Association of Structural and Geotechnical
Consulting Engineers
Vadakumthala building, Pullepady, Kerala state
Email:asgckeralam@gmail.com, Ph: 04842367824, Fax 2371643
President: Er. Reji Zachariah Secretary: Er. Rathish V.A. Treasurer: Er. Jude Antony
Mob: 9846026162 Mob: 9847314000 Mob:9847371658
Email:rejizac2004@gmail.com Email: rathishva@gmail.com Email:judeantony19@gmail.com
: Palarivattom Flyover:
An Open Letter to Dr E Sreedharan
Respected sir,
Congratulations for taking the step of returning from your retirement and taking the lead
role for assisting the government in demolition and reconstruction of Palarivattom Flyover. The
Apex court of the country had clearly given the verdict in favour of the demigod of Engineering,
whom we all love and respect. Over the years, you are a role model for us and we cherish the
moments spend along with you and greatly admire your Engineering Calibre and the simplicity and
humble nature you have shown…
As the demolition of the bridge has commenced today, as ordinary engineers who believe
in the engineering principles, ethics and codes of practices, we have few doubts which remain
unanswered and request you to enlighten us. Quoting the words of Late Dr P.K.Aravindan, One of
the greatest Bridge experts of the country: “When you are arguing on technical matters, unless and
until you are convinced, you can argue with even God”…..
Association of Structural and Geotechnical Consulting Engineers have experienced senior
engineers who have done more than 100000 structures overall India in the last 30 years. They
consist of Post Graduates and Doctoral Engineers from Prestigious engineering colleges of India
including IITs. Senior members experienced in construction ranges from 20 to 40 years. We are
working as consultants in various fields of civil engineering construction. Association is guiding the
new generation of engineers, conducting seminars and involve in legal activities and helping public
in the construction based events. Association also has helped the public in construction based
disasters. Some of the examples are Pothys touch pile retaining failure, Aroor Church construction
collapse and demolition of Maradu Flats... In the case of Pothys, collector requested the association
help to determine the cause of the failure and remedies. We had submitted a detailed forensic
investigation on the same and remedial measures suggested has got implemented.
The collapse of Aroor Church was investigated by the team from Association, found out the
root cause of the problem which led to the collapse and loss of life and helped the Church to build
Association of Structural and Geotechnical
Consulting Engineers
Vadakumthala building, Pullepady, Kerala state
Email:asgckeralam@gmail.com, Ph: 04842367824, Fax 2371643
President: Er. Reji Zachariah Secretary: Er. Rathish V.A. Treasurer: Er. Jude Antony
Mob: 9846026162 Mob: 9847314000 Mob:9847371658
Email:rejizac2004@gmail.com Email: rathishva@gmail.com Email:judeantony19@gmail.com
the structure as envisaged. The remuneration which was given to the association was handed over
to the family of the bereaved in the disaster.
For the demolition of Apartments at Maradu, Association had helped the government in
successfully completing the demolition without causing damage to the surrounding houses,
buildings, bridges, pipe lines and river despite not understanding the apex court verdict of
destroying houses of 357 families and converting to debris assets worth Rs 400 crores in matter of
minutes.
Palarivattom flyover: My Story : Foundation stone for my construction was laid on 1stJune
2014 and work commenced with piling, pilecap, pier, piercap, girder and decking slab. The total
length is 634 meters and a width of 17 meters. I have a total of 19 spans with a centre PSC Span of
35m and all other spans with R.C.C. girder of 22 meters. Budget of my construction was 42 crores
and my structural design was done by M/s Nagesh Consultants, Bangalore who have designed 100’s
of bridges across India. Government appointed RBDCK for my construction. RBDCK entrusted my
construction with RDS and KITCO was authorised to make sure that my construction is as per the
quality standards. During the course of my construction more than 3700 cubes were taken and
tested in the presence of KITCO and RDS Engineers and recorded in cube register. My work was
running continuously during the day & night and the team of young engineers were there to make
sure that my quality is intact. I am happy to say that all the results were more than specified strength
of 35N/mm2 and ranged upto 50 N/mm2.
Unfortunately a new concept of design as per IRC SP66-2005, for continuous bridges was
adopted in my construction and later on the code itself was amended. It was the first time, in Kerala
that the Tied deck slab system was implemented to provide more riding comfort at the expansion
joints. In this system the deck slab is hinged over the pier using partly debonded dowelling. The
continuity slab over pier shall be designed for the forces arising out of the effect of such continuity
duly taking into account the effect of rotation of the girders subsequent to casting of the continuity
slab. Unfortunately the team involved didn’t have the experience to properly execute the same.
Moreover the bearing pads provided for my smooth movements to absorb the impact was not
sufficient to take care of the lateral movements due to the tied deck.
Association of Structural and Geotechnical
Consulting Engineers
Vadakumthala building, Pullepady, Kerala state
Email:asgckeralam@gmail.com, Ph: 04842367824, Fax 2371643
President: Er. Reji Zachariah Secretary: Er. Rathish V.A. Treasurer: Er. Jude Antony
Mob: 9846026162 Mob: 9847314000 Mob:9847371658
Email:rejizac2004@gmail.com Email: rathishva@gmail.com Email:judeantony19@gmail.com
I was Inaugurated on 12th October 2016 with triumph, in the presence of who is who in our
society and it was indeed a very proud moment for me. The vehicles including huge containers with
a load of 40 tonnes started plying over me. My top tarring was carried out in a hurry during the rainy
season and due to the deck continuity issues and the poor quality of bearing pads and tarring, pot
holes started forming on my surface. As movement was restricted, hair line cracks started forming
in my girder surface based on the traffic intensity. The same was observed by RDS and reported to
KITCO and RBDCK on 23rd November 2016. A small intervention at that time, could have saved me
and minor correction would have rectified my problem. But due to the lethargy of the officers in
charge, my rectification was never done and I kept on taking the loads and absorbing the stresses
leading to increasing of distress in me. RDS appointed Late Prof P.K. Aravindan of IIT Madras to
study my problem and the respected professor after undertaking detailed study suggested to
replace my damaged bearing and to remove the deck continuity which was the root cause of my
problem and rectify my cracks formed by using grouts and carbon wrapping on 17th February 2018.
On 20thFebruary 2018, I was inspected by TPF Engineering Pvt Ltd. as per the direction of
Regional office ministry of Road Transport and Highways as part of consultancy services for
collection and analysis of bridge condition and bridge inventory data by MBIU for the purposes of
major or minor bridges on all NH’s including those with NHAI. They have done 2nd and 3rd cycle of
inspection on 16th March 2018 and 23rd April 2018. They have suggested to conduct Non destructive
testing including crack mapping and to measure my deflection and stress for moving and static load
inorder to assist in validation of the considered design data or deficiency if any by load testing. It
was also advised to register me with IIT’s of repute to carry out the design check. They also suggested
that I can be strengthened by using CFRP composite technology based on the deficiencies if any
arrived at. Moreover they have pointed out that the rehabilitation work has to be taken up on
priority and to be completed before monsoon as application of CFRP composite is not advisable in
monsoon seasons. Still nobody intervened to solve my problems and the plying of vehicles
continued.
Association of Structural and Geotechnical
Consulting Engineers
Vadakumthala building, Pullepady, Kerala state
Email:asgckeralam@gmail.com, Ph: 04842367824, Fax 2371643
President: Er. Reji Zachariah Secretary: Er. Rathish V.A. Treasurer: Er. Jude Antony
Mob: 9846026162 Mob: 9847314000 Mob:9847371658
Email:rejizac2004@gmail.com Email: rathishva@gmail.com Email:judeantony19@gmail.com
On 30th July 2018 in the meeting between RBDCK and RDS it was decided to involve IIT
Madras to evaluate my detailed design and provide recommendation for rectification as per the
suggestions of TPF and RDS agreed to bear all the expenses. On 22nd September 2018, TPF team
after evaluating me in the next cycle, submitted inspection report and pointed out that the distress
in me has magnified and the recorded cracks are propagating and widening. Also it was noted that
new cracks have been recorded in the girders clearly pointing out that if corrective measures were
taken at the right time the damage induced could have been prevented. They also pointed out that
the distress in me is progressing and suggested that remedial measures have to be expedited for
urgent rehabilitation of the bridge and recommended that till complete rehabilitation work is
carried out OWC/ODC Vehicle may be stopped from plying on me. Still the suggestions were only in
paper and was never implemented. Also it is to be noted that similar or more damages were pointed
out by TPF in my friends at Aluva Flyover at Km 330+800Km, Chalakudy flyover bridge at km
296+300Km, Potta flyover bridge at Km 293+300Km, Kodakkar flyover at Km 287+600Km, Mannuthy
flyover at Km 277+100Km and in Kuttanalur flyover at Km 272+300Km. My next neighbour, the
Vytilla ROB had much more severe defects as per the TPF studies and I wonder only so much of
limelight is on me.
After conducting a detailed study spanning months, by conducting non destructive testing
and review of the design, IIT Madras team headed by Prof P Alagusundaramoorthy submitted report
on 25th March 2019 (1) on non destructive and partially destructive testing and (2) on the Analysis
and design of the bridge. From the report on the non destructive testing it was noted that overall
10380 points in Girders and 1820 points in Piers were subjected to Rebound Hammer test and all
values were greater than 35N/mm2 and ranged upto 80N/mm2. UPV test were conducted at 5190
points and 93 percentages values are found to be greater than 3km/sec indicating good quality of
concrete and 7 percentage showed lower values especially where the distress were present. 39
cores from 13 RC girders were taken and 79% of them were found to be having strength greater
than 35N/mm2 and ranged upto 51N/mm2. The lowest value noted was 22N/mm2. Carbonation test
indicated no corrosion damages in me. From the inspection of bearings it was noted that one of the
pot bearing at Pier no: 18 has failed and certain neoprene bearing pads were also distressed. From
the analysis and design report it was noted that the short term deflection of the RC girders was
Association of Structural and Geotechnical
Consulting Engineers
Vadakumthala building, Pullepady, Kerala state
Email:asgckeralam@gmail.com, Ph: 04842367824, Fax 2371643
President: Er. Reji Zachariah Secretary: Er. Rathish V.A. Treasurer: Er. Jude Antony
Mob: 9846026162 Mob: 9847314000 Mob:9847371658
Email:rejizac2004@gmail.com Email: rathishva@gmail.com Email:judeantony19@gmail.com
found to be 41.88mm and the long term deflection was found to be 67.92mm . The formation of
the cracks are due to excessive deflection, lack of proper side face reinforcement and reduction in
strength of concrete. IIT Madras suggested to grout the girders and piers with low viscous epoxy
resin where UPV values were found to be doubtful and advance composite materials such as
thermoset resins and carbon fibre fabrics shall be used for repair & strengthening so that I can be
brought back to shape to complete my life span and perform my duties.
On 1stMay, 2019, I was closed for traffic and the rectification work on me was commenced
by RDS, as per IIT guidance. They completed the re-laying of the bituminous layer, replacing of
bearings and replacing the deck continuity joints spending an amount of 2.3 crores, After the
maintenance works proposed by IIT Madras, I was stronger and was ready to take loading as per
the IRC requirements. If a load testing was done at a cost of Rupees three lakhs with a time frame
of 3 days, I would have been ready to serve the public for the next generation. On 3rd July 2019
after inspecting me on 17th and 27th June 2019, Sir, you submitted the report to Chief Minister stating
that no strengthening is required for the foundation, piers and pier cap needs to be strengthened
with R.C.C. Jacketing suitably designed, no strengthening of special spans consisting of PSC girder is
needed but the metal bearing has to be replaced with more robust ones. It was also pointed out
that all 17 RCC Spans have to be dismantled and replaced with PSC Girders. The financial implication
was worked out to the tune of Rs. 18.71 crores and was also recommended that if the cost estimated
by IIT Chennai is more than 50 percent of replacement cost the total replacement of RCC Girder will
be an ideal solution or else IIT suggestions may be adopted.
It is noted in your report that “According to Mr Mahesh Tandon, the UPV test has brought
out very low quality concrete of just M10 corresponding to the UPV value of 3.5Km/sec.” But as per
velocity criteria for concrete quality grading the pulse velocity range of 3.5Km/sec falls in the
medium to good category of concrete. On 12th September 2019, IIT Madras in its final report
suggested to repair and strengthen the precast RCC Girders in 17 standard span and pier caps in
eighteen piers P1 to P18. The total estimate cost for the repair and strengthening were estimated
at Rs. 7.31 Crores, which is much lesser than 50 percentage of the cost of replacement by PSC
Girders.
Association of Structural and Geotechnical
Consulting Engineers
Vadakumthala building, Pullepady, Kerala state
Email:asgckeralam@gmail.com, Ph: 04842367824, Fax 2371643
President: Er. Reji Zachariah Secretary: Er. Rathish V.A. Treasurer: Er. Jude Antony
Mob: 9846026162 Mob: 9847314000 Mob:9847371658
Email:rejizac2004@gmail.com Email: rathishva@gmail.com Email:judeantony19@gmail.com
On 14th September 2019, Sir, you have submitted a report to the state government in which
it was reported that the cost of repairs appear to be underestimated and also pointed out that IIT
has not mentioned what will be my residual life. I feel that definitely it would have been better if
the questions were asked to IIT team directly.
On 19th September 2019, Letter was send by Sir, you giving an offer on behalf of DMRC to
take over the bridge for rehabilitation and stated that if your plans were carried out, a 100 years
guarantee would be given for the newly constructed flyover. The state government set up a high
level committee consisting of 5 Engineers from Public work departments and they submitted a
report on 4th October 2019 within 5 days of constituting the committee stating that the “findings of
IIT Madras can be accepted and relied upon. IIT has recommended load test after strengthening of
one span of the flyover but has not mentioned the service life of the flyover after retrofitting. The
committee observed that “Dr Sreedharan has mentioned that a new construction with proper
design, quality materials and strict technical supervision can ensure a service life of 100 years. In
view of the assurance by Dr E Sreedharan with the service life of bridge would be 100 years the
committee suggested that it is better to accept the proposal by Dr E Sreedhran”.
On 22nd September 2020 the Supreme court pointed out that the High Court, instead of
applying the well established parameters of Judicial review and ascertaining whether the decision
of state government would violate article 14, went into the matter itself and stated that it is better
to have a load test conducted to avoid any further controversy in the matter. “Given the fact that
an expert committee which is a high level committee of five experts was set up to go into the
divergent option of IIT Madras and Dr E Sreedharan and the experts having come to a particular
conclusion it is very difficult then to say that the government in accepting such expert committee
report could be said to have behaved arbitrarily. On this ground alone we set aside the judgement
of high court and also the review judgement.” And finally it was decided that all my RCC Girders
have to be demolished and my pier and piercaps to be strengthened so that I will have a new life
span of 100 Years. Hoping to be back in service at the earliest after the remodification.. yours truly
…Palarivattom Flyover
Association of Structural and Geotechnical
Consulting Engineers
Vadakumthala building, Pullepady, Kerala state
Email:asgckeralam@gmail.com, Ph: 04842367824, Fax 2371643
President: Er. Reji Zachariah Secretary: Er. Rathish V.A. Treasurer: Er. Jude Antony
Mob: 9846026162 Mob: 9847314000 Mob:9847371658
Email:rejizac2004@gmail.com Email: rathishva@gmail.com Email:judeantony19@gmail.com
Respected Sir, few technical doubts which arise in us:
(1) Why wasn’t IIT directly asked whether load test can be conducted or not
(2) What made you point out that the cost of repair work by IIT is under estimated and why
was IIT not called in to clarify the same.
(3) We are going to place the PSC Girder with 100 Years life on top of the pier and pier caps
which are going to be strengthened only by Jacketing as suggested by IIT. You yourself
have pointed out that the life span of such retrofitting cannot be guaranteed, then how
a life span of 100 years will be achieved.
(4) Moreover in your report submitted to Chief Minister it has been pointed that “out of
the 18 pier caps, 16 have visible shear cracks and the three pier caps of special span
shows extreme distress condition. It is suspected that the designer has designed the
pier heads as corbal instead as Cantilever”. Based on this it is clear that the distress is
much higher in pier caps than on the girders, for which the replacement is suggested.
(5) If the RCC girder is replaced by PSC Girder how can the government recover money from
the contractor as it is a violation of contract. It is like you have ordered for a Maruti car
and it is noted that the product has got a dent, if we want the service provider to replace
the same at his cost, it should be a Maruti car and we cannot get compensation for a
Mercedes.
(6) Considering the six lane bridges in Vytilla and Maradu, do you think that for the next
100 years we only need a deck strengthened 4 lane bridge at Palarivattom. Based on
the traffic growth after 15 years itself it might be changed into a six lane bridge, then
what is the benefit of having a deck with 100 years life.
(7) A load test to be conducted needs only a few days preparation and why was it not
done?. IRC 51, clearly states that when a newly constructed bridge is to be accepted,
may be because its design is of an unusual type or where the quality of the construction
is suspected to be not as specified, then a full fledged testing of the bridge has to be
Association of Structural and Geotechnical
Consulting Engineers
Vadakumthala building, Pullepady, Kerala state
Email:asgckeralam@gmail.com, Ph: 04842367824, Fax 2371643
President: Er. Reji Zachariah Secretary: Er. Rathish V.A. Treasurer: Er. Jude Antony
Mob: 9846026162 Mob: 9847314000 Mob:9847371658
Email:rejizac2004@gmail.com Email: rathishva@gmail.com Email:judeantony19@gmail.com
resorted to as an assurance test by application of loads at least equivalent to the design
loads.
(8) It was clearly pointed out by IIT and Prof Aravindan, that the primary reason for the
distress formation is the deck continuity and if it is removed the problem will be sorted
out. Since after doing the same why the testing was not advised, such a post-mortem
would have identified the real reasons before dismantling.
(9) KITCO has pointed out in the Supreme Court that if the bridge is dismantled without
conducting the load test as per the contractual obligation, the compensation for the
reconstruction cannot be claimed from the contractor and the public exchequer will be
lost.
(10)For similar damages noted KSTP has conducted load test on the Neelimangalam bridge
as per the direction of the World bank and it was observed/documented that the
deflection and cracks formed from the base data and the elastic performance of the
bridge deck on removal of the test load was noted to be satisfactory.
(11) How is the residual life after retrofitting worked out to be only as 20 years
(12) Have you considered the environmental, economic damages and public nuisance due
to the dismantling
(13)Wasn’t this a great opportunity for the engineering fraternity to study the static and
dynamic behaviour of the bridge for academic purpose and to understand the inherent
problem of this bridge which is not yet understood.
(14) As members of the Engineering fraternity we feel that by not conducting load test and
going for dismantling and partial rebuilding without assessing the actual strength of the
existing bridge, we failed to do justice to the Engineering ethics and code of conducts
and also we failed our younger generations who toiled hard for the construction and
the contractual obligation also had provision for the load test. As recently pointed out
by one of our ministers that Caesars wife must be above suspicion and in this scenario
we know our demigod should have a definite Engineering reason.
Association of Structural and Geotechnical
Consulting Engineers
Vadakumthala building, Pullepady, Kerala state
Email:asgckeralam@gmail.com, Ph: 04842367824, Fax 2371643
President: Er. Reji Zachariah Secretary: Er. Rathish V.A. Treasurer: Er. Jude Antony
Mob: 9846026162 Mob: 9847314000 Mob:9847371658
Email:rejizac2004@gmail.com Email: rathishva@gmail.com Email:judeantony19@gmail.com
Hope you will reply to our queries and we wish all cooperation and prayers for the
successful completion of the new assignment.
For Association of Structural & Geotechnical Consulting Engineers,
Er Reji Zachariah
President
ErRathish A
Secretary
ErKurien Mathew
Rtd., Chief Engineer, PWD
Dr Yacub Mohan George, Deputy Chief Engineer (Rtd.), National Highway & Member, B8 Technical
Committee of IRC for the maintenance & rehabilitation of Bridges
Er Suresh S, Past President, ASGCE
Dr Anil Joseph, IPP, ASGCE, National Executive Committee member of IGS, Representative from
India in International Society of Soil Mechanics & Geotechnical Engineering in Field Monitoring and
instrumentation.
Er Jude Antony, Treasurer, ASGCE
Er Abhilash Joy, Executive Committee Member, ASGCE
Er Pramod K O, Executive Committee Member, ASGCE
Er Bindu Sunil, Executive Committee Member, ASGCE
28 September 2020
Cochin
