1. NORTHERN RAILWAY
CONSTRUCTION DEPARTMENT
(AMBALA DIVISION)
FABRICATION OF COMPOSITE
WELDED STEEL PLATE GIRDER
R.O.B OVER LEVEL CROSSING
2nd june to 6th july

2. NORTHERN RAILWAY
 Northern Railway, the Jewel Set in the Crown of Indian Railways. Its
headquarters is in Delhi at New Delhi Railway Station. .Formally
established in the year 1952, it remains the largest zone in terms of
route Kilometres, even after the re-organization of the Indian
Railways into 16 zones. Northern Railway now comprises of 5
Divisions-Ambala, Delhi, Ferozpur, Lucknow and Moradabad.
 The Civil Engineering is responsible for the construction and
maintenance of all civil engineering assets, viz all buildings including
station buildings, residential quarter, hospital, sheds, workshop
structures,goods sheds etc., water supply and sanitary
installations, Railway tracks, sidings and all allied structures, Bridges
including Road over bridges and Road under bridges.

3. ROAD OVER BRIDGES
 The structure crossing the railway track and
carrying road way above is called a Road Over
Bridge. The portion of this ROB structure within
the Railways jurisdiction is almost invariably
constructed and maintained by the Railway
administration, the remaining portion being left to
the custody of State Govt. or local body as the
case may be. ROBs are used to nullify the
hurdles for traffic flow across the railway tracks at
level crossing.

4. What is a plate girder bridge?
 A plate girder bridge is a bridge supported by two or
more plate girders braced together to the required stiffness. The
plate girders are typically I-beams made up from
separate structural steel plates (rather than rolled as a single
cross-section), which are welded or, in older
bridges, bolted or riveted together to form the vertical web and
horizontal flanges of the beam

5. Composite steel girders
 The RCC deck is cast in situ after launching steel girders on
substructure. Shear connectors are provided on top flange plates
of steel beams with channel sections welded all round with side
fillet welds. Shear connectors are required to make cast in situ
RCC slab and steel girder act together under load
Composite girders consist of the following components:
 A) RCC deck (Cast in situ at the site of bridge) with shear
connectors embedded in the slab.
 B) Steel beams with shear connectors welded on top flange
(Fabricated in workshop).
 C) Cross frames
 D) Bearings

6. Advantages of using steel for girders
 Reduced dead loads.
 More economic foundations.
 Simpler erection procedures.
 Shorter execution time.
 Faster and easier rehabilitation.
 Durability.

7. Overview of project work in Ambala
division (Indian Railway)
 Construction of composite welded steel plate girder type ROBs is in
progress at Barnala (Punjab) and Budhwala (Punjab) level crossing by
the Indian railway in Ambala division.
 ROB 92-B at Barnala
This level crossing is falling between the city Barnala, it joined not only
the city Barnala on both sides of Railway line but also join the by pass
approach to the sangrur Highway.
 This bridge is being constructed on deposit basis.
 This level crossing is at km.110/2-3 on Ambala- BathindaRail section.
 It consist of single span of 46.029 M (overall span) and is inclined at 55
degree to the level crossing.

8. Plan of the Barnala Project

9. Sectional elevation of ROB at Barnala

10. START DATE 6.01.10
EXPECTED DATE OF COMPLETION 30.09.2012
EXPECTED COST 4.62 crores
DESIGN CONSULTANT Structure Consultant Pvt. Ltd.
B-1/116 YAMUNA VIHAR DELHI-110053
CONTRACTOR M/S MAAN BUILDERS
PUNCHKULA
OWNER CLIENT NORTHERN RAILWAY

11. ROB AT BUDHLADA
 R.O.B in replacement of level crossing No. C-194 at
KM.228/814.20 on jakhal-bathinda section near railway station at
budhlada.
 It consist double span of 22.992m and 36.662m. It will join Bhikhi
and Rattia, bhikhi is a town of Punjab and Rattia is a town of
Haryana ( State highway)
START DATE 08.7.2011
EXPECTED DATE OF COMPLETION 31.7.2012
EXPECTED COST 5.62 crores
DESIGN CONSULTANT Structure Consultant Pvt. Ltd.
B-1/116 YAMUNA VIHAR DELHI-110053
CONTRACTOR M/S MAAN BUILDERS
PUNCHKULA
OWNER CLIENT NORTHERN RAILWAY

12. Site plan Budhlad

13. Works already been done at the sites
 All the foundation and pier works at barnala and budhlada was
already completed.
 At Barnala
 CAST-IN -SITU 1m DIA and 16m piles was used as foundation.
 2m dia pier with 8.323m height with adjacent centre to centre
clearance of 5m was constructed.
 At Budhlada
 CAST-IN SITU 1m dia and 16m long piles as foundations.
 2m dia pier with 6.5m heigh with adjacent centre to centre
distance of 7m was constructed.

14. Cross-section details of
piers

15. Piers at Barnala Piers at Budhlada

16. Instructions for the construction
 All RCC work to be done as per IRC-21
 C.C mix for substructure M-35 and for
superstructure M35.
 All structural steel shall conform to IS: 2062-2006
grade ‘B’
 All RCC work shall be of concrete mix M-35 and
reinforcement bars shall conform to IS: 1786-
1985 of minimum grade Fe-415.

