stainless steel plate of the lunching track. On top of the sledges
elastomeric bearings will be placed in order to achieve a uniform distributed load
on the sledge. As the friction between the elastomeric bearing and the bottom
truss chord is greater than the friction between the PTFE and the SS Plate of the
track, the sledge is fixed to truss. Therefore the truss and the sledges will slide
on the launching track.
In order to keep the sledges on the axis of the launching, the launching sledges
on both sides are laterally connected by two steel girders and each sledge is
guided at the top flange of the launching track steel girder.
The camber of the truss will be adjusted by the construction height of the sledges
which are as follows.
There are 6 different sledges:
i) Sledge at BJ1, h = 442.5 mm,

ii) Sledge at BJ2, h = 426.5 mm,
iii) Sledge at BJ3, h = 382.5 mm,
iv) Sledge at BJ4, h = 310.5 mm
v) Sledge at BJ5, h = 212.5 mm
vi) Sledge at BJ6, h = 97.5 mm

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Fig-7: Launching Sledge at BJ1 – Side View
FIG-8: Launching sledge at BJ1 – section 1-1
The sledges are connected to the truss with wooden wedges at their cross
beams. With this construction, the sledge will be guided (pulled forward) by the
truss even if there is no load on the Sledge.

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Fig-9: Sledge – Guiding
At the end of launching track there is a sledge run out (refer to drawing M607)
where the sledge can easily be removed during or after the launching.
15.3.3.3 Check Point
During launching, the sledges shall be connected by chain hoist / ropes to the
cross beams.
When the sledges are set free they can either be removed from the track or they
can be connected by a rope to the truss in order to move forward to the end of
the track. At the end of launching track the sledge can easily be removed during
or after the launching.
The PTFE may also be applied with soft soap in order to lower the friction
coefficient.
At the sledge run out the launching level will be lowered by 40 mm.
All bolts at the construction joints of the sledges are “non-preloaded” bolts. They
shall be manually tightened according to the Attachment E1. The procedure shall
be recorded.
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15.3.4 Foundation for Camber Check
15.3.4.1 Purpose
Associated drawings: M – 606
In order to check and verify the pre-camber, to be achieved after final assembly
of each truss, four foundation blocks with facility to jack up the whole truss are
provided at each corner of the truss. These foundations also accommodate
hydraulic jacks to lift the whole truss. These foundations also support the
launching track.
Fig-11: Assembly Bed
15.3.4.2 Installation of Camber Foundation
In order to check the camber of the span truss 4 jacks (4 x 500 t jacks with tilt
saddle) will be assembled at the jacking points of the foundation. In order to
safely transfer the weight of truss, RCC foundation of 4.5x5.1x1.5 m is adopted.
To minimize any settlements and to distribute the loads, rubble soling is also

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provided below the foundations. This will ensure that the top of sliding track
remains at 118.0585m RL.
The jacks required for lifting the truss are provided with tilting saddle at top and
safety lock nut. During the lifting operation, the ends of truss are likely to move
outward due to loss of camber due to self weight. To allow such movements, a
steel plate of size 600x400x40 mm with PTFE sheet on top will be placed over
the jack.
Fig-12: Section for Camber Foundation

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118.156m
Fig- 13: Section Jack for Checking Camber
15.3.4.3 Camber Checking Procedure
After the truss is completed, four hydraulic jacks of capacity 500T each are
placed over specified locations on the foundation pads. Steel packing plates shall
be used below each jack. All the packing plates shall be connected to each other
[bolted to each other].
• The span truss will be lifted up for approx. 100 – 150 mm until all the load
of truss is on the four jacks. And a clearly visible gap between the sledge and the
bottom truss at all of the temporary supports (sledges) will be achieved.
• Before starting jacking operation, initial levels of truss at all the

support points (22 points) shall be taken and recorded.

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• Two jack on each end of the truss shall be hydraulically synchronized to

ensure uniform load distribution.
• At the end of jacking, it shall be ensured that the four end supports are
almost at same level.
• After the jacking operation is complete, the lock nuts of all the four jacks
shall be engaged to avoid any hydraulic failure.
• Levels of the truss at all nodes shall be taken again and recorded. If the
foundation supports show any settlements, the same shall be suitably
compensated in the residual camber calculations.
• The measured camber shall be recorded in the respective tables of the

quality control.
• C/C Distance of both side jacks should be 8.10m in transverse direction.

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15.3.5 Launching Bearing at P-31(v)
15.3.5.1 Purpose
Associated drawings: M – 605
Launching bearing is installed at pier P31(v) to support the truss during launching
operation. The launching bearing is designed to distribute the reactions
uniformly. The launching bearing at the pier P31(v) is also designed for jacking-
up, to control the reactions at various stages of launching as defined in launching
operation.
15.3.5.2 Installation of Lunching Bearing
• To facilitate mounting of the launching bearing, the pile cap is cast over
the piles of the foundation at P31(v).
• Two bearing pedestals of required size are also cast with top of concrete
at -116.341m RL.
• An anchor plate is required to be embedded on to the bearing pedestals.
• In order to maintain accurate level of the top of anchor plate, the anchor
plate is fixed over pedestal on temporary shims.
• By adjusting the shim plates, the top of anchored plate is accurately

leveled to get top of anchor plate at 116.406m RL.
• The gap between pedestal and anchor plate is grouted with non shrink
grout.
• Four hydraulic jacks (400T Capacity) are mounted on either side of each
launching bearing to facilitate raising or lowering of the launching bearing at
various stages of launching as explained in launching procedure.
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• As defined in the launching procedures launching shall stop at designed

location.
• 4 jacks (4 x 400 t) will be installed underneath each launching bearing and

it will be lifted to the required level. Filler Plates will be installed between the
launching bearing and the anchor plate.
Fig-14: Launching Bearing at Pier P31(v) –

Section at Launching Level RL 118.156

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Fig-15: Launching Bearing at Pier P 31(v) – Section at Launching Level RL

118.6
15.3.5.3 Check Points
•Top of Pile cap shall be at 116.126m RL
•Top of anchor plate shall be at 116.406 m RL.
•Top of stainless steel plate of launching bearing shall be at 118.1385 m RL.
•The top of launching bearing on any pier shall be within +/- 1.0 mm.
According to the design the launching level at Pier 31(v) shall be adjusted. For
that following filler plates shall be used for the adjustment of launching level:

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Phase -1
Level (mm) Filler Plates (mm)
25 25
120 2 x 60
225 3 x 60 + 20 + 25
320 3 x 60 + 20 + 2 x 60
Phase – 2
Level (mm) Filler Plates (mm)
100 1 x 60 + 2 x 20
80 1 x 60 + 1 x 20
25 25
145 1 x 60 + 1x 25 + 1 x 60
265 1 x 60 + 1 x 25 + 1 x 60 + 2 x 60
100 1 x 60 + 2 x 20
Depending on the measured camber these lifting operations will be adjusted as

shown in the tables on the next pages.
If the measured camber is deviating by more than +/- 10mm, adjustment will be
done in the lifting operation at P31(v) (Rounded to the nearest 5mm)

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Table for Phase - 0

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Table for all other Phase except 0

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15.3.6 A-Struts (For temp. strengthening of truss)
15.3.6.1 Purpose
Associated drawings: M104 - 105
In order to reduce the stresses due to the local bending of the bottom chord
vertical temporary beams will be arranged between the bottom chord and top
joint of both sides of the truss. Due to its geometry these members are called “A”
-struts. The “A” - struts are placed in the zones of the maximum vertical forces
due to launching.
Based on the detailed design of launching stages, “A” struts are required for the
first and last trusses of each segment of 10 trusses (9 for last segment).
Launching Nose
Fig-16: A-struts – span 40, 30, 20 and 10 (31, 21, 11 and 1 – location A-
struts mirror images)
15.3.6.2 Installation of A - Struts
At Assembly yard during assembly of span truss in final vertical position, “A” -
struts will be bolted to the top joint and the bottom chord of the truss.
When the launching segment reaches its final location and the single span truss
girder is lowered the “A”- struts will be removed.

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All bolts at the construction joints of the A-Strut are “non-preloaded” bolts. They
shall be manually tightened according to the Attachment E1.
15.3.6.3 Check Points
• Filler plate of 10mm shall be inserted while doing the connection with top
joint & bottom chord.
• M24, 10.9 grade bolt shall be used for bolt connection

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15.3.7 Temporary Connection of Span Truss
15.3.7.1 Purpose
For the launching process it is necessary to connect the single span truss girders
with each other to form a segment of 10 trusses (9 for last segment).This will be
done at the “connection point” at a distance of 13.16 m behind P 31(v). At the
connection point the last assembled truss (i.e. Tn-1) will be connected to the
already launched segment’s truss (i.e. Tn).
Launching Direction -----
Temporary Connection
Already launched segment’s truss (i.e. Tn)
Last assembled truss

(i.e. Tn-1)
Fig-17: Location of Connection Point

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Fig-18: Temporary Truss Connection – Top Chord: (Detail “A” Top Chord)
Fig-19: Temporary Truss Connection – Top Chord: (Section 1-1)

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15.3.7.2 Installation of Temporary Connection
The already launched segment is supported at the launching bearing at Pier

P31(v) and at the Pier P1. The lately assembled truss is supported on the 2 x 11
sledges at each node.
• After checking of camber, the two trusses to be joined (Tn and Tn-1) will be
accurately aligned in transverse direction since the trusses may be slightly
off centre during launching.
• Accurate dimensions of the gap between the two trusses shall be taken.
• The already fabricated connection unit shall then be cut as per actual
dimensions.
• The unit will be placed between the two trusses with the help of a
crane/gantry.
• Temporary supports shall be arranged as per Attachment L
Fig-20A: Temporary Connection of span truss

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Fig-20B: Temporary Connection of span truss
•The end faces of the connection piece shall be edge prepared as required.
•The face of assembled truss shall be matched with temporary connection with
the help of jacks
•Welding between the temp connection piece and span truss Tn-1 & Tn shall be
completed.
•The welded portion shall be grinded properly to make the surface smooth,
especially bottom surface which will be in contact with launching bearing during
launching of span truss
15.3.7.3 Check Points & Tolerances
The vertical level at both ends shall be same. In order to achieve it, the launched
segment will be lifted, if required, at P31(v). If necessary small adjustments shall
be done with the help of a jack placed on the temporary support.

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Allowable vertical tolerance between north end of truss in the yard and south end
of already launched truss - Both ends of the truss: +/- 2mm
Vertical alignment of truss (Tn) shall be adjusted by jacking from P31(v)

foundation.
In lateral direction adjustments will be done with the help of the lateral guiding at
the camber foundation.
The camber foundation is available at both ends of the truss. If necessary jacks
can be connected with the lateral guiding and the truss can be moved in
transverse direction.
It is important that the truss to be welded is in the same horizontal alignment as

the already launched sections. This shall be checked at both ends of the truss by
measuring the distance from the truss outside the designed bridge line.
Allowable tolerance: +/- 5 mm
The welds are complete penetrated welds. The welds shall be checked 100 % by
ultrasonic. Defects shall be evaluated according to the same quality class as per
the bridge. The results shall be recorded.

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15.3.8 Launching Nose & Tail
15.3.8.1 Purpose
In order to reduce the reactions and bending moments in the members of

truss during full cantilever, a nose is attached to the front end of the first
truss of each segment. Similarly for the same reason, a tail is attached to
the rear end of the last truss of each segment.
According to the launching scheme, launching will be done only from the
south embankment. As has been explained, the launching is divided into 4
segments (3 segments of 10 trusses and 1 segment of 9 trusses). In order
to launch the segments to its final position a launching nose at the
beginning and a launching tail at the end of the segment is required.
Length of Nose and Tail is 52 mt. as per the design. The construction of the
nose is similar to the tail. Therefore the explanations given below for the
nose are also applied to the tail.
The nose is a steel truss construction with bottom bracing. The bottom
chord of the nose is box section similar to the bottom chord of the truss. The
other sections of the nose are open sections. In order to disassemble the
nose part by part the nose is bolted. The connection to the superstructure is
also bolted.
At the connection of the bottom chord of the nose with the bottom joint of
truss the bottom flange will be assembled with a smooth alignment.
During maximum cantilever stage, the nose will deflect considerably. As

such the bottom of the nose is tapered in the front to ensure that the nose
rides over the launching bearing without any requirement of jacking.

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The total weight of the nose is approx. 190 T
Fig 21: Top View and Side View of Launching Nose
15.3.8.2 Installation of Launching Nose
Associated drawings: BB/97/MC/97[sheet 1 to 4]
The stages of erection of nose are also applicable for the assembly of Tail.
The nose will be assembled in front of the launching segment. The first
truss girder of the launching segment (span 40, 30, 20 or 10) will be
assembled at the end of the track at the location of the block foundation for
camber checking (15.560 m next to axis P31(v)).

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• After the camber has been checked the truss will be lowered onto the
sledges again.
Afterwards Pre fabricated nose shall be assembled. First the bottom chord
of the nose will be assembled.
• It is important to maintain the level of the temporary supports accurately,

specially tapered part of the bottom chord (refer to the drawings M501 –
M503).
• Afterward the top chord, the diagonal members, the cross beams and the
bracing will be assembled. The connections will be bolted.
• All bolts at the construction joints of the nose shall be tightened according
to the Attachment E1. The procedure shall be recorded.
• After the assembly is complete, the temporary support shall be removed.

This can also be achieved by jacking the launching bearing at P31(v)
• A check of Deflection of the nose shall be done and compared to the

design values (refer to the Attachment B [Drg. Nos: EW/97/SK - 21 to 42]
and G1)
Launching Tail: For the assembling of the launching tail the situation is
slightly different. When the last truss of each launching segment has been
assembled and launched the tail will be assembled. At this the truss is
supported at the Pier P31(v) (level + 100 mm) and at the Pier P1. The tail
will be assembled, as explained above for the nose, with the help of
temporary supports. After the tail has been connected to the truss the
temporary supports will be removed. A check of Deflection of the tail shall
be done and compared to the design values. At the same time it shall be
taken care that the bottom chord of nose is assembled in the same line as

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that of the bottom chord of the bridge (no kink in top view between
superstructure and nose).
The distance from the reference line (bridge axis = reference line for
launching) shall be checked and reported at every joint of the bottom chord.
The distance shall be measured at the outer side of the bottom chord.
• Reference value : 11.700 m / 2 = 5.850 m
Allowable tolerances:
Deviation from reference line of the bridge: +/- 5 mm
Total distance between outer edges of both bottom chords 0 / + 10 mm
Fig-22: Launching bearing & Truss for reference Value

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15.3.8.3 Corrosion Protection System for Launching Nose and Tail
• Surface Preparation: Grit Blasting SA-2.

• Surface Profile: 30 µm.
• Prime Coat: Red Oxide 40 µm, Top Coat: Enamel Paint 35 µm.

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15.3.9 Pulling System
15.3.9.1 Pulling Arrangement (At Vertical Assembly Yard)
Associated Drawing M604
15.3.9.1.1 Purpose
The pulling device shall be constructed at Assembly Yard 4 to pull the Truss from
Assembly Yard 3 to the connection point for launching at Assembly Yard 4.
15.3.9.1.2 Installation of Pulling Device
This pulling device has to pull a single truss (~1700 t) to the connection point. A
steel transverse beam between the two launching tracks will be assembled.
Two strand jacks of 200T capacity each will be installed at the locations shown in
drawing No M-604.
Launching
Assembly Bed -4
Anchor Beam Jack

For Jack
Jack
Construction
Camber
Foundation
Extended Foundation for
Pulling at Assembly Yard 4
Fig-30: Pulling Device at Yard – Side View

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The strands are running in two lines between the two bottom truss chords – each
at an offset of 1250 mm from the centre line of the bottom chord of truss.
Fig-31: Pulling Device at Yard

(Construction for Jack at the Extended Foundation at Assembly Bed 4)
Installation of the Strands
Installation of strand (15.2mm dia uncoated stress relieved low relaxation seven-
ply strand) shall be done manually. Prior to installation of HT strand, they shall be
cut at required length and kept in covered shed to protect from dirt, rust etc.
Marking over the front bearing and rear bearing plate shall be done to ensure
that the strands are threaded in straight line.
Once threading is completed wedges at rear anchor block shall be inserted to

lock the strand in position and jack shall be erected at front end.

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Fig-32: Pulling Device @Yard – Anchor Beam Detail

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Detail of Strand Jack (200T Capacity)
Fig-33: 200T Multi strand jack

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15.3.9.1.3 Check Point:
• The C/L of strands (strand axis) shall be at 117.476m RL (680 mm below

launching level of 118.156m RL).
• The strands shall be located at 4.05m (in lateral direction) on either side of
bridge axis (also called bridge center line).
• During Pulling of individual truss, the maximum force required for pulling is
expected to be 85T(5% of weight of truss).The hydraulic pressure setting
in the power pack shall be fixed at 95T(both jacks together.). This will
ensure that the pulling system will stop if the force required is higher than
95T.
• All the strands, grips etc shall be checked periodically to be free from any
damage, oil, grease, dust etc.
• The strands should be coated with a thin coat of water soluble oil to
prevent rusting.
15.3.9.1.4 Tolerance:
• Level strand axis: 117.476 m

o Allowable tolerance: +/- 10 mm
• Strand distance from bridge axis: 4.050 mm
o Allowable tolerance: +/- 5 mm

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15.3.9.2 Pulling arrangement at pier location
15.3.9.2.1 Purpose
Associated Drawing: M200 - 202
As mentioned before, 10 (9) trusses form a launching segment. In order to pull

this launching segment a pulling device is required. This operation will be done
with the use of multi strand jacks that are connected to the substructures (piers).
These multi strand jacks will be used to pull strands which are anchored at the
launching segment. The strand jacks are placed at the piers P1, P11, P21 and 31
at vertical beam. The strands are anchored at the anchor beam. In order to limit
the strand length the anchor beam will be shifted after each launching stage of
125 m. The anchor beam is located at the first cross beam of the truss.
Two 1000t multi strand jacks (Model K1000 by Freyssisnet) will be used. The
level of the strands will be 680 mm below the bottom chord of the truss.
Fig-34 (A): Side and Top View Pulling Device

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Fig-34 (B): Side and Top View Pulling Device
15.3.9.2.2 Installation
- Vertical Beam at the Piers
The vertical beam will be assembled by a mobile / floating crane and to access
the pier cap top, light weight ladder shall be provided which will be shifted to
each pier as and when required. The detail scheme of shifting and installation of
the pulling device and construction at piers is enclosed in Attachment N.
The sections used for construction of pulling device at Piers for Jacking
arrangement shall be as per M202. Alternatively, the sections shown in Drg. No.
EW97FS-07, 08, 09 can also be used.
With the use of filler plates the vertical beam will be set on top of the Well Cap
incase of P1 and Fender Wall Top incase of P11, P21, and P31. The beam shall

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be anchored on top of the pier cap with SHS 80x8 (refer to the sketch below).
SHS 80x8 is located away from the reinforcement area.
SHS 80x8
Fig: 35: Pulling Device – Vertical Beam – Bolt Connection
The level of the strands is marked at the vertical beam (center line of the
adapter plate of the strand jack). The beam shall be installed according to
this level (680 mm below launching level).
• Level strand axis : 117.476 m

• Allowable tolerance : +/- 10 mm
The vertical beam shall be installed vertical. The location in horizontal view
is defined by the line of the strands. The strands run in a line with a lateral
distance of 4.050 mm from the bridge axis.
• Distance from bridge axis : 4.050 mm

The gap between the vertical beam and the pier cap shall be filled with
elastomeric bearings (size as mentioned in the related drawings, allowable

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stress 15 N/mm²). In order to fix the location of the elastomeric bearing it

shall be glued with Mageba glue or any other epoxy base glue shall be
used to the vertical beams before erection. A small cleat shall also be
welded underneath the elastomeric bearing in order to keep it in place. It
shall be ensured that there is no gap remaining.
Afterward the lateral cross girder between the vertical beams shall be
installed.
Finally the bottom frame will be installed. Elastomeric bearing (bearings size
as mentioned in the related drawings, allowable stress 15 N/mm²) between
the pier and the steel girder shall be installed in the same way as explained
above. It shall be ensured that there is no gap left.
After the installation of vertical beams and lateral supports, as explained

above, the working platform for Pulling Device shall be assembled.
The following loads have been considered in the design of the working
platform:
• Hydraulic oil 27 kN (2,7 t)

• Strands 66 kN (6.6 t) at each strand line
• Strand jacks 31 KN (3,1 t) each strand jack
• Live Load : 2,5 kN/m²
Now, strand jack shall be erected and bolted to the vertical beam. It shall
be ensured that the assembling of the strand jack will be perpendicular to
the vertical beam at its defined level.
All bolts at the construction joints of the pulling device are “non-preloaded”
bolts. They shall be manually tightened according to the Attachment E1.

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- Anchor Beam
The anchor beam will be assembled between the first two bottom cross
girders of the next truss girder to be launched. The anchor beam consists of
a horizontal box girder and vertical girder. Both girders are welded together
and will be assembled as one part. The horizontal girder is supported on the
top flanges of the first two cross girders of the truss. At both the top flanges
elastomeric bearings (Allowable Compression <= 15 N/mm²) shall be
placed before placing the anchor beam.
The level of the strands is marked at the vertical truss (center line of the
adapter plate for the strand anchor). The vertical truss shall be positioned
according to this level (680 mm below launching level).
• Level strand axis : 117.476 m

The anchor beam shall be installed in the line of the truss. The location in
horizontal view is defined by the line of the strands. The strands run in a line
with a distance of 4.050 mm from the bridge axis.
• Distance from bridge axis : 4.050 m

The anchor beam shall be wedged in lateral direction with hard wood. At the
first cross beam the wedges will be assembled between the node of the
truss and the brackets for the stringers. At the end cross beam the anchor
beam will also wedged to the node of the truss. Due to the construction of
the horizontal box girder at that location two additional girders ISHB
150x150 are required in order to wedged it to the stringer bracket.

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The construction of the Anchor Beams shall be UT checked. Defects shall

be evaluated according to the same quality class as for the bridge. The
results shall be recorded.
All bolts at the construction joints of the anchor beam are “non-preloaded”
bolts. They shall be manually tightened according to the Attachment E1.
The procedure shall be recorded.

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15.3.10 Launching Bearing at Pier
15.3.10.1 Purpose
The launching bearings (or sliding bearings) are arranged under both side of the
bottom chord of the truss. The bearings are placed on a spherical plate in order
to divide the support reactions equally to the two webs of the bottom chord and to
take over the rotation angle of the superstructure due to the launching.
The launching bearings consist of a welded steel box. The top plate of this box is
a 100 mm thick plate. On top of this plate in the line of the bottom chord’s webs
of the truss, elastomeric bearings 900 x 150 x 40 mm will be placed in order to
obtain a uniform distributed stress between the launching bearing and the
superstructure. On top of the elastomeric bearings a 40 mm thick steel plate will
be fixed. A stainless steel plate (t=12 mm) is welded on top of this plate.
The launching bearing has a length of 5700 mm + 2 x 800 mm for the insertion of
the sliding plates. The total height of the launching bearing from the top of the
final bearings anchor plate is 1750 mm.
Fig-39: Side View of launching bearing

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Both launching bearing are connected with each other by two beams at distance
of 2000 mm. In the line of the cross beams two lateral guiding are located. The
lateral guiding takes over the lateral forces due to wind and transfer them to the
bearing pedestal. Forces in longitudinal direction due to friction are transferred to
the bearing pedestal by cleats.
Fig-40: Cross Section Launching Bearing
During launching process, sliding plates will be inserted between the bottom
flange of the superstructure and the 40 mm steel plate with the welded stainless
steel plate on top. The sliding plates consists of steel plate and 6 numbers of
5.5mm thick PTFE. The PTFE is chambered in the steel plate.

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Fig-41: Sliding Plates
Weight of the launching bearing
Launching bearing (each) : 14.6 t
Bottom bearing plate + cleats : 2.75 t
Cross beam (each) : 5.8 t
Top part (on top of elastomeric bearings) : 0.75 t
Total : 2 x 14.6 t + 2 x 2.75 t + 2 x 5.8 t + 2 x 0.75 t ~ 48 t
At every pier a working platform will be erected as shown in the sketches’ below:

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Fig-42: Working Platform @ Piers

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15.3.10.2 Installation
The launching bearing shall be installed according to the drawings M300 and
M301.
On top of the bearing pedestals the anchor plate of the final bearing will be
installed and grouting will be done as per installation methodology of permanent
bearing. Before concreting of the Pedestals and fixing of the anchor plates, the
centerlines of Pier shall be marked on each Pier with the help of Total Station by
a qualified surveyor. All the corners of the points of pedestals shall then be
marked on top of pier cap with reference to the pier centre line. After ensuring the
correct position of the pedestals, further works of concreting of pedestals be
taken up. The measurements and coordinates shall be recorded. Similar method
shall be adopted for fixing of anchor plates as well. Detailed methodology is
mentioned in SQP for Installation of Spherical Bearings.
Based on the bridge axis the centre line of the bottom truss girder is marked with
red permanent colour on the bearing pedestal. This line shall be the reference for
the installation of the launching bearing.
Distance between the reference lines : 10.60 m
Installation of anchor plate - allowable tolerances for the launching process at

one pier axis:
Longitudinal (bridge axis) direction : +/- 5 mm
Horizontal direction : +/- 5 mm
Level deviation between both anchor plates <= 2 mm
The top surface of the anchor shall be plain in order to guarantee the load
transfer by contact.

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Allowable tolerance: 0.003 x DLP < 1 mm
DLP = diagonal length of the anchor plate
On top of the anchor plate the bottom part of the launching bearing will be
installed. The bottom part consists mainly of the 100 mm thick base plate and at
it welded cleats.
Allowable tolerance : 0.003 x DLP < 1 mm
DLP = diagonal length of the 100 mm plate
The centre line of the 100 mm plate shall be in line with red marked reference
line on the bearing pedestal.
Installation of bottom part launching bearing - allowable tolerances:
Longitudinal (bridge axis) direction : +/- 5 mm
Horizontal direction : +/- 5 mm
The bottom part of the launching bearing will be finally fixed in lateral direction by
putting filler plates or hard wood wedges between the cleat s and the bearing
pedestal.
The main part of the launching bearing will be put on top of the 100 mm plate.
Finally the cross beams will be assembled and bolted. On top of the launching
bearing the elastomeric pads and the 40 mm plate together with the stainless
steel plate will be installed.
The top level of the completely assembled launching bearing shall be checked.
[RL should be 118.1385m]
Allowable level tolerance at the top surfaces of the launching bearings at

one pier axis:

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h = +0 /- 2 mm (related to launching level)
∆ h = 2 mm (level deviation between pair of launching bearings)
Allowable level tolerance at the top surfaces of the launching bearings

between different pier axes:
h = + /- 10 mm (related to launching level)
If the measured level exceeds the tolerances, filler plates shall be installed
underneath the elastomeric pads. The filler plates shall have similar size as the
elastomeric bearings. When the pedestals are cast and anchor plates of
permanent bearings installed, it will be ensured that the levels are not higher than
required. Anchor plate is fixed much before launching bearings.
The point of touching of the Nose and the point of leaving of the tail shall be
marked with paint on the Sliding Bearing during installation of the sliding Bearing.
All bolts at the construction joints of the launching bearing shall be “non-
preloaded” bolts. They shall be manually tightened according to the Attachment
E1. The procedure shall be recorded. [Format No. HCC F 097 10 06, Rev No. 00,
Rev Date - 07.09.2013]

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15.3.11 Bracket at Pier P10, P20 and P30
15.3.11.1 Purpose
Associated drawing: M400 and M401
In order to launch the launching segment 2, 3 and 4 to their final position a

bracket is required at the piers P10, P20 and P30. The launching bearing
will be located on the bracket with an offset of 9000 mm to the pier axis. As
we pull the segment over the launching bearing on the pier bracket, a
section of the nose beyond the launching bearing will be dismantled with a
crane or suitable system. Launching will continue further till next section of
nose clears the launching bearing. This process is repeated till the front
truss of segments 2, 3 and 4 reach their final position. A typical
representative sketch is shown below.
Pic-3: Dismantling of the Launching Nose – e.-g. At Pier 30

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Due to this requirement of dismantling the nose in stages, the members of

Nose are with bolted connections. The Pier bracket which is attached to the
piers P30, P20 and P10 consist of a triangulated frame with the launching
bearing located on the top horizontal beam at the nodal point. The inclined
strut of the Pier bracket is supported on a RCC column over the piers. A
general arrangement of the Pier bracket is shown in Drg M400.
15.3.11.2 Installation / Assembling
The loads coming from the launching bearing at Pier bracket (each about
330 t) will be transferred by a RCC column to the pier. Connection dowels
are drilled and fixed on the pier for stability as per drawing M-401. On top of
the concrete column a block out will be assembled in order to concrete and
grout a head plate with shear studs later.
The steel column will be welded to the head plate on site and bolted to the
steel crossbar. The cross bar is anchored to the pier cap with 8 nos of 40
mm dia Mac alloy or equivalent Hi strength bars that are embedded in the
pier cap.
Both steel columns are connected by a bracing. The crossbars are

connected by a steel girder. On top of the cross beam and the cross bar a
wooden working platform will be installed.
The launching bearing similar to the one used at the other piers will be
added. In order to maintain the required launching level, steel filler plates as
required will be used. The tolerance in the levels between the two launching
bearings shall be within 2mm.
In order to transfer horizontal forces during launching, all filler plates /

girders shall be connected with each other by welding. The cleats of the 100
mm launching bearing base plate will be wedged to the top steel girder.

