NHSRCL erects 1st full span 40-metre box girder for Mumbai-Ahmedabad bullet train corridor
The first full-span pre-stressed concrete (PSC) box girder spanning 40 metres was erected in a casting yard in the Navsari district of Gujarat, today, on the upcoming high-speed bullet train corridor between Mumbai and Ahmedabad.
The National High Speed Rail Corporation Limited (NHSRCL) - responsible for the development, execution, and maintenance of the bullet train project, said in a statement today that the 40 metre full span box girder weighing around 970 MT, involving 42 MT of steel was cast in a single piece - without any construction joint on November 1, 2021.
NHSRCL Erects First Full Span 40 mtrs Box Girder for Mumbai-Ahmedabad High Speed Rail Corridor.
Infrastructure conglomerate Larsen & Toubro's built equipment was used to launch the girder - which has designed using state-of-the-art finite element analysis software. The machines are checked for various critical loading cases and optimized using combinations of different material grades to ensure long and efficient operation, at a minimum operating cost, said L&T in its statement today.
This 40-metre full span box girder, weighing about 970 MT, involving 390 Cu m of concrete and 42 MT of steel, was cast in a single piece, ie without any construction joint on November 1. This is also the heaviest PSC Box Girder in the construction industry of India. To expedite the construction of the viaduct for the Mumbai- Ahmedabad High Speed Rail corridor, NHSRCL is adopting Full Span Launching Method.
The precast girder was picked up from the stacking yard by the Straddle carrier and moved to the predefined location from where it was lifted by the Bridge gantry for erection. This is a technical procedure that requires high level of precision and expertise. The 40-metre Full Span Girder was then placed between the Pier P11 and P12 at the Chainage 238 of MAHSR corridor. The height of the piers is 13.4 metres from the ground level.To expedite the construction of the viaduct, the 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 the 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 machineries over the cast Pier Caps.
For the 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.
23 casting yards are being developed along the alignment for the casting of Full Span girders of 30, 35 & 40 meters. Each casting yard is spread in an area of 16-93 acres as per requirement and is located near to the High-Speed Rail Alignment. Planning of casting yards and heavy machineries for launching has been done in a way to meet the peak requirements of superstructure casting & erection.
The precast girder was picked up from the stacking yard by the straddle carrier and was moved to the predefined location from where it was lifted by the bridge gantry for final erection. The erection marks an important milestone towards completing the Surat-Billimora stretch of the project, said L&T.
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