18. Fabrication of steel girders
TESTING OF STEEL PLATE FOR FLAWS
 Primarily necessary step
 If internal flaw present in steel plate it can grow due to bending
moment and shear force.
DIGISCAN-322 ultrasonic testing
equipment used at
BARNALA (PUNJAB)
Ultrasonic Testing (UT) uses high
frequency sound energy to
conduct examinations and make
measurements.
Ultrasonic inspection can be used
for flaw detection/evaluation,
dimensional measurements,
material characterization.

19. Worker checking for flaws in Steel plate at Barnala
By Normal beam Inspection.
Diagram showing how Testing equipment works and data appears on the
screen.

20. Cutting of steel plate
 This is a operation done at the site to get the desired
shape of steel plates being use in the construction of
deferent components of the structure. Oxy-fuel gas
cutting is use for this purpose at site.
 Oxy-fuel cutting are processes that use fuel gases
and oxygen to cut metals.
 LPG is used as fuel gas at site for the cutting
purpose.

21. Oxygen and LPG Gas cylinders at BUDHWALA

22. PUG CUTTING MACHINE
 Pug cutting machine is automated flame cutting machine which is
used for cutting of ferrous metal sheets and plates .
 An aluminium track is designed over which the machine moves and
the speed of this machine can be adjusted according to the
thickness of the cutting metals by electronic control switch.
Pug cutting machine over aluminium track being used in Fabrications of 46m
span composite girders of Br. No 92-B at Barnala by Northern Railway.

23.  Being small in size and light weight, the machine
can be easily carried to the worksite and placed
directly track fixed on the on the plate to be cut.
 It cuts with rectangular and smooth surface with
minimum wastage of steel in cut width.
Finished surface after gas cutting

24. Drilling of holes
 Prior to welding the plates into the girders required number
of holes of prescribed dimensions has been done at the site
in the plates with the help of drilling machines.
 These driven holes will be use for connecting adjacent girder
with help of steel plates, bracing and gusset plate.
 At the site drilling of has been done by two types of drilling
machine:
•Portable drilling machine.
•Fixed drilling machine.

25. •Portable type drilling machine have electromagnetic base.
•Easy to move.
•Generally Use for the drilling in web plate and splice plate.
Portable drilling machine use by a person for drilling holes in web plate at
budhlada (Punjab)

26. Steel plate showing holes driven by portable drilling machine at
Barnala(Punjab

27. Fixed type drilling machine
 Use for drilling of holes into
flange plate and splice plate
which is use for connecting
of adjacent girder.
 Bottom part of the machine
is fixed over the base
 The upper assembly can
rotate over the base and
drilling part of the machine
can move with the help of
track attached to the upper
part of the machine.

28. Steel plates and girder

29. WELDING PROCEDURE
 During the fabrication, welding of the girder has been done in the
different phase.
 Fillet welding of 8mm unless specify.
 Procedure is described in the following photographs shown below.
Placing of web plate over platform at Barnala

30. Flange plate is being placed by the side of web plate

31. Welding of U-shaped plate to the
web and flange plate to keep flange
perpendicular to web at
Barnala(punajb)
Tack welding

32. Welding of inclined road to keep web
& flange at perpendicular to each
other (Barnala)
Hammering to remove the U-
shaped plate

33. Placing of temporary welded girder over inclined platform for
welding with the help of SAW tractor at Barnala

34. Setup to place web perpendicular to flange plate at Budhlada

35. SAW tractor at Budhlada Specification of SAW tractor

36. STIFFENERS
 Stiffeners are required where factored concentrated loads or
reactions exceed the factored Compressive (vertical) resistance
of the plate girder web.
 Failure due to concentrated loads can be as local buckling of the
web in the region where it joins the flange, or overall buckling of
the web throughout its depth
 Transverse stiffeners
 If a girder has insufficient strength (web local yielding or web
crippling) to support concentrated point loads then a pair of
transverse stiffeners can be added to the web to transfer the
concentrated force to the web.

37. Transverse
stiffeners

38.  Bearing Stiffeners:
 Bearing stiffeners are placed over the end bearings of welded
plate girders and over the intermediate bearings of continuous
welded plate girders.
 They consist of two or more plates placed on both sides of the
web.
Bearing
stiffners

39. Splice plate or cover plate
 Splice plate or cover plates are used to join the web and flanges
of plate girder bridge. These are connected to the steel girders
through bolts or fasteners.
 Bolts or fasteners are used because bolted joint is more flexible
than welded one.
 if any bolt fails it can be easily replaced by another one without
giving any support.
 If any girder fails then it can be replaced easily in bolted
connection as compared to the welded one

40. Splice detail at inner girder near mid Splice detail near support

41. Splice plate temporary welded to the flanges befor drilling of holes
(Barnala)

42. BEARINGS
 Bridge bearing is an element of superstructure which provides an
interface between the superstructure and substructure. This
interface is vital because superstructure undergoes dimensional
changes and deformations due to various factors which are listed
as follows:
 Thermal expansion/contraction
 Elastic deformation under live load
 Seismic forces
 Creep and shrinkage of concrete
 Settlement of supports
 Longitudinal forces - tractive/ breaking
 Wind loads.

43. Details of the bearing to be used at barnalaDetails of the bearing to be used at barnala
Details of the bearing to be used at barnala

44. Specifications and instruction for the bearings to be used at Barnala