Pamban Bridge - a presentation by Rajesh Prasad

Concept (3D Model) Completion (Reality)
By
Rajesh Prasad, Ex. IRSE
Former Director (Operations)/RVNL and Now Advisor CC IRCON
What is N.E.W.- (New-Noteworthy Excellent Engineering Wonder)
in
New PAMBAN BRIDGE- A testament of Excellence

PAMBAN BRIDGE LOCATION MAP
Pamban Bridge was a railway bridge that connected the town of Rameswaram on Pamban
Island with Mandapam in mainland India. Opened on 24 February 1914.
➢Rameshwaram was once part of the Mainland
➢Cyclone in 1480 separated it from Mainland

Planned for a bridge to connect to mainland was suggested in 1870 as the
British Administration sought ways to increase trade with Ceylon (Sri
Lanka).
The Bridge was constructed during the reign of Lord Pentland, Governor of
Madras between June 1911 and July, 1913 with Meter Gauge Track by
South Indian Railway Company.
Opened for Rail traffic on 24th February, 1914, it was India's first sea bridge,
and was the longest sea bridge in India until the opening of the Bandra–
Worli Sea Link in 2010.
OLD PAMBAN BRIDGE
Span 145 x 40’ + 1 x 225’ : Total length 2058 M

OLD PAMBAN BRIDGE
Lord Pentland, Governor of Madras 1912-1919

OLD PAMBAN BRIDGE
During the cyclone on 24th December 1964, 124 out of 145 spans were washed away by tidal waves
leaving 20 pre-stressed concrete girders and the Scherzer span.
DISASTER DURING THE YEAR 1964
Storm surge was 7.6 m, Passenger train got washed away killing 200 passengers, Dhanushkoti Town got fully submerged

SCHERZERS ROLLING LIFTING SPAN 68.58 M
Restoration work
OLD PAMBAN BRIDGE
Restoration work in progress under Dr. E. Shridharan, DEN / MDU

First train passing over the bridge after completion of restoration work.
OLD PAMBAN BRIDGE

11
The Bridge was closed for Gauge conversion on 15.07.2006 and opened for traffic on
12.08.2007 after the gauge conversion.
Scherzer Rolling Lifting Span 65.58 M
OLD PAMBAN BRIDGE

INDIRA GANDHI HIGH LEVEL ROAD BRIDGE CONSTRUCTED PARALLEL TO PAMBAN RAILWAY BRIDGE
2345m long high level Road bridge connecting Rameswaram
Island with Main land parallel to Existing Railway Bridge was
commenced on 17.11.1974 and completed on 30.09.1988 .
Opened to traffic on 02.10.1988

Foundation stone for the new Pamban bridge was laid by the
Prime Minister Shri Narendra Modi in November 2019
Honourable PM’s speech dt 24.10.2016 during
inauguration for which Foundation Stone was laid
by him on 25.12.2014 in Varanasi
Ready for
commissioning
since Sept. 2024
Lifting using SCADA
CRS Authorization

New Pamban Bridge Annai Indira Gandhi Road Bridge
• Year of Sanction : Feb. 2019
• Foundation Stone: Nov. 2019
• Inaugurated on 6th April 2025.
Construction in less than 5 years
(in between Covid 19 impact – 2 years)
• Work Commenced in Nov 1974
• Completed in Sept. 1988
14 years in construction

Corroded Bridge now in disuse..

WHY TO BUILD A NEW PAMBAN BRIDGE ?
• The Scherzer Span (Double Bascule) of the existing Bridge has severely corroded.
• There is a PSR of 10 kmph over the 2 km long bridge
• Strain in the critical members of the girder used to be constantly monitored by IIT
Madras Strain Gauges were installed at 84 locations and Accelerometer at 24 locations.
• The alarm used to blow once the strain exceeds the safe threshold limits and trains are
stopped.
• The data used to get transferred to the Division and IIT-Madras instantaneously.
• IIT-Madras used to analyse the data and later suggested for major attention. Corrosion
was noticed to be very severe. The traffic got fully suspended from Jan 2023.
• Therefore, it was decided to construct a new bridge on a detour in 2019.
• New Bridge is proposed with Vertical Lift Span – 72.5m span with a vertical lift of 17m
• The total air draft above High Tide Level is 22m when the Girder is in lifted condition

What is NEW?...
Maximum speed is 80 kmph though designed for 125 kmph, curve in approach of lift span- 2.65 degree

Is it First Vertical Bridge, probably YES…
Br No K 1 at Km 5/5C -4C of Circular Rly of Sealdah Division (34 m Through Type) but
as per record it was not functional and the section got electrified in 2005…

What is NEW….
Baltimore collapse in March 2024… how addressed in the NEW
Pamban Bridge….
Cargo Ship Dali, Bridge Francis Scott Key Bridge
Supply Chain disturbed- 2.5 billion $
New Bridge 2 billion $ TDC- Fall 2028
Part closure of port for 3 weeks

(26.2m x 14.5m x x2.25m)
NAVIGATION SPAN
P77
P78
Fender piles, integrated with strap beam
to protect the structure from stray ships
Fender pile arrangement (Baltimore USA bridge incident March 2024 taken care of)

Corrosion in Road Bridge..
Noticed in Nov 2024…

Stainless Steel used to combat Corrosion..

What is NEW?...
MI Inspection note dt 11.07.24
Extensive use of FRP in corroded environment
eg Walkway, hand rails, gangway plates, stairs,
sleeper tie, cable trays, gate etc.
CRS Rear Window Inspection..

➢ Used Stainless steel reinforcement – Grade G ferritic – 410 L (SS 550) conforming
to IS: 16651 – 2017 as per Railway Bd. Letter dated 02.05.2018.
➢ 19.65m long steel plates were specially got rolled to eliminate Splice joint in the
approach span girders of 18.3m span. This provided flat top surface and prevented
loose fittings, viz. Packing plates.
➢ 20m long Rails 60 Kg have been specially got tolled to reduce number of rail joints,
while maintaining the Rail joints at 1/3rd span in all girders.
➢ Fully welded girder (Box sections) is adopted for lift span truss to reduce
corrosion.
➢ Rail Level increased by 3.0m from existing Rail level to minimize the effect of
splashing of sea-water.
➢ Corrosion inhibiting admixture used in RCC
➢ Adopted higher diameter piles of 1.50m to reduce the number of piles.
➢ Adopted piling by ‘Piling gantry’ method on Mandapam end due to shallow depth.
NEW- INNOVATION/VALUE ADDITION/IMPROVISATIONS

➢ Scanning of all Butt welds by PAUT (Phased Array Ultrasonic Test)
➢ Robust Surface Protection Scheme adopted as per ISO 12944 and its efficacy has
been established through Accelerated Test (continuous Salt-Spray test) for 1440 Hrs
at Central Electrochemical Research Institute, Karaikudi.
NEW- INNOVATION/VALUE ADDITION/IMPROVISATIONS
Electrical:
➢ Exclusive SCADA for the operation of vertical lift span.
➢ Complete automation of lifting and monitoring of various parameters using latest
IGBT technology.
➢ Monitoring of critical parameters from the control room of Divisional Office.
➢ Operation by single person.
*IGBT- Insulated Gate Bipolar Transistor is a power transistor that can handle high currents n high voltage

CONCEPT
➢ Only Lift span Local Diversion with Lift span Full diversion with Lift span
➢ Navigation span : Bascule, Vertical lift, Swing
➢ Approach span : PSC girder, *Steel girder
➢ Diversion : 30m 50m
*Steel- Better Quality Control
Greener Construction, Faster, Easier, Simpler

PLANNING:
Alignment
Ch:655/079m to Ch: 657/157m : Length 2.078Km
➢ Diversion - 47.35m towards North of the existing Bridge.
➢ Curve R-5000m - Transitioned without SE - Ch:655/276m to 655/706m
➢ Curve R-660m - Transitioned with 60mm SE - Ch:656/892m to 657/442m
➢ Gradient - Rise 1 in 250 - Ch:654/354m to 655/260m
- Level (+6.957m) - 655/260m to 656/877m
Fabrication of Girders:
➢ Work shop established at Sathirakudi beyond Coastal region (30km from shore) for segment
fabrication & at site for assembling
➢ Launching by Launching girder method

Concept visualization - 3D animation video

NEW PAMBAN BRIDGE – KEY PLAN
Key team members involved:
• Executing Agency :- Rail Vikas Nigam Limited (RVNL)
• Client :- Indian Railways. Zone:- Southern Railway
• Contractors: Ranjit Buildcon Ltd., Ahmedabad & ITD Cementation India Limited
• PMCs: BARSYL - Construction and Supervision of Substructure and Superstructure of approach spans;
• TYPSA-STUP-MC2(JV) – Design of Sub-structure and Superstructure and Construction Supervision of
Lift Span

VIEW OF PROPOSED LIFT SPAN ACROSS NAVIGATION CHANNEL
Existing Road Bridge
Proposed Vertical lift span
Existing Scherzer Rolling lift span
Image:Indian
Railways logo.png
Pamban
Mandapam
34

ARIEL VIEW OF NEW PAMBAN BRIDGE
-:ENGINEERING MARVEL:-
Bridge is located across Pamban strait, connecting Main land of India
and Rameswaram Island, in Manamadurai – Rameswaram Section at
Km 655/000 – Km 657/200. Lattitude & longitude of the bridge
location are 9° 16' N & 79 ° 11' E

SALIENT FEATURES
SN ITEM FEATURES
1 Year of Sanction February, 2019
2 Award of Contract August, 2019
3 Length of Bridge 2078 M
4 Location of Proposed Bridge Parallel to existing bridge at 50 M towards North
5 Span 99 x 18.3m G + 2 x 10.2m G + 1 x 71.794 TOWG
6 Foundation Bored cast-in-situ RCC piles 1500 mm dia (3 pile group for
Piers, 6 pile group for Abuts & 15 pile group for Navigation
piers)
Average depth of piles : 38.50m
7 Substructure Pile cap cum Pier cap- Constructed for double line
8 Super structure 99x18.3 m Steel Girder –Approach spans (Single line),
2x10.20m
Steel Girder for Auxiliary spans (Single line) & 71.794m Steel
Girder for Lift span (Double line)

SALIENT FEATURES
SN ITEM FEATURES
9 Lifting Mechanism & Type Electromechanical - Vertical lift
10 Lifting Height & Vertical
clearance
Maximum lift -17m,
Air Draft - 22m (Matches with adjacent road bridge)
11 Gradient 1 in 250 on A1 end & 1 in 190 on A2 end.
12 Curvature RH Curve of Radius 5000m (0.35 degree) from Span
11 to 32 & RH Curve
of Radius 660m (2.65 degree) from Span 87 to 100
13 Standard of Loading 25 T Axle loading - 2008

DESIGN BASIS REPORT :
Design Basis Report (DBR) – ‘Guidelines for RDSO approval of planning and DBR
for Important Bridge’ issued by RDSO vide report no. BS-122-Nov. 2015.
Alignment
Ch:655/079m to Ch: 657/157m : Length 2.078Km
➢ Diversion - 47.35m towards North of the existing Bridge.
➢ Curve R-5000m - Transitioned without SE - Ch:655/276m to 655/706m
➢ Curve R-660m - Transitioned with 60mm SE - Ch:656/892m to 657/442m

DBR : SUBSTRUCTURE
➢ Loads as per Bridge rules
➢ Basic wind speed 39m/sec
➢ Seismic Zone : II
➢ Pile is analysed with soil spring stiffness based on the Bore log detail
➢ Pile cap analysed as 3D model plate element.
➢ Crack width : 0.10mm (Extreme exposure condition)
➢ Pile foundation : 1500 mm dia piles (3 pile group for Piers, 6 pile group for
Abuts & 15 pile group for Navigation piers) Average depth of piles : 38.50m

SUBSTRUCTURE
➢ Grade of concrete : M45
➢ Reinforcement : Stainless steel of Grade - G ferritic - 410L (SS 550)
conforming to IS:16651 -2017, Binding wire:1.2mm dia, SS Grade 304
➢ Clear Cover : 75mm
➢ Bipolar, migratory, integral, non-nitrate based concrete penetrating corrosion inhibiting
admixture conforming to RDSO BS-88 specification has been added @ 2kg/cum of
concrete.
➢ Permeability tests on Concrete : Varies from 5mm to 9mm, which is less than the
permissible limit of 25mm.
➢ Coal tar epoxy coating applied on concrete surfaces

SUPERSTRUCTURE
Approach spans:
⮚ 18.3m steel plate Girder to Drg. No. RDSO/B- 16015/R with steel of E250 B0.
⮚ Spacing of “I” Girders increased from 1850mm to 1950mm to suit 2.65 degree curve.
⮚ Plate Bearing
Navigation Span:
⮚ Lift Span: Fully welded open web girder (535 MT) – Steel Grade: E350 B0 for Double
track.
⮚ Spherical Bearing & Centering device
Fabrication of Girders:
⮚ Fabrication Shop established at Sathirakudi, exclusively for this bridge. It is beyond
Coastal region (30km from shore) and approved by RDSO.

DESIGN CONSIDERATIONS
Super structure - Approach spans
➢ DRG. No. RDSO/B-16015/R (Straight portion)
➢ For Curved portion, the girder is checked for the following additional load effects
➢ Centrifugal forces
➢ Curvature effect
➢ Track shift effect

DESIGN CONSIDERATIONS – LIFT SPAN
➢ FEM modelling has been done in SAP with Lift span, Tower, Strut, Rope, Sheave and
Machine room analyzed as one entity.
➢ Checked with Normal and Lifted condition
➢ Lifted : Dynamic effect of Machinery and Wind
➢ Normal: Live load and Counterweight independently supported
➢ Linear analysis and second order effects are taken as per EN Code
➢ Checked for its adequacy as per Steel Bridge code
➢ Fatigue assessment done as per Steel bridge Code (Damage equivalent factors)

MODEL CREATED IN SAP & ANSYS*
*SAP 2000 Structural Analysis Programme
ANSYS- Analysis System

DESIGNERS AND PROOF CHECKERS
SN Item By Agency
1 Design of Substructure of Approach
Spans
STUP/MUMBAI TYPSA-MC2-STUP (JV)
2 Substructure of Lift Span STUP/MUMBAI TYPSA-MC2-STUP (JV)
3 Super Structure of Approach spans RDSO Drawing No. RDSO/B-16015/R
4 Super Structure of Lift Span MC2 TYPSA-MC2-STUP (JV)
5 General Electrical and Electro
Mechanical
TYPSA TYPSA-MC2-STUP (JV)
6 Proof Checking of Design – Substructure,
General Electrical and Electro
Mechanism
Initially by IIT Madras Subsequently by IIT-
Bombay
7 Proof Checking of Design – Super
Structure
IIT-Bombay
8 Approval of Drawings RVNL

DESIGNERS AND PROOF CHECKERS
SN Item By Agency
9 Third Party Inspection of
Welding
WRI/Trichy WRI/Trichy
10 Inspection and Approval of
Fabricated
Girders
FIU/Southern Railway
11 Proof Checking of Design Adequacy
of
Girders on curve
IITB/Mumbai IITB/Mumbai
12 Proof Checking of Design Adequacy
of H
beam sleepers on curve
IIT Guwahati IIT Guwahati
13 Proof Checking of Design of Rail
Joint
IIT Guwahati IIT Guwahati

EXECUTION
➢ Pile foundation : Land mode Piling rig mounted on Jack up barge Gantry
➢ Casting of pile cap : Shuttering from bracket support welede to pile liner
➢ Fabrication of Approach span Girders: Complete Girder – 19.65m long - fabricated at shop, moved to
site as whole and erected in respective span by Gantry girder.
➢ Fabrication of lift span: Lift span Girder 77.1m long, 11.8m wide and 10m high (525MT) fabricated at
shop in various segments, moved to A2 approach, assembled by welding.
Whole span was moved to respective span no.78 using launching girder by
auto launching method.
➢ Fabrication : Towers, lintels and counter weights fabricated in segments, moved to site by
Road, floating pontoon, erected using marine cranes
and connected with HSFG bolts.

LIFTING TOWER FOR VERTICAL LIFT SPAN
➢ Lifting Towers : 2 Shafts of varying section with struts.
➢ Size of tower shaft : 3.0mx2.3m at Base and 3.0mx4.0m at Top
➢ Clear Spacing between shafts : 15.3m.
➢ Height of tower : 34.825m (above pedestal)
➢ Vertical Lift of Span : 17m.
➢ Weight of tower : 300 MT
➢ Weight of Counter weight : 312 MT
➢ Control Room / Machinery Room : 21.30m x 6.30m at top of each tower
➢ Access to control room : Stairs in one shaft & elevator in the other.

OPERATIONS
➢ Lift span is well balanced by counter weight at both ends.
➢ Lift span and counter weight are connected by wire Ropes,
which moves over sheaves
➢ The operating motors and gear boxes drive the sheave
assembly for lifting/lowering the span.
Machinery room
Wire rope
Counter weight
Girder
Tower
shaft
Pile cap
Tower
shaft
OPERATIONS-SCADA
SCADA
➢ Exclusive SCADA for the operation of vertical lift span
➢ Complete automation using latest IGBT* technology
➢ Monitoring of critical parameters from the control room of Railway office.
➢ Operation by single person.
*IGBT Insulated Gate Bipolar Switching Technology

PILING BY JACK-UP BARGE
Challenges…

PILING BY FILLING OF SEABED FOR 7 SPANS (LAND MODE)
Challenges…

PILE FOUNDATION BY PILING GANTRY
Challenges…

Leading Of Liner/Reinforcement cage using Motorised Dip-lorry On Walkway Girder
M.S. Liner
Motorised Trolley

DESIGN CONSIDERATIONS
Sub structure – Approach spans
➢ Loads as per Bridge rules
➢ Basic wind speed 39m/sec
(Design speed with factors 56.43m/sec) Wind
pressure 195 Kg/m
➢ Seismic Zone : II
➢ Pile is analysed with soil spring stiffness based on
the Bore log detail
➢ Pile cap analysed as 3D model plate element.
➢ Crack width : 0.10mm (Extreme exposure
condition)
➢ Plate girder supported on Plate bearing

Floating Batching plant with Boom Placer
Boom Placer
Concrete Batching Plant

Transfer of concrete from Transit Mixer to Floating Pontoon

PILE CAP - PIER P77 (NAVIGATION SPAN) CONCRETING
CONCRETE BEING MOVED BY
TRANSIT MIXER MOUNTED ON
BARGE
CONCRETING IN PROGRESS
Pile cap size : 26.20mx14.50mx2.25m
Volume : 855 cum

Concreting of Lift Span Pile cap (855 Cum/36 hours)
Roof covering done to protect the concrete from rain
during continuous pour of 855 cum

Coal Tar Epoxy Painting of Substructure

➢ Pandemic: Covid 19 pandemic affected with in 4 months of commencement of work.
➢ Access to Work site: Narrow approach to work site affected ODC movement.
➢ Supply of materials: Single supplier of Stainless steel reinforcement (7000 MT) affected supply.
➢ Transportation of material: Special truck used to transport 20m long specially rolled steel plates
from factory.
➢ High Humidity: Delayed the welding activity, Metalizing and Painting
➢ Low Dew Point: Delayed the Metalizing and painting.
➢ Rough Sea: Affected the movements of materials
➢ High Wind Velocity: Affected welding works at hights, Painting, movement of materials by
barge, Erection of segments.
➢ Working in heights: Welding of Lift span at a height of +16.0m above MSL.
➢ Height of Tower segments at a level up to +36.350m/+40.0m above MSL.
➢ Launching of Lift span on curved alignment
CHALLENGES FACED

GIRDER FABRICATION ACTIVITIES AT SATHIRAKUDI WORK SHOP
WEB & FLANGE PLATE CUTTING STIFFENERS AND GUSSET
CUTTING _ CNC MACHINE
ASSEMBLING OF “I” GIRDER
SUBMERGED ARC WELDING –
“I” SECTION
CHECKING OF WELD
PARAMETERS
TRIAL ASSEMBLY

WELD INSPECTION BY
Manager/WRI
CHECKING OF BLASTING PARAMETERS
CHECKING THE PARAMETERS OF
METALISED/PAINTED SURFACE
PAINTED “I” GIRDERS

FABRICATION OF LIFT SAPN IN SEGMENTS AT SATHRAKUDI SHOP
EACH TRUSS -- -- – 10 SEGMENTS
CROSS GIRDERS & STRINGER – 15 sets,
TOP TIE -- -- – 5 Nos,
END CROSS GIRDERS -- – 2 Sets.

Flame Cutting Of Steel Plates By CNC Machine
Fabrication of Approach Span Girders

Submerged Arc Welding for Fabrication Of Approach Span Girder

Dye Penetration Testing of Approach Span girders

Surface Preparation By Grit Blasting Approach Span Girder Zinc Metallizing
Fabrication of Approach Span Girders

Painting of Approach Span Girder with Polysiloxane Paint

DFT checking of Coatings of Approach Span Girders

FABRICATION OF LIFT SPAN AND TOWER

FABRICATION OF
LIFT SPAN AND
TOWER

FABRICATION OF LIFT SPAN AND
TOWER
SAW
GMAW

FABRICATION OF LIFTING TOWER SHAFTS

Torqueing of HSFG bolts of Approach Span Girders

Assembled Approach Span Girder - Final Inspection by FIU

Sr.DGM/RVNL- CHECKING
THE PERMEABILITY OF TEST
CUBE
PERMEABILITY TESTING
MACHINE
QUALITY ASSURANCE

CONCRETE –
SLUMP TEST
CONCRETE –
CASTING OF TEST
CUBES
CONCRETE –
TEMPERATURE CHECK
Sr.DGM/RVNL-
WITNESSING TESTING OF
CONCRETE CUBES
QUALITY ASSURANCE
MOISTURE
CORRECTION

FABRICATION OF LIFT SPAN AND TOWER –
WELD INSPECTION BY PAUT

WELD INSPECTION BY PAUT – SAVED IMAGE OF A DEFECT

SL.No CONVENTIONAL ULTRASONIC TESTING (UT) PHASED ARRAY ULTRASONIC TESTING
(PAUT)
1 One directional beam angle transducer (Probe) is used ‘Array’ of transducers ‘Phased’ in single Probe is used
2 Multiple probes needed to locate a defect Single probe adequate to deduct a defect
3 Entire cross sectional area not possible to scan in single
run
Entire cross sectional area can scan in single run
4 No recorded data of scanning All scans being recorded and permanent data acquired for the
defects. Scanned images are saved and interpreted/viewed at any
time.
5 Not replacing the Computed Radio graphic testing (CRT)
of welds
PAUT can replace the CRT.
6 Probability of detection of defects very low Probability of detection of defects very High
7 Low cost 5 Times costlier than conventional UT
8 Not used in this project 100% of Butt welds being tested in this project.
UT Vs PAUT

PREVENTIVE MEASURES AGAINST CORROSION
Superstructure (Approach spans) :
▪ Eliminated bolted splice joint in the Steel Plate Girder to
avoid corrosion, by using 19.65 m long steel plates.
▪ Used surface protection system consisting of Zinc metalising
(200 microns), Epoxy Sealant(25 microns) and two coats of
Polysiloxane paint (125 microns) with total DFT of
350microns, as per ISO:12944.
▪ Zinc Flake Coating applied on HSFG bolts.
▪ Eliminated holes in the top flange by providing welded gusset
plates for connecting lateral bracings.
▪ All sharp edges have been rounded off.

PREVENTIVE MEASURES AGAINST CORROSION
Superstructure (Lift span) and Lifting towers:-
• Lift Span Girder is a fully welded girder, which eliminates all corrosion
pockets.
• Rail level has been raised by 3m for Lift span to prevent splashing of sea
water.
• All Truss members have been fabricated with Box Sections for avoiding
water stagnation.
• Used surface protection system consisting of Zinc metalising (200
microns), Epoxy Sealant (25 microns) and two coats of Polysiloxane paint
(125 microns) with total DFT of 350 microns, as per ISO:12944.
• Stringers have been joined with Cross Girders with transition
arrangement to avoid stress concentration at the junction, reducing the
possibility of corrosion at stressed locations.

Launching of Approach Span Girder on Self Propelled Trolley

Girder Being Moved On Self Propelled Trolley For Launching
Lifting of Approach Span Girder using A-frame

Linking of Track
Launching of Track Panels by motorized trolley and Erection by A-frame on
Approach Span Girders

Launching of Approach Span Girders and Track Panels from Pamban End

View of Completed Track on Bridge from Mandapam End

Assembly of Lift Span Girder at Pamban End

Launching of Lift Span Girder across channel

Electro-Mechanical Equipment on tower top

Mock Trial of Electro-Mechanical Equipments

Electro-Mechanical Equipment after erection

BEARINGS AND CENTERING DEVICES
CD1 & CD2 are Centering Devices
D1, D2, D3 & D4 are Spherical Bearings
34
mm
55
mm
P77 P78

CAST STAINLESS STEEL CENTERING DEVICE
Roller Guide

TOWER - A
TOWER - B
ELECTRICAL BUILDING
MADURAI CONTROL ROOM
MAIN
REMOTE
REMOTE
LIFT SPAN
SCADA FOR PAMBAN BRIDGE
*PLC- Programmable Logic Controller

SCADA for the Bridge Operation- lifting time 326 Seconds..
• Exclusive SCADA for the operation and continuous monitoring of
safety parameters
• Provided in both towers (operation), sub station & control
room/MDU (monitoring)
• Controls the train operation as well as ship movement duly
interlocking signal aspects
• Monitor all critical parameters continuously incl. wind velocity
and that can be monitored from control room, MDU
• Critical parameters are being ensured before starting of the
operation
• Variable speed drive parameters during lift and descent,
checking unbalanced movements and skew monitoring and its
position.
• Automatic application of hydraulic brakes in case of emergency

Surface mount linear RGBNW
Grazer
Surface Mounted RGBW Grazer
Projector up light RGBNW
Handrail underneath
profile light Neutral White
Surface mount linear dynamic
RGBNW
RGB Lighting on Lift Span & Towers

ANIMATION VIDEO
ANIMATION VIDEO
Lighting Concept and Visualization

View of Electrical Building adjacent to Lift Span

Health Monitoring System*
Sensors to Monitor
Data Acquisition and
Transmission
Real-Time Feedback
Basic functional modules
Health Diagnose
➢ Environmental loads
➢ Global performance
➢ Local performance
➢ Data simultaneous acquisition
➢ Database system
➢ Data remote transmission
➢ Member stress estimation
➢ Real-time feedback on the responses
➢ Alert messages to the concerned officials
➢ Load standard
➢ Health criteria
➢ Health evaluation
➢ Prognostic Evaluation
*CSIR Structural Engg Research Centre Chennai

Integrated online SHM framework –
Schematic representation

Parameter Nos. Sensor
Strain and vibration in
the main truss members
25 to 30 nos. Electrical Resistance Strain
Gages/Fiber optic sensors,
accelerometers
Strain in the stringer
beams
5 to 10 nos Electrical Resistance Strain
Gages/Fiber optic sensors
Trigger sensors 2 nos. (one at each end for
automatic start and stop)
Accelerometers
Weather station for
measuring the weather
conditions
1 no. Temperature, wind speed etc
Sensors for Tower
Structure
5 to 10 nos. Electrical Resistance Strain
Gages/Fiber optic sensors,
accelerometers
Instrumentation scheme

✓ Modular and expandable DAQ (Data Acquisition System)
✓ Real-Time Embedded controller for data logging
✓ Realtime operating system
✓ Inbuilt memory >200GB SSD (Solid State Drive) Possibility to expand storage with Exchangeable CFast 2.0
card, USB 3.0 stick / HDD
✓ Record data continuously for a specified duration on trigger and save it to a file without data loss or black
out time.
✓ Recording rate 4 to 5 MS/s
✓ Synchronous data acquisition from all channels
✓ Ethernet ports with embedded Web and file servers for remote user interfacing and directly connect to
mobile internet
✓ Trigger channels to trigger acquisition on exceedance of a preset criteria of an analogue or computed signal
✓ In built Surge protection
✓ Input channels for strain gages, piezo based accelerometers
Control Station

SAFETY
• Load Tests have been conducted on the Piles, Approach Spans and Lift Span to check adequacy
of the structure.
• Track Recording has been done during speed trial conducted by CRS at 80 kmph. No peak
exceeding 0.15g was recorded.
• Train service is not permitted beyond wind speed of 58 kmph, for which anemometer has been
provided at approved location and interlocked with Bridge Signals.
• Detection of for Seating of Rail Joint is ensured through Limit Switch, which is interlocked
through SCADA
• Lifting / Lowering operation of Lift Span and locking of Span and Counterweight are done using
SCADA.
• Guidelines have been issued for certifying proper seating of Lift Span Girder and Rail Joint after
Lifting /Lowering operations,
• Bridge Operators and SSEs have been imparted Training for 4 days from at Divisional Training
School, Madurai and Field Training for 5 days on Train passing duties and Lifting / lowering
operations of Lift Span on SCADA.
• Counter weight is locked, when the bridge is seated, before the control is transferred to
signalling system for working of trains.

Lowering of Lift Span, media coverage in July 2024
Paper Cutting 28th July 2024
Celebrations once lift span got placed in July 2024

View of Bridge towards Mandapam End

View of Bridge towards Pamban End

Electrification on the New Pamban Bridge
• ROCS (Rigid Overhead Conductor System) is planned
on the Movable bridge and conventional OHE at
both ends
• ROCS details:-
 System voltage : 25kV AC
 Track length : 85m (approx.)
 Contact wire height : 5800mm
 Support insulator : 25kV, 1600mm creepage
 Electrical clearances : 270mm static, 170mm dynamic
 Design speed : 100km/h
 Contact wire : 107mm2 Cu, Round bottom type
 Contact wire tension : 10kN (only at termination arrangement)

Electrification of Pamban bridge is being planned as part of RVNL
work, which includes erection of both ROCS & Conventional OHE
in the bridge under construction.
However there is an approval waiting from Defence Min to carry
out part of Electrification (about 1km) in between Mandapam &
Rameswaram in order to have Electric traction running upto
RMM, which covers the newly under construction of Pamban
bridge too

Lift Span illuminated in Tricolour

OMS Trial and Lifting using SCADA

Media Coverage- Bad n Good….

NEW PAMBAN Bridge- nicely explained….
Night view when illuminated….
Media Coverage, nicely explained...

Controversy and guidelines issued…
Rly Bd’s letter dt 10.01.25 for planning n execution at
various stages- specially getting CRS involved…
PED Bridge’s letter dt 18.10.24 for planning n execution of
non-standard spans of Girder Bridges…

Project Management explained at one worksite of Railway..

Privileged and proud to be associated with this iconic project…..

What is our AIM?
Financial Express – 07th April 2025
A.I.M. stands for
An Infrastructure
Marvel

We are in transition from Aazadi Ka
Amrut Mahotsav to Viksit Bharat..

THANK YOU
FOR
YOUR PRECIOUS TIME.
धन्यवाद….

Pamban Bridge - a presentation by Rajesh Prasad

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