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  /  Projects   /  UHPC overlay to strengthen Railway Over Bridge (RoB) 
RoB Saphale near Mumbai

UHPC overlay to strengthen Railway Over Bridge (RoB) 

(Project: Dedicated Freight Corridor, RoB Saphale near Mumbai)

RoB Saphale near Mumbai

The bridge deck of RoB at Saphale, a part of the Dedicated Freight Corridor system connecting Mumbai to Delhi, was designed for 40 MPa grade concrete. Upon construction of the deck, the top cover of the concrete deck showed several structural cracks and was deemed to be low quality. In addition, one of the post-tension anchorage zones also burst during the stressing activity. This problem was delaying the track completion underneath and commissioning of this phase of the Delhi-Mumbai freight corridor.

UHPC India Pvt Ltd (UIPL) was approached to provide an accelerated solution that would also provide a 100-year service life. A thin bonded UHPC overlay was designed to strengthen the existing deck. This required removing the top 40mm of concrete cover and creating adequate roughness for bonding with the UHPC overlay. A 50 mm thick UHPC was laid over the prepared (roughened) concrete surface. During the process the anchorage zone was also filled with UHPC.

This ensured not only sufficient compressive strength of the bridge deck, but also made the bridge deck more durable and maintenance free for a longer period, with minimal added dead load. As UHPC gains quick strength, all other activities were completed in a short schedule and traffic opened over the RoB.