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The working load on the platform is limited to 100 kg/m²
All bolts at the construction joints of the bracket will be non-preloaded bolts.
They shall be manually tightened according to the Attachment E1. The
procedure shall be recorded.
Fig-48: Bracket – Side View
The coving of the steel shall be checked. Coving shall be < l/300 (l = length
between head plate and crossbar.

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Fig-49: Bracket –Cross Section
The erection scheme is included in Attachment Q.

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15.4 Operation Method of Pulling Device @ Pier Location
Depending on the number of trusses to be launched the number of strands

will be adjusted accordingly as shown in the table below.

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Limiting Load on
Pressu
Number of Truss Jack Practical
Wt friction Ram area re
Girders @1.05*Design value
@5% Setting
Load
T T T cm2 Kg/cm2 Kg/cm2
T1 1750 87.5 45.94 1727.88 27 30
T1+Nose 1950 97.5 51.19 1727.88 30 30
T1+T2+Nose 3700 185 97.13 1727.88 57 60
T1 to T3 +Nose 5450 272.5 143.06 1727.88 83 85
T1 to T4 +Nose 7200 360 189.00 1727.88 110 110
T1to T5+Nose 8950 447.5 234.94 1727.88 136 140
T1to T6 +Nose 10700 535 280.88 1727.88 163 165
T1 to T7 +Nose 12450 622.5 326.81 1727.88 190 190
T1 to T8 +Nose 14200 710 372.75 1727.88 216 220
T1 to T9+Nose 15950 797.5 418.69 1727.88 243 245
T1to T10 +Nose 17700 885 464.63 1727.88 269 270
T1to T10 +Nose+Tail 17900 895 469.88 1727.88 272 275
Note - If we provide less strands and do not control the total force by jack, the
strands may break if the friction is higher than expected or if there is some
obstruction. We should restrict the maximum force in jacks at every stage by
limiting the hydraulic pressure.
-Multi-Strand Jack
As explained earlier strand jacks shall be used as a pulling device and it

should be mounted over the vertical beam in such a way so that strand axis
should be 680mm below the launching level (118.156m). Total load of 10
truss (10x1700T) and one nose (1 x 200T) and tail (1 x 200) is 17400 T.

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Accordingly maximum pulling load on each jacks should be 5% of

17400=870T total hence 435 T per jack.
Fig-36: Multi Strand Jack [1000T]
Working Principle of the Strand Jack
Two 1000 mt capacity jacks will be installed on the vertical beam (reaction
frame) both of the jacks will be connected to one common stressing pump
(EOHP) to ensure the uniform movement of both of the jacks. The pump is
designed in such way that within one hour duration 9-10 mtr of effective
pulling can be done.
The jack will be provided with the front and the rear anchorage. While
pulling operation, the load will be transferred on the rear anchorage and the
front anchorage will be free. After pulling operation is completed the front
wedges will be locked with sufficient pressure (sufficient pressure is the
required pressure that will generate force equal to the frictional forces.
Maximum frictional force is considered as 5% of the total load at given time)
to transfer the load from rear anchor to front anchor and then the piston will

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be returned back to its original position. After tightening the grip in the rare
anchor block the above mentioned operation will be repeated.
The stressing pump will be placed on the scaffolding at Pier 1, 11, 21 and
31.Details of stressing pump are shown on the next page.
Installation of the Strands
Strands are checked for their compliance to the specification at the time of
procurement. Strands will not be new for every span launching. The same
strand shall be used. Physical inspection for any damage will be carried out
before every launching process. For this purpose the working loads are kept
within 0.5UTS of strands.
During the installations of the strands they shall be checked for cracks and
fractures. Damaged strands shall be replaced.
The strands must be clean of dirt, rust etc. before they are installed.
Installation of strands shall be done manually. All strands shall be laid over
the bracket hanging below the span truss. The scheme for the strands
(removal and support during launching) is shown in the Attachment F.
- Detail of Hydraulic Pump (EOHP)
Pump will be consist of 3ph motors suitable to provide discharge of 80 ltrs

per/minute. It will be equipped with Analog type, glycerin filled pressure
gauges up to 700 bar capacity with 10kg/cm2 least count and Hydraulic
hoses of 10 mtr length will be attached with quick change connector for
each connection.
Pump will be provided ultimate pressure capacity of 400 kg/cm2 and

working pressure capacity of 350 kg/cm2.

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Pump will have pressure relief valve, direction control valve, check valve
and lever activation for operation. The connection between jack and pump
will be provided by working ports suitable to operate two jacks
simultaneously as well as if required any one jack at a time without
changing any Hose pipe.
An experienced operate of the hydraulic equipment (power pack) shall be

deployed to operate the hydraulic pump. During launching this engineer will
ensure that the hydraulic pressure is limited to 110% of the pressure
required for pulling (considering maximum friction of 5%). In case the
hydraulic pressure exceeds the allowable maximum pressure the hydraulic
power pack will be blocked and the launching procedure will be stopped
immediately.
Fig-37: Power Pack (EOHP)

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Fig-38: Power Pack (EOHP)

Anchor Block / Bearing Plate
Each jack will have 3 nos. of anchor plates / bearing plates. Hence for 37K15
system 12 nos. is required and for 7 K15 8 nos. of bearing plate is required.
- Wedges
Specially designed wedges with a special alloy steel duly heat treated shall be
used.
Calculation for wedges for 37K15 System with 1000T capacity Multi strand Jack
Wedges required for one jack (37K15) 74Nos.

Wedges required for Anchor Block at end 37Nos.
Total Wedges required 111Nos.
Length of span 125M

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Stroke of jacks 0.4M

No of stroke / operation required for one span 313Stroke/Span
Description No of span No Of Stroke

For 1st train (A1- P40) 40 12500
For 2nd Train (A1 - P30) 30 9375
For 3rd Train (A1 - P20) 20 6250
For 4th Train (A1 - P10) 9 2813
Total Stroke with one jack 99 30938
Wedges reuse assumption 1200stroke / wedge

Nos. of wedges required = (74*31250)/1200 1908Nos.
Total Wedge required for 1st Set of Jack 1945Nos.
Total Wedge required for 2nd Set of Jack 3890Nos.
Calculation of wedges for 5K15 System with 200T capacity Multi strand Jack
Total Nos. of wedges required (for one set) 10 Nos.
For Anchor end 5 Nos.
Total Wedges Required 15 Nos.
Total No Span to be launched 40Nos.
Length of One Span 125M
Stroke of jacks 0.45M
No of stroke / operation required for one span 278Stroke/Span
No Of Stroke required to complete (40 Span) 11111Total Stroke with one jack
Wedges reuse assumption 1200stroke / wedge

Nos of wedges required 93Nos.
Total Wedge required for One Jack 98Nos.
Total Wedge required for 2nd Jack 195Nos.
Total Requirement of Wedges 4085Nos.

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15.5 Operation of Launching Bearing
For the launching process sliding plates will be inserted with the PTFE on the
bottom side of bottom chord of span truss. At this PTFE will be connected to the
stainless steel of the launching bearing. Because the friction between the sliding
plates steel surface and the contact area of the stainless steel / PTFE is much
higher the whole superstructure can be launched forward.
The sliding plates will be inserted at one end of the launching bearing. With the
launching they will be moved forward to the other end of the launching bearing.
There the sliding plates will be taken out again and carried again to the end of
the launching bearing. The weight of one sliding plate is around 10 kg.
In order to lower the friction coefficient the PTFE shall be applied with soft soap.
Both ends of the stainless steel plate are rounded so that sliding plates can be
easily inserted. The procedure of inserting the sliding plates is shown on the next
page.
Number of sliding plates required at each launching bearing:
• Total length of the launching bearing: 5.70 m + 2 x 0.8 m = 7.30 m

• Length of the sliding plates 0.62 m
• N = 730 cm / 62 cm = 12 pieces + 3 pieces for standby = 15 pieces /
launching bearing
• Total number of sliding plates at each pier: 2 x 15 = 30 pieces

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Pic-2: Installation of Sliding Plate

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Fig-43: Launching - Insertion of the Sliding Plates

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During the launching process there is a systematic gap of 20 mm between the

horizontal guiding and the bottom chord. This gap will be monitored by the
workers and the supervisor at each pier during the launching process. If the
bottom chord touches the lateral guiding, the supervisor will inform the launching
manager at the hydraulic equipment and the launching will stop.
Fig-44: Lateral Guiding in launching position
The top plate of the lateral guiding which is bolted to the vertical beam will be
shifted for 150 mm and bolted again. Between the guiding and the bottom chord
a hydraulic jack (2 x 50 t) will be placed and the superstructure will be pushed
back to the designed line. The designed line of the superstructure shall be
marked on the launching bearing.

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Fig-45: Lateral Guiding in shifted position
Parking Position
The launching process will be finished, when the axis of the first end cross beam
of the first truss (span 40, 30, 20, 10) reaches the centerline of the launching
bearing / bearing axis.
Fig: 46: Parking position @ pier location

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The axis shall be marked on the truss as well as on the launching bearing and for
P40 Location it should be marked over launching nose which will match with the
axis line marked over launching bearing.
Longitudinal fixing
Due to the fact that the whole launching level is a straight line in the horizontal
alignment no special longitudinal fixing in the parking position is required.
After the above mentioned position is reached the pressure in the strand jack can
be realized.
Mobilisation of the lateral guiding
At all launching bearings the gap between the bottom flange of the bottom chord
and the lateral guiding of the launching bearing shall be blocked with filler plates
or hard wood wedges.
Fig-47: Lateral Guide

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15.6 Operation Method of Launching Nose

a) Nose Reaching to Launching Bearing
N-3
N-1 N-2
Fig-23 Launching Nose tip
Node 6036 [N-3] Tip of the nose (first cross beam)
Node 6034 [N-2] Between first and second cross beam
Node 6032 [N-1] Second cross beam
According to the design the end of the nose will pass the axis of the
launching bearing for about 3.00 m before it touches the launching bearing.
At this the following deflections are expected (cantilever of 128 m):
Location At N-1 N-2 N-3
Camber [mm] 1200 1350 1500
Deflection G [mm] 1323 1350 1377
The point of touching of the Nose and the point of leaving of the tail shall be
marked with paint on the Sliding Bearing during installation of the sliding
Bearing.

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If the nose touches the launching bearing earlier (i.e. before the axis of
launching bearing), a jack (50 t) shall be put underneath the launching
bearing as shown in the following sketches. When the nose touches the
launching bearing the jack will be lifted in order to prevent the launching
bearing from tilting. When the whole launching bearing is loaded the jack
will be released.
Sliding plates shall be placed on the top of the launching bearing. It is

important that the PTFE-surface of the sliding is on the bottom side (as
always). When the nose touches the bearing a sliding plates shall be in
between.
50 Tonne
Hydraulic Jack
Fig-24: Nose touches Launching Bearing

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Before the nose touches the launching bearing, the lateral guiding will be
assembled [Ref. Drg No M-301] in shifted position. At this there is a gap of
170 mm between the guiding and the bottom chord. (Refer detail of Lateral
Guiding in Cl. 15.6)
Maximum lateral deflection of the nose according to the Dynamic Wind

Analysis (refer to page 20 of the Report):
a) Vy = 162 mm (at wind speed of 20 m/s)
Due to the fact that the launching will not executed at wind speed exceeding
15 m/s the maximum expected lateral deflection is lower (about 15²/20² x
162 mm ~ 91 mm).
When the nose passes the second lateral guiding (in the line of launching)
the lateral guiding [Ref. Drg No M-301] will be shifted to the launching
position.
If necessary a jack (50 t) will be placed between the lateral guiding and the
bottom flange of the nose at one launching bearing. At the other launching
bearing the lateral guiding will be assembled in the launching position. With
the help of the jack the nose will be pushed until the central line of the
bottom chord meets the reference line at the launching bearing. Then the
other lateral guiding (at the same launching bearing) shall be shifted to the
launching position. Finally the jack will be removed and the lateral guiding
will be shifted and bolted in launching position as well.

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Fig-25: Lateral Guide in shifted Position
At the tip of the nose a steel girder for jacking the nose is assembled.
This steel girder ends about 3.50 m in front of the nose. If there should be
any further deflection of the nose – deviating from the design calculation –
and nose reaches the launching bearing below the designed level.
In such condition, launching must be stoped about 300mm before the nose
reaches the launching bearing. Before the launching continues, a 50 t
capacity jack with arrangement as given in Drg. M-504 shall be placed on
top of the temporary steel support [as shown in figure below]. On top of the
arrangement sliding plates with PTFE shall be placed. Then the nose will be
jacked up so that bottom level of nose match with the top level of launching
bearing and the launching train will be launched forward. Detailed sequence
is provided in M-504.

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Fig-27: Jacking Nose on Launching Bearing

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Fig-28: Jacking Nose on Launching Bearing – Top View
Jack removed
Fig-29: Nose set on Launching Bearing

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Launching of the nose will be done over this arrangement. When the nose
reaches the launching bearing, jacks will lowered until the nose is supported
on the launching bearing. After the nose touches the launching bearing the
launching will proceed as described before. Procedure shall be recorded as
per ‘CHECKLIST FOR DEFLECTION DURING LAUNCHING PHASE-0’
[Format No. HCC F 097 10 08, Rev No. 00, Rev Date - 07.09.2013] and
‘CHECKLIST FOR LAUNCHING PHASE-1-4’ [Format No. HCC F 097 10
09, Rev No. 00, Rev Date - 07.09.2013].
Workers at the launching bearing have to take care that the insertion
of sliding plates is continuous.

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15.7 Operation Method of launching tail

Tail Leaving the Launching Bearing
According to design, the tail will lose contact with launching bearing before
the end of tail will reach the axis of the launching bearing (similar to the
described procedure for the nose).
Fig-29[c]: Tail leaving the Launching Bearing
If the tail doesn’t lose contact with launching bearing in that situation the
launching will be stopped about 300 mm before the end of the tail reaches
the axis of the launching bearing.
Before the launching will continue, a 50 t capacity jack with arrangement as

given in explained above for Nose shall be placed on top of the temporary
steel support. On top of the arrangement sliding plates with PTFE shall be
placed. Then the tail will be jacked up until the tail isn’t supported on the
launching bearing anymore (visible gap). Similar to the nose a jack (50 t)
will be also assembled underneath the launching bearing. Then the

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launching segment will be launched forward. If the launching reaches the

end of the steel girder the launching shall stop. The jack will lowered and
the tails is set free. The launching can continue.
15.8 Launching Procedure
15.8.1 Sequence of Launching (QAP Clause: 4.1.1)
In order to explain the various stages of launching, we consider the start

point of launching as the support foundation for camber check. Hence this
position is defined as position 0.0 which means that the truss no 1 front
support is exactly over the foundation for camber checking. This
foundation is located at a distance of 15.56m behind P31(v). Hence this
position of Truss is defined as X=0.0.
Further, Launching stages are divided into following parts
PHASE 0: This stage covers the operations to be carried out on the first
truss of every train till the first truss reaches Pier P1. Thus this stage is
common for all the four trains of trusses.
PHASE 1: This stage covers the launching process of the segments

(Segment 1 T1 to t10, Segment 2 T11 to T20, Segment 3 T21 to T30, and
Segment 4 T31 to T39) till the segments reach their final positions.
PHASE 2: This stage covers the launching of subsequent trains of

trusses Segments 2, 3 and 4. The process is basically same as for
Segments 1 but the only difference is in the last stage of launching where
in the Nose in front lands on a pier bracket. After this, launching and
dismantling will be done in small stretches to enable dismantling of the
nose in parts. This stage is common for second, third and fourth
segments.

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This phase also explains the dismantling process for the tail of segments
2, 3 and 4.These operations are done at different pier nos as listed below
Operation Segment 2 Segment 3 Segment 4

Launching Pier P1 to P30 Pier P1 to P20 Pier P1 to P10
No of trusses in each train 10 10 9
Nose dismantling At P30 At P20 At P10
Tai Dismantling At P20 At P10 At P1
PHASE 3: This phase covers the operation of systematic lifting and

lowering of supports to minimize the residual stresses in the connection
between the two trusses so that the member forces and stresses in the
connections and other members of the truss are well within the limits of
design. This will also minimize the sudden changes in the structural
behavior from continuous to simply supported conditions of the supports.
15.8.1.1 LAUNCHING PHASE 0:
In this stage a detailed work procedure for the launching stage for the first
truss of every train till the first truss reaches Pier P1. Thus this stage is
common for all the four trains of trusses. A detailed step by step
procedure along with important observations and checks are detailed
below.
Step 0.0 Assembly and camber check
• Complete the erection of the first truss as per fabrication and

assembly procedure (Ref HCC N 097 17 02 & HCC N 097 17 06).
The truss is erected on sledges LS100 to LS 110 with LS 110 being
at the front. The first truss is erected over the foundations
earmarked for Camber check.
• Erect A struts.

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• Using 4 Hydraulic Jacks of 500T capacity each, the truss is lifted

up, till all the sledges are free. The Hydraulic jacks are provided
with a sliding plate on top to allow movement of the ends. At this
stage the truss is supported only at four points (bearing locations).
Lock the Lock nuts of the Jacks.
• Note down the levels of the bottom chord of the truss at four
bearing points and also measure the bottom chord levels at every
node. Lower the Truss back on the sledges. The truss at this stage
is considered at level 0.00 mm
Step 0.1 Assembly of Launching Nose
• The Main Truss at this stage is at level 0.00 and the x distance is
considered as 0.00m in longitudinal direction. The launching nose
is totally 52 m in length and weighs about 200 T.
• Install Launching Bearing at P31(v) with top RL of stainless plate at
RL 118.1385m
• Launching Nose is erected on temporary supports to facilitate
erection of individual components of the Nose.
• The Nose is erected temporary support with bottom of nose in
straight portion at launching level RL118.156.
• Once the Nose is erected and all the connection bolts are torque,
the temporary supports below the nose, except the support over
Pier P31(v), are removed.
• Install 8 hydraulic jacks [400t capacity] below launching bearings
(two per bearing), lift simultaneously the launching bearing by
25mm, new level of launching bearing will be 118.1635m (top of
SS plate)
• Check the vertical alignment of the Nose.
• Now the tip of nose is at x=52.00m. With support on pier P31(v)
(over hanging by 52.00-15.66=36.34m from Pier P31(v).

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• Check the deflection at the tip of Nose using and compare with
the design value according to attachment G1
• Erect the Anchor beam at the front end of the Truss. Install Pulling
device on Pier P1 along with strand jacks, and strands.
• Due to overhang of the Nose, sledges LS109 and LS 110 are free.
Remove the sledges LS 109 and LS 110
• Fill out the Inspection Plan(Check List)
• Shim plates below P31(v) bearing=1x25 thk
Step 0.2 Launching for 6.1 m
• Check Hydraulic connections of strand jacks.

• At this stage, the total Load to be pulled is about 1800 T.
• Set the pressure control valve of power pack to 100T (about 10%
higher than maximum expected force of 90 T with maximum friction
of 5%).
• Remove slackness of strands by applying 15% of the expected
force using mono strand jacks.
• Start Launching in stages corresponding to the stroke of jack.
• Continue Launching for a distance of 6.1m.
• At this stage Nose is cantilevering by 42.44 m from Pier P31(v).
Check deflection of Nose and confirm with design values.
• At this stage Sledge 108 is free but should remain in place since
it may get loaded at further stages.
Step 0.3 Launching 12.2m
• During this phase of launching between x=6.1 to x=12.2,

sledge108 which was free in previous stage is likely to get loaded
again.
• Sledge 107 is free. But should remain in place.

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• At the end of this stage, Nose is cantilevering by 48.54m from Pier

P31(v). Check deflections at tip of Nose and confirm with design
values.
Step 0.3A Launching 18.6m
• During this phase of launching between x=12.2 to x=18.6, sledge

107 & 108 which was free in previous stage is likely to get loaded
again.
Step 0.4 Launching up to 22.8m
• Continue launching till x= 22.8 m.
Step 0.5 Lifting Launching bearing at P31(v) by 95 mm
• Stop launching after x= 22.8

• Install 4 Hydraulic jacks [500t capacity] (two below each launching
bearing) below launching bearing at Pier P31(v).
• Lift the launching bearings (both simultaneously) by 95 mm to get
launching bearing level of +120mm at Pier P31(v).
• Insert Shim plates below the bearing
• Release jacks.
• Check levels of launching bearings. Maximum allowable difference
is 2.0 mm between U/S and D/S bearings.
• Launching Sledges 105, 106,107 and 108 are free and can be
removed.
Step 0.6 Launching 36.8 m
• Continue launching till x= 36.34 m

• At this stage the Nose is fully cantilevering by 52 m.

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• Check deflection of nose tip and confirm with design values.

• Continue launching till x= 36.8 m
Step 0.7 Jacking of launching bearing at P31(v) by 105 mm
• Stop Launching at x =36.8m

level of +225 mm at Pier P31(v).
• Release jacks.
• Launching Sledges 104 is free and can be removed.
• Launch 38.01 m. at this stage the Nose tip is over A1. However
since the cantilever span is only 74.35 m the Nose will not touch
the launching bearing at A1
• Launch up to X= 52.0. Sledges 100 and 101 are free but should
remain in place.
• Launch up to X= 58.1. Sledges 100 to 102 are free but to remain
in place.
• Load is on launching bearing at P31(v) and sledge 103
• Launch to X= 59.3 m. at this stage the Nose touches launching

bearing on Abutment A1.

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• Sledges 100,101 and 102 are free but to remain in place.
• Launch to X= 62.7 m. & Stop
Step 0.11 Jacking of launching bearing at P31(v) by 95 mm

level of +320 mm at Pier P31(v).
• Release jacks.
• Launching Sledge 102 is free and can be removed. Sledge 103 is
free but remains in place.
• Launching Noses loses contact at launching bearing on abutment
A1.
• Load shared by P31(v) and Sledges 100 and 101.
• At this stage the truss along with Nose is cantilevering by 99.04 m.
• Check and verify deflections at the tip of Nose.
Step 0.12 Launching up to X=97.5m
• Launch 64.2 m. At this stage Nose touches launching bearing at A1

• Launch 76.4 m Sledge 100 free but to remain in place
• Launch 82.4m Sledge 100 free but to remain in Place, sledge
101 and 102 are loaded
• Launch 94.6m Sledges 101 and 102 are free and can be removed.

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• Launch 97.5m Nose will touch launching bearing on P1. Sledge

100 free and can be removed. Load only on P31(v), A1 and P1.
All sledges are free.
Step 0.13 launching up to X=125.00m
Launch 100.7m launching bearing at A1 free.
Continue launching up to X= 125.00.
Step 0.14 Lowering of Bearing at P31(v) by 220 mm.

• Lift slightly and remove shim plates below the bearing.
• Lower the launching bearing by 220 mm to get launching bearing
level at +100 mm over Pier P31(v).
• Release jacks and check the launching bearing levels. Maximum
tolerance 2.0 mm
• Release strands by de-stressing.
15.8.1.2 LAUNCHING PHASE 1.0
In this phase of launching, we cover the process of joining of the two

trusses, launching from pier P1 to P40/A2 including the stages of tail
erection, nose dismantling and dismantling of the tail.
The following steps will explain the whole process.
Step 1.0
• Erect the truss No T2 on sledges in a separate assembly bed.

• Complete the camber checking process for truss T2.

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• Install the pulling device in Yard as explained earlier in launching

phase 0.0
• Install the anchor beam at the end cross beam with the help of a
crane. Install strands from the pulling device in yard to the anchor
beam.
Remove slackness of the strands by mono strands or other suitable
device.
Step 1.1A
• With the help of strand jacks and pulling system in yard, pull the
Truss T2 forward up to the connection point.
• At the end of pulling, the c/c of end cross beams of truss T1 and
Truss T2 will be at 3.4m c/c.
• It is likely that the truss T2 is out of axis in transverse direction by
few mm during pulling operation due to the clearance at lateral
guiding system.
• Align the Truss T2 (if required rear end of T1 also) and bring them
in their true axis. (Max tolerance 2.0 mm).
• Accurately measure the gap between ends of the trusses T1
and T2. It is to be noted that the gaps will be different for top
chord and bottom chords due to pre-camber.
• In order to account for the actual gaps, the connection piece will be
fabricated with slightly higher length (say 1450 mm instead of
1400 mm for bottom chord).
• Trim the pre-fabricated connection piece to the actual dimensions.
• Fit up the connection piece on temporary supports.
• Weld the connection piece as per specifications.
• Complete required tests on welds.
• Grind the welds carefully, especially the bottom sliding surface of
the bottom chord.
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• Parallelly install Launching bearing at Pier P2 with top of launching

bearing at 118.1385 m RL.
• Install 4 hydraulic jacks [500t capacity] below launching bearing at
P31(v).Prior to lifting of the launching bearing, the launching
bearing top is at 118.2385 m RL(before lowering).
• Lift the launching bearing at P31(v) slightly and remove 20 mm of
filler plates below the launching Bearing to get launching bearing
top level at 118.2185 m RL. (launching level higher by 80 mm than
std launching level of 118.156m RL)
• Lower the jacks simultaneously to bring the top of launching
bearing at 118.2185m.
• Check the RL of top of launching bearing. This should be 118.2185
m RL.
• Verify and ensure that the level difference between two launching
bearings on P31(v) is not more than 2 mm.
• Release strands from T1 by de-stressing.
• Shift anchor beam from Truss T1 to T2. And install strands.
• Remove slackness of strands. Now the system is ready for further
launching.
Step 1.1B.
• Using Pulling device on Pier P1, launch forward by 5.2 m.

(X=130.2m).
Step 1.2
• Stop launching at X=130.2 m

P31(v).

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• Lift the launching bearing slightly and remove 55 mm of packing

plates.
• Lower the jacks simultaneously to get top of launching bearing at
118.1635 m RL.
• Check levels and confirm. Ensure the level difference between the
two launching bearings to be not more than 2.0 mm.
• Sledges 119, 120 and 121 are free and can be removed
Note: when any sledge is expected to free and it is not free then will move
truss forward and make that sledge free then remove.
Step 1.3A
• Continue launching for 7.0 m i.e. X=137.2 m

• Sledges 117 and 118 are free & can be removed.
Step 1.3B
• Continue launching for another 12.5 m i.e. X=149.7m.
Step 1.4A
• Stop launching at X=149.7m(24.7 m in launching phase 1)

P31(v).
• Lift both the launching bearing by 120mm and add filler plates
(120mm) below the launching bearing to get top of launching
bearing 118.2835 m RL.
• Lower the jacks simultaneously. Check and confirm top of
launching bearing at 118.2835 m RL.
• Ensure the level difference between the two launching bearings to
be not more than 2.0 mm.

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• Sledges 115 and 116 are free and can be removed.
Step 1.4B
• Continue Launching up to X= 164.9m (39.9 m in phase 1)

• Sledges 111 & 112 are likely to be free but to remain in
place.(tied with truss)
Step 1.5
• Stop Launching at X= 164.9m(39.9 m in phase 1)

P31(v).
• Lift both the launching bearing by 120mm and add filler plates
(120mm) below the launching bearing to get top of launching
bearing 118.4035 m RL.
• Sledges 111 and 112 are under load.
• Sledge 113 is likely to be free but to remain in place.
• Sledge 114 is free & can be removed.
Step 1.6A
• Continue launching till X=171.00m (46 m in phase 1)

• Sledges 111,112 and 113 are under load.
Step 1.6B
• Continue launching till X= 183.1m (58.1m in phase 1)

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• Sledges 111 is free but remain in place
Step 1.6C
• Continue launching till X= 201.00(76.0m in phase 1)

• Nose likely to touch Launching Bearing at P2 between X=198.0m
to X=201.0m(73.0m to 76.0m in phase 1)
Step 1.6D
• Continue launching till X=219.6m(94.6m in phase 1)

• Sledge 113 is free and can be removed.
Step 1.6E
• Continue launching till X= 250m. (125.0 m in phase 1)
Step 1.7
• Stop Launching at X=250.0m (125 M IN PHASE 1)

P31(v).
• Lift the launching bearing slightly and remove 165mm of filler
plates below the launching bearing.
Step 1.8
• Repeat steps 1.0 to 1.7 to complete launching up to X=375.0m

(250.0m in phase 1).
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• This stage completes launching of Truss no T3.
Step 1.9
• Repeat step 1.8 to complete launching stage up to X=1250.0m

(1125.0m in phase 1).
• At this stage Truss No T10 is ready for erection of the tail.
Step 1.10
• Shift Pulling device from P1 to P11.

• Shift Anchor beam from Truss T10 to Truss T1.
• Install Strands and remove slackness.
• Erect Tail at the rear end of Truss T10 on temporary supports
Tighten all the bolts to their specified Torque.
• Remove the temporary supports below the tail by lifting the
launching bearing at P31(v).
• Check the deflection of the Tail and compare with the design
values of deflections.
• Inspect all the joints of the tail and confirm.
Step 1.11
• Start Launching and continue up to X= 1313.0m (63.0m after

erection of Tail)
• When the launching position is between 1310.0m and 1313.0m,
the tail will start loosing contact with the launching bearing.
Step 1.12
• Continue launching till X=1326.0m (76.0m after attachment of

tail.)

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• At this stage the Nose in front will touch Launching bearing at Pier
P11.
• Now the System is free from Pier P31(v) and further launching will
continue as explained above till the Truss T1 reaches the final
position.
Step 1.13
• After the tail leaves pier P31(v), continue launching up to

pier P40.
• At P40 match axis line of marked on Launching and nose to confirm
bearing line and truss is exact the same line.
• Now the Nose is beyond P40 and can be removed by a land based
crane.
• The tail is between P29 and P30. Tail is dismantled in parts by a
floating/land based crane
Step 1.14
• Similar to the procedure for Segment 1, complete launching of

Segments 2, 3 and 4 till the Nose reaches Pier bracket on Pier P30.
• Nose of Segments 2, 3 and 4 are dismantled in stages involving
part launching and part dismantling.
Tail for other segments are dismantled in similar way as for segment 1

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15.9 Dismantling of Nose for Launching train 2, 3 and 4
Due to already launched segment, tip of Nose for Launching train 2 cannot
be launched beyond P30. Similar situation is there for Launching train 3 at
Pier P20 and Launching train 4 at Pier P10.
Considering above restrain part by part dismantling of nose is proposed

with use of Bracket at P10, P20 and P30 for Launching train 4, 3 and 2
respectively.
Dismantling of nose will be carried out with Help of 80 MT capacity Land

or Barge mounted crane.
Following are the steps to be followed for dismantling.
1. For dismantling of tip portion following are the two different conditions.
a. If end truss of previous launching segment is in already lowered

condition, then launch the truss till it reaches point, 1175mm away from
vertical of end truss of previous launching segment( for example, Truss
T10 of first segment when we are launching segment 2). The temporary
stringer projecting outside nose in Launching operation will be
dismantled before. Start dismantling of tip piece. Dismantling should be
carried out in following chronological order.
• Temporary stringer ISUB 600

• Bottom cross beam of tip portion
• Tip portion of Bottom Chord.
1. 2. Start launching operation and continue till subsequent part of Nose

reaches a point, 800mm away from vertical of end truss of previous lunching
segment.

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Start dismantling of subsequent part of nose.
Before dismantling it needs to be assured that Joint of bottom chord is

outside Launching bearing.
This dismantling should follow following sequence.
• Top Cross Beam

• Top Chord Member
• Diagonals
• Verticals
• Bottom Plan bracing
• Bottom Chord
2. Repeat step two and dismantle nose completely.
The general procedure of the dismantling is shown in the sketches on the next
pages for the first 6 stages

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Fig-50: Bracket – Dismantling Launching Nose - Stage 1 and 2

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Fig-51: Bracket – Dismantling Launching Nose – Stage 3 and 4

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Fig-52: Bracket – Dismantling Launching Nose – Stage 5 and 6

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15.10 Dismantling of Tail
The dismantling of the tail will be done part by part with the help of a mobile /
floating crane.
Dismantling of the tail should be done from the tip of the tail proceeding towards
the main truss.
Dismantling should be done bay by Bay (bay is the portion between the nodes of
the Tail).
At any instant only one bay at a time shall be dismantled.
Each bay of the tail (portion between the nodes of the Tail) should be dismantled
with the following sequences for the members of the bay.
• Top Cross Beam
• Top Chord Member
• Diagonals (end bay)
• Verticals (end bay)
• Bottom Plan bracing
• Bottom Chord
Only after dismantling all the members in one bay, we proceed to dismantle the
next bay.

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15.11 Removal of Launching Bearing and Cutting Connection Joints

15.11.1 General
Associated drawing: M 013
The trusses in the launching segments are connected to each other with
connection piece welded to either of the truss. After launching segments reaches
its final position, it is 10 span continuous beams with nose and tail overhanging
at either end of launching segment. As per design each truss has to behave as
simply supported structure resting on the permanent bearings. To assure above
structural behavior, the connections pieces between two trusses shall be cut so
as to separate each of the truss from others.
However, after completion of launching, there are considerable stresses in the

connection pieces between the trusses. Due to the process of cutting, the truss
will undergo sudden change in the support system from continuous supports to
simple supports after cutting. This will also induce sudden change in the
deflections of the trusses. To avoid such sudden changes, it is essential to
carryout stress relieving process for these connection pieces so that the impact
of sudden change in support conditions is minimized. As such a systematic
raising and lowering of the truss is done to ensure that the stresses in the
connection piece are minimal and thus there are no sudden changes in the
behavior of the trusses during cutting operation.
Following are the preconditions considered for design of cutting and lowering
operations.
The procedure of removing launching bearings, lowering superstructure and

cutting connection joints considers the following boundary conditions:
- Jack forces at each lifting location should be smaller than 1000 t.

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- The stroke of jacks [600T capacity] in one stage should be more than
300mm in order to do the lowering operation it should be done in two stages as
maximum stroke length is 200mm.
- Forces in the connection joints due to the hooking moment during lowering
should be smaller than during launching. Stresses in the structural members
should be smaller than 90 % of the allowable stress.
- Stress in members to be cut (Joining Piece) is negligible.
15.11.2 Jacks required for Operations:
1. 4 x 600 t jacks with tilt saddle and fixing collar for span lowering
2. 4 x 600 t jacks with tilt saddle and fixing collar for Stress release
15.11.3 Weather Conditions during cutting and lowering of Trusses
- During the process of cutting of the connections, wind speeds shall be

less than 15m/sec
15.11.4 Bearing axis
In the following procedure the bearings axes of the piers are called as follows:
• Rear Axis of pier is called “support axis-1”.

• Front Axis of pier is called “support axis-2”

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Axis-1 Axis-2
Fig-53- Bering Axis

15.11.5 Operational Procedure:
The methodology of Lowering of Span Truss shall be covered in detail in

Document No. HCC N 097 17 10 titled ‘SQP for Lowering of Span Truss”. Below
is described in brief the lowering procedure for the first launching segment
between pier axis 30 and axis 40. The principle reaction of the structure is
explained and shown by some pictures.
Step 3.1
Superstructure is supported on launching bearings in its final Launched position.
Fig-54: Step 3.1
Step 3.2
• Remove Nose and tail.

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• Place Jacks (2x600 t at the jacking points) at axis 40.1 and remove
launching bearing at axis 40.2 The jacks shall be hydraulically synchronized.(axis
40.1 is the front cross beam of truss T2 and axis 40.2 is rear cross beam of truss
T1)
Fig-55: Step 3.2
Step 3.3
• Place Jacks (2 x 2 x 600 t at jacking point) at axis 39-1 at the jacking

points. The jacks shall be hydraulically synchronised.
• Remove Launching Bearing at Axis 39-2
Fig-56: Step 3.3

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Fig-57: Support arrangement [with launching bearing]

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Fig-58: Support arrangement [without launching bearing]

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Step 3.4
• Operate Jacks at Axis 40-1 raise level by 180 mm above launching level
(In Synchronised mode).
• Operate Jacks at axis 39-1 (In Synchronized mode) and lower it by 137
mm below launching level.
Fig-59: Step 3.4
Step 3.5
• Add Jacks (2x 500 t) at axis 39-2 (to eliminate the shear forces in the
connection piece). Activate the jacks to ensure force in Jack should be 4000 kN
(In Synchronized mode).
• Install temporary steel support at bearing plinth axis 39.2
• Cut and remove Joining Piece (Temporary connection part)
Fig-60: Step 3.5

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Fig-61: support at bearing plinth axis 39.2

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Fig-62: Cut temp Connection
Step 3.6
• Lower Span 40 to the final level. (Refer separate Procedure for Lowering
and Bearing Installations Methodology).
• Lift the axis 39.1 Launching Level.
• Replace 2x600 t jacks at axis 39.1 with 600 t jacks.
• Shift 2x600t jack to axis 38.1.

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Fig-63: Step 3.7
The procedure of the other spans is similar to as described above for the span
40. Only the lifting and lowering values shall be adjusted according to Drawing
M013.
16 CORROSION PROTECTION
The Repair procedure for any damage on painting surface due to launching and
associated activities shall be carried out as per document for ‘REPAIR ROCEDURE
FOR PAINTING’ HCC P 097 17 07, which has been submitted to the Client for
approval.

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17 GRINDING OF BOTTOM CHORD WELDING
Truss Girder
The welds at the downside of the bottom truss chords bottom flange shall be
grinded in the workshop. Before each launching stage this has to be checked
again for the latest assembled truss girder.
Fig-64: Grinding Bottom Chord

Nose and Tail
Same shall be done for the nose. Especially at the bolted connection the edges
shall be smoothed.

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18 CHECKING SETTLEMENT
Height controls at the top of the launching bearing shall be done before every
launching step. Measuring points shall be set at the bearing axis of the pedestal.
The measured values shall be recorded before every launching step.
Deviation to the planned height ≥ 2 mm shall be compensated by shim plates.

The shim plates shall be added underneath the elastomeric bearings. In order to
install the shim plates the superstructure will be jacked up. At this a temporary
support will be arranged at the jacking point of the later jacks and a jack will be
installed. All girder of the temporary support have to be bolted or welded with
each other.
This job will be done – if necessary – in parking position. At this time the
maximum load at the launching bearing is about 4700 kN. Therefore a jack with a
capacity of at least 500 t shall be used at each launching bearing.
Fig-65: Grinding Bottom Chord

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19 QUALITY CONTROL PROCEDURES
Before each launching stage and as a precondition for the approval of the
launching operation by the launching manager the Inspection Plan added
as Attachment C to this Segment Quality Plan shall be filled out and
signed.
19.1 Inspection & Testing Plan:
Inspection and Testing shall be done as per QAP, HCC-DSD-

VNR/BS/QAP/01-R5.Clause no: 4.0 and sub clause of the same.
20 OHS & ENVIRONMENT MANAGEMENT PLAN:
All safety and precaution shall be taken care as per Project Occupational
Health & Safety Management Plan (HCC N 097 15 001).
Environnent: -
As per Project Environnemental Management Plan (HCC N 097 18 001).
21 EMERGENCY PLAN
The attachment D to this Segment Quality Plan contains an Emergency

Plan.
At this errors /mistakes that might happen during the launching operation
are mentioned. For each of this errors / mistakes the actions to be taken in
such a case are mentioned.

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HCC N 097 17 007
22 ATTACHMENTS:
22.1 Attachment A: Extracts from Structural Analysis
22.1.1 A1 Bearing Forces Launching Phase 2 Page A1/1 – A1/8
22.1.2 A2 Bearing Forces Launching Phase 0-1 Page A2/1 – A2/15
22.1.3 A3 Launching Yard Single Truss Page A3/1 – A3/10
22.1.4 A4 Launching Yard Sledges Phase 0 Page A4/1 – A4/30
22.1.5 A5 Launching Yard Sledges Phase 1 Page A5/1 – A5/28
22.1.6 A6 Deflections Launching Phase 2 Page A6/1 – A6/12
22.2 Attachment B: Methodology Sequence Drawings
22.3 Attachment C: Inspection Plan
22.3.1 C1 Inspection Plan Launching
22.4 Attachment D: Emergency Plan
22.4.1 D1 Emergency Plan
22.4.2 D2 Bracing Nose
22.5 Attachment E: Bolts - Torque Moment
22.5.1 E1 Torque Moment
22.6 Attachment F: Strands Scheme
22.6.1 F1 Strands Scheme
22.7 Attachment G: Table of Level
22.7.1 G1 Tip of Nose Phase 0 and 1
22.7.2 G2 Connection Piece Phase 0 and 1
22.7.3 G3 Tip of Tail Phase 1

CEMG
HCC N 097 17 007
22.8 Attachment H : Specification of Major Equipments

22.9 Attachment I : Erection Scheme of Launching Nose
22.10 Attachment J : Erection Scheme of Launching Tail
22.11 Attachment K : Erection Scheme of “A” Strut
22.12 Attachment L : Erection Scheme of Connection Member
22.13 Attachment M : Erection Scheme of Launching Bearing
22.14 Attachment N : Erection Scheme of Pulling Device
22.15 Attachment O : Scheme for Camber Check at Assembly Yard
22.16 Attachment P : Erection Scheme - Pulling Device Anchor Beam
22.17 Attachment Q : Erection Scheme of Brackets
22.18 Attachment R : Scheme for Removal of Connection Piece
22.19 Attachment S : Checklist Format
22.19.1 CHECKLIST FOR SLEDGE ERECTION & PRECAMBER
[Format No. HCC F 097 10 01, Rev No. 00, Rev Date - 07.09.2013]
22.19.2 CHECKLIST FOR RESIDUAL-CAMBER

22.19.3 CHECKLIST FOR LAUNCHING NOSE ERECTION

22.19.4 CHECKLIST FOR TEMPORARY CONNECTION PIECE

ERECTION
22.19.5 CHECKLIST FOR INSTALLATION OF PULLING DEVICE &

LAUNCHING BEARING
22.19.6 CHECKLIST FOR INSTALLATION OF LAUNCHING BEARING


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HCC N 097 17 007
22.19.7 CHECKLIST FOR LAUNCHING AT P31(v)

22.19.8 CHECKLIST FOR DEFLECTION - LAUNCHING PHASE-0

22.19.9 CHECKLIST FOR DEFLECTION - LAUNCHING PHASE-1

22.20 Attachment T : Inspection Scheme for Bottom Chord and A Strut

During First and Second Truss Launching.
23 DISTRIBUTION
The document shall be distributed to all the concerned users.
24 RECORDS
This segmental methodology shall be retained till project completion.

CEMG

SQP For Launching of Span Truss

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SQP For Launching of Span Truss

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HCC-DSD-VNR Consortium Management System

Segment Quality Plan For The Launching Of Span Truss

Revision No.: 2; Revision Date: 20.11.2013 Page 2 of 134

Revision No.: 2; Revision Date: 20.11.2013 Page 3 of 134

15.3.1.1 Typical Sequence of work at Assembly Yard................................... 24

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15.3.11.1 Purpose .............................................................................................. 73

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22.18 Attachment R : Scheme for Removal of Connection Piece .......... 133

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The purpose of this document is to establish the specific methods and

Construction of Composite welded steel truss girders having span of 34 x

Revision No.: 2; Revision Date: 20.11.2013 Page 8 of 134

The Scope of this methodology covers the following activities:

o Normal Span (125m c/c of Pier) : 39 Nos.

• Two numbers of End span shall be erected by crane with

5 ENVIRONMENTAL & CLIMATIC CONDITION OF PROJECT SITE

Revision No.: 2; Revision Date: 20.11.2013 Page 9 of 134

During launching process, weather forecast shall be maintained at site

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6 TERMS, DEFINITIONS & ABBREVIATIONS

The words like Contract, Consortium, Contractor, Engineer (Synonymous

Terms and Definitions

SUB-CONTRACTOR The firm selected by the Contractor on the

PQP Project Quality Plan

Revision No.: 2; Revision Date: 20.11.2013 Page 11 of 134

7 DESIGN & DRAWINGS REFERENCES

All Launching work shall be done as per approved GFC Drawing.

• Design Report M 151-A - E Structural Analysis Superstructure

• Design Report M 250 Structural Analysis Pulling Device Pier

• Design Report M 251 Structural Analysis Pulling Device Yard

• Design Report M 350-B Structural Analysis Sliding Bearing

• Design Report M 450 Structural Analysis Brackets Pier 10,20 and 30

• Design Report M 550-A Structural Analysis Launching Nose

• Design Report M 650 Structural Analysis Launching Track

Revision No.: 2; Revision Date: 20.11.2013 Page 13 of 134

This Methodology shall be read in conjunction with the following

• Tender Document Specification

It shall be ensured that supervisory personnel at all level and workmen

Manpower required for the critical activities are as follows.

• Senior Launching Manager: 1

Revision No.: 2; Revision Date: 20.11.2013 Page 14 of 134

Skilled workers shall be positioned on each pier during launching for

At each pier, following skilled workers shall be deployed:

The supervisors will be in contact with walkie-talkies to the launching

12 ASSUMED DURATION OF THE OPERATION

Launching from assembling bed 3 to connection point 15 h

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Equipment List For launching

6 1000 T Capacity multi strand 4 Nos. Pulling arrangement at

Revision No.: 2; Revision Date: 20.11.2013 Page 17 of 134

Equipment List For launching

20 D.G Set (125KVA) 1 No. For P11/P21/P31 & For

Specification of major Equipments is provided in Attachment H.

Revision No.: 2; Revision Date: 20.11.2013 Page 18 of 134

15 METHODOLOGY FOR THE LAUNCHING OF FBARICATED TRUSS

A Rail cum Road Bridge is proposed by Indian Railways across River

The span configuration of the main bridge consists of

15.2 Proposed Launching Method (QAP Clause: 4.1.1)

A brief process of the whole launching method is explained below to get

The superstructure is proposed to be launched by “Incremental