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REPLACEMENT OF CORRODED CROSS GIRDER

AT BRIDGE NO-1554UP line

Zone- East Coast Railway


Division- Waltair
Section- Vizianagaram
BRIDGE DETAILS

• Bridge No:1554 UP
• Section: Vizianagram
• Block section: Korukonda(KUK)-Almanada(ALM)
• Km.No.:830/35-831/9
• Span: 5x30.5m Triangulated Girder
• Girder Type: BA-5061
• River name: Bheem Singhi
NECESSITY OF CROSS GIRDER REPLACEMENT

 The bridge comes under the coastal belt area due to


which corrosion took place at web plate area.
 This bridge is present on the main line between
HWH-VSKP as a result so many coaching trains are
plying over it. Due to continuous fall of urines and
waters from coaching trains the cross girder was
heavily corroded.
 Sectional loss found in almost 20 cross girder and
demands immediate replacement.
PHOTO GRAPHS OF CORRODED CROSS GIRDER
CHALLENGES FACED DURING REPLACMENT

• Our first objective was to replace the cross girder with


lowest possible time with utmost safety.
• The weight of the girder is approximately 1.5 MT so we
need to have a light trolley which is capable of taking the
desired load with minimum transportation time.
• To hold the cross girder firmly over the old cross girder a
beam is required.
• There is no vertical post at end cross girder to fix the
beam, so suitable arrangements require to fix the beam
and chain pulley assembly.
REQUIRED TOOLS, PLANTS & MATERIALS

• Compressor
• Rivet cutting and rivetting set.
• Ring spanner-20 nos.
• Box spanner-02 nos.
• Crow bar- 6 nos.
• Tommy bar-02 nos.
• Drifts- 20 nos.
• Hydraulic Track Jack 15 Ton- 02 nos.
• Manila rope with hooks- 02 nos.
• Chain pulley-03 nos.
• 6” pipe for beam- 01 nos
• Light material Trolley-01 set
• Rail dolly-03 nos.
• HT Nut and bolts of required sizes-1000 nos.
WORK SEQUENCE

• PRE-BLOCK WORK:
 Fixing of scaffolding at work location.
 Cutting of rivets and fixing of nut and bolts connecting vertical posts and rail
bearer.
 Cutting of gusset plate rivets and fixing nut and bolts for fixing new cross
girder bottom flange angle.
 Fixing of clamps at vertical post for supporting beam.
 Shifting of gang pathway chequered plate from work location.
• POST-BLOCK WORK:
 Riveting of nut and bolt connections.
 Stacking of the released materials at safe place.
 Rivet testing of new rivets.
 Painting rivetted connections and cross girder.
 Shifting of scaffolding to next location.
BLOCK WORK SEQUENCES OF CROSS GIRDER REPLACEMENT
Shifting of new cross Fixing of lifting beam & Shifting of running Lifting of old cross
girder to work site chain pulley to lift rails, guard rails from girder upto rail level
cross girder work location

Shifting of old cross


girder from work
location to bridge
approach.

Lifting of new cross


girder & placement to
its desired location

Fixing of cross giders


with vertical post, rail
bearers etc.

Tightening of running Checking of gauge and


Shifting of running Shifting of lifting beam,
rail clips , cross girder- cross level
rails, guard rails to its chain pulley from work
vertical post cleat
original position location to bridge
bolts, CG-RB joint nut
approach
bolts
A light material trolley innovated to easily shift cross girder
Beam arrangements to lift and place cross girder
Fabrication of Derricks with chain pulley arrangements for
replacement of end cross girder
PRECAUTIONS TO BE TAKEN DURING EXECUTION OF
WORK

• One spare chain pulley is always preferable as some times chain pulley does
not work properly.
• Hand gloves are necessary during the block work.
• If block is provided at hot climate condition, the running rails length increases
as a result during fixing of running rail it does not fit into the slot, so necessary
arrangements like 2-3 buckets of normal water are required at work locations
to cool the rail temperature.
• It is not quite often but some times the rail bearers present on either side of
the replaced cross girder show some sagging and cross girder-railbearer joint
holes donot match. To overcome from such type of difficulties necessary
clamping arrangements should be done so that railbearers can be lifted to
desired level.
• Scaffolding which are erected at work locations must be strong enough to
cater for 15 persons and also capable of withstanding loads of bottom flange
angle and joint cleat angles.
• The labourers which are engagged for the work may be uneducated and does
not know the safety related issue involved during the work. Necessary
awareness should be made among them in connection with the works and
safety.
conclusion
• Total 1.30hrs required to tackle one cross
girder.
• 20 cross girders replaced successfully.
• The light material trolley was found very
effective in transporting the 1.5 T cross girder
and considerably reducing the block time.
• clamping arrangements for lifting sag
railbearers found very effective.