First Full Span 40 m Box Girder being cast for Mumbai - Ahmedabad High Speed Rail corridor by National High Speed Rail Corporation Limited (NHSRCL)
Weighing around 970 MT, it will be the heaviest Pre-Stressed Concrete Box Girder in India
Planning of casting yards and heavy machinery for launching is being done to meet peak requirement of approx 300 Full Span Box Girder in a month
NHSRCL started the casting of the First Full Span Pre-Stressed Concrete (PSC) Box Girder of 40 meter span to expedite the construction of viaduct for Mumbai- Ahmedabad High Speed Rail corridor (MAHSR), in a casting yard in Anand, Gujarat on 28th October 2021.
PSC Box Girder of 40 m span weighs around 970 MT and will be the heaviest PSC Box Girder in the construction industry of India. The 40 m Span Girder is being cast in a single piece i.e. without any construction joint, involving 390 Cum of Concrete and 42 MT of steel.
Addressing the gathering, Shri Ashwini Vaishnaw, Hon’ble Minister stated that to encourage Aatma Nirbhar Bharat Abhiyan initiative, full span launching equipment of 1100MT capacity is indigenously designed and manufactured by M/s Larsen &Toubro at Kanchipuram, Chennai. M/s L&T has partnered with 55 Micro-Small Medium Enterprises (MSME).India is now coming in the select group of country like Italy, Norway, Korea, and China which have been designing and manufacturing such equipment. This will expedite construction of high speed railway, as is the proven technology in metro and similar projects. Work has already begun on 325 km (in Gujarat state) out of 508 km corridor between Mumbai & Ahmedabad. More than 97% land has been acquired for the project in Gujarat and Dadra & Nagar Haveli and 30% land in Maharashtra. This project will improve skillset in various rail construction technologies. Japanese counterparts will provide training to National.
High Speed Rail Corporation Limited employees and also to contractors. More than 6000 workers are already working at various construction sites for the project, thus creating employment opportunities for the local youth.
He further stated that the Mumbai Ahmedabad High Speed Rail project expected to create more than 90,000 jobs in this area including 51,000 jobs for technicians, skilled and unskilled workers.This project will boost the overall economy of the area by deploying 1000s of trucks, dumpers, excavators, batching plants, tunneling equipment and so on. It is estimated that 7.5 million ton of cement, 2.1 million ton of steel and 70000 tonnes of structural steel will be used in the construction.
National High Speed Rail Corporation Limited is also preparing detailed project reports for seven high speed rail corridors. With the experience of execution of Mumbai-Ahmedabad High Speed Rail project, the works of other corridors will be faster. For the construction of viaduct superstructures of 508 km long, Mumbai-Ahmedabad High-Speed Rail Project (MAHSR), the State-of-the-Art construction methodologies like Full Span Launching Methodology (FSLM) will be adopted. This technology will expedite the process of launching girders as the precast girders of full span length will be erected as a single piece for double track viaduct. FSLM is used world over as it is faster than the segment by segment launching method, usually adopted for the construction of viaducts for metro system. India is now coming in the select group of countries like Italy, Norway, Korea, and China which have been designing and manufacturing such equipment. The standard precast Pre Stressed Concrete (PSC) Box Girders (weight ranging from 700 to 975 metric ton) of span 30, 35 and 45 meters will be launched by using FSLM methodology for the high speed corridor. The heaviest PSC Box Girder weighing 975 MT and of 40 meter length will be used for the first time in the construction industry in India for MAHSR project.
To encourage Aatma Nirbhar Bharat Abhiyan initative, FSLM equipment of 1100MT capacity is indigenously designed and manufactured
Mumbai-Ahmedabad High-Speed Rail Project is 508 km long and out of 508 Km, 352 Km lies in the state of Gujarat (348 Km) and Dadra & Nagar Haveli (4 Km), and the balance 156 Km lies in the state of Maharashtra. Out of 352 Km, M/s L&T is the executing agency for 325 Km length.
To expedite construction of viaduct, construction of substructure and superstructure has been taken up in parallel. While the work of substructure i.e. Pile, Pile Cap, Pier and Pier Cap, is in progress, for superstructure, casting yards have been developed along the alignment to cast Full Span Girders and Segmental Girders so that they can be launched using heavy machinery over casted Pier Caps.
For casting of Girders, twenty-three casting yards are being developed along the alignment. Each casting yard is spread in an area of 16 - 93 acres as per requirement and is located near to the alignment. For expeditious casting of Girders with quality, facilities like jigs for making Rebar cage, Casting Beds with Hydraulically Operated Pre-Fabricated Moulds, Batching Plants, Aggregate stacking area, Cement Silos, and Labour Camps have been developed in each casting yard.
Most of the Girders will be of Full Span 30, 35 & 40 m, however, for locations having site constraint, segmental launching of small precast segments will be used. Full Span Girder are preferred over Segmental Girder as their launching progress is seven times faster.
These Precast Girders will be launched using heavy machinery like Straddle Carrier, Bridge Gantry, Transporter and Launching Gantry. To ensure the continuous supply of girders for launching, the Girders will be cast in these casting yards in advance and stacked in a systematic manner. The Straddle Carrier will pick the Box Girder from the stacking yard and will feed to the Bridge Gantry, which in turn will lift the Box Girder and place it over the bearing on Pier Cap. Bridge gantry will launch first 3-4 Box Girder, on which Girder Transporter will be placed and further launching of Girders in sequential manner will continue using Transporter and Launching Gantry.
Attachments:
- The engineering features of STRADDLE CARRIER and GIRDER TRANSPORTER
- Photographs of the event
The engineering features:
STRADDLE CARRIER
This equipment is designed to handle the Full Span Precast girders from casting bed to stacking yard and further feeding them to Bridge Gantry for further erection. This is a tyre mounted selfpropelled gantry crane having lifting capacity of 1100MT
Technical Parameters:
Self-weight | 845 T |
Dimensions | 52.5 x 37.0 x 21.9 Mtr (Length x Breath x Height) |
Speed of Travel | 1 Kmph – With Load 2 Kmph – No Load |
Hook Hoisting & Lowering Speed | 0.5 Mtr/Min – With Load 1.5 Mtr/Min – No Load |
Total no of Tyres | 80 Nos (20 x 4) |
Wheel Dimensions | Diameter – 1.82 m |
Components Sourced from |
India (85%), Germany, Spain and Austria (15%) |
GIRDER TRANSPORTER
This equipment is designed to transport the Full Span precast girders fed by Bridge Gantry to erection location.This is 27 axle tyre mounted self-propelled trolley of carrying capacity of 1100MT
Technical Parameters:
Self-weight | 387 T |
Dimensions | 58.5 x 8.5 x 3.5 Mtr (LxBxH) |
Speed of Travel | 5 Kmph – With Load 10 Kmph – No Load |
Total no of Tyres | 216 Nos (27 x 2 x 4) |
No of Axles & Axle load | 27 nos & 55T/Axle |
Components Sourced from | India (85%) Germany, Spain and Austria (15%) |
Planning of casting yards and heavy machinery for launching has been done in such a way so as to meet peak requirement of approx 300 Full Span Box Girder Casting and Launching in a month, which equals to approx 12 Km of superstructure casting & erection in a month.
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