https://www.cici.co.in/index.php/mrts/25-delhi-metro-railway-project-contract-nc02

1. Presentation on U-Girder casting
By
RAVINDER SINGH
Noida Metro Rail Project
CEC-SAM-JV.

2. Project Route Map

3. Casting Yard

4. Scope U-girder
Scope of Work
Sl no Package Nos of Girder 27 m standard span Non standard span Concrete Qty Steel Qty.
1 NC-01 656 460 196 38376 6667.58
2 NC-02 704 532 172 41184 7155.46
Total 1360 992 368 79560 13823

5. U-GIRDER MIX DESIGN
Grade of Concrete:M55
Ingredients Source/Brand Qty/M3
Cement(Kg) Ultratech OPC-53 450
Microsilica(Kg) Elkem/Comiche 25
20mm Aggregate(Kg) Kotputli 577
10mm Aggregate(Kg) Kotputli 532
Fine aggregate(Sand)(Kg) Bajpur 765
Free Water(Kg) Batching plant 141.66
Admixture(Kg) Don super flow PC-250 4.037
Slump after 2 hours retension(mm) 140
7days strength(Mpa) 61.55
28 days strength(Mpa) 74.61
W/C Ratio 0.31
U-GIRDER MIX DESIGN

6. CASTING YARD INFRASTRUCTURE
1. Total No of BAY-4.
2.U-girder bay-03 nos
3.Pier cap Bay-1
4. No of U-girder bed 36 (6 bed in each row).
5. Pier cap mould-16.
6. 100 MT capacity gantry 02 nos in each u-girder bay.
7. T ime cycle is 10 days FOR U-girder casting.
8. Peak Max production 6*6*3=108 nos u-girder per month

7. STACKING CAPACITY
1. Bay-1 28*2= 56
2.Bay-2 28*2 56
3.Bay-3 23*2 46
Total 158

8. Casting Bed Preparation
PCC for casting bed

9. Casting Bed preparation
Rebar fixing

10. C/Bed Wall

11. Casting Bed Wall
Longitudional Wall
300*1100
2800mm
RCC Wall 1100*300 mm

12. Shutter Making
Outer
Shutter
Bottom
Shutter
Outer
Shutter
Lifting hole
Lifting hole
5050mm
3800mm
1850 mm

13. Lifting hole
Lifting hole
Inner shutter
Inner Shutter

14. Outer shutter
support
Outer Shutter

15. Outer shutter
Bottom shutter
Outer form

16. Buffing of Shutter
Buffing/cleaning
of shutter

17. Applying shuttering
oil(Reebol)
Girder Mould

18. Automatic bar cutting & Bending M/c

19. Automatic bar cutting & Bending M/c
Capacity 100 MT/Day

20. Automatic bar cutting & Bending M/c
Format Line 12
12mm dia rebar coil

21. Format line 16

22. Bending upto 32mm

23. Bending upto 32mm

24. Re-bar zig
Rebar zig

25. Re bar cage placing
Rebar zig.
Rebar cage

26. Pre Fab Rebar
Pre Fab Rebar
Rebar zig.

27. Cage lifter
Wt. of cage 10.2
MT
Cage Lifting

28. Cage Placing

29. Cage Placing

30. Cage Lifter
Cage Lifter

31. Cage Lifting
U-girder cage 27
mts long
wt.10.12 MT

32. Cage lifting from zig.

33. Outer Shutter
2500mm c/c
Turn buckle

34. Shutter vibrator
Shutter vibrator

35. Shutter vibrator
Shutter vibrator

36. Rebar cage Placing
Rebar cage
Bulk Head
Shear Key Box

37. Cage Placing
Re bar is coated with inhibitor
solution for corrosion protection

38. HT Coil despenser
HT Coil despenser
HT coil

39. HTS CABLE
Cross section 140 mm2

40. Cable Threading
HT Cable
Bulk head

41. Cable Threading
Bulk head
Floating Beam
15.2mm dia . 7 ply
LRPC Class-2

42. Stressing end
75mm dia Macalloy bar
Wedge & Barrel

43. Grip for cable
15.2 mm
cable grip
wedge 3
segmental
Barrel
15.2mm dia HT cable

44. Prestressing
300MT Capacity hyd. Jack
600mm stroke

45. Prestressing
1. HT cable 15.2mm
dia
2. Load in each
cable 195.5
KN/19.92 MT
3. Total load
1434.24 MT
4. Ram area of jack
529.2 sq.cm
5. Required
pressure 460.55
kg/cm2
6. Modified
elongation
1179mm
Hydraulic hose
700 bar.

46. Stressing operation
Power pack 10 HP motor
Stressing line
Return line
700 bar cap. Hyd
.hose

48. Washer plate
75mm dia
macalloy nut
Hollow device
Stressing jack
Washer plate
Nut
75mm dia Macalloy
bar
Stressing Mechanism
300MT cap. 600mm stroke

49. Prestressing
Piston
Nut
Washer
Stressing line
Return Line

50. Dead End
Reaction wall
6500*1450*1200 mm Cable grip

51. Cable Threading
Drainage
spout
Debonding
tube

52. Debonding
tube 20 mm id
HDPE pipe
Debonded length 2175 mm both side
Debonded tube

53. Stressing End
Floating
Beam
Anchorage/Grip
HT strand
Bulk head

54. Stressing End
Washer plate & Nut. 75mm dia.
Macalloy bar.

55. Concreteing by Boom placer
Grade of conc. M55 with micro silica
Cement content 450 kg.
W/c Ratio 0.31
Admixture Don super flow PC-250
4.037 Kg/m3.
Conc. Qty per girder 60m3
Concrete placing
Boom Placer

56. Boom Placer
Concreting

57. Transit Mixture
Concreting

58. Load Transfer

59. Load Transfer criteria
After 3 days of
concreting with a
minimum
compresshive
strength of conc.
35 Mpa.

60. Load Transfer To Concrete

61. Pre cast pier cap cage

62. Precast pier cap cae

63. Pier cap
Anchor cone
19T15
Anchor cone 12T15

64. Cross Arm

65. Anchor cone
Anchor cone

66. Rebar for Bearing
pedestal Rebar for seismic
restrainer

68. Cross Arm

69. Jack fixing

70. Stressing Jack

71. Stressing operation

72. Bearing plate
Anchor cone
Grout vent
Seathing pipe

73. Anchorage arrangement

74. Stressing
Multipull stressing jack

75. Girder Lifting
Girder lifting &
shifting

76. Girder Lifting From Bed
Lifter 02 nos
40 mm dia
Macalloy bar 4
nos

77. Girder Lifting
Lifting hole

78. Girder Lifting
Washer plate
40 mm dia Macalloy
nut

79. Girder Lifter
Girder Lifter
40mm Dia. Macalloy Bar

80. Girder Lifting from Bed

81. Double layer Stacking

82. Stacking

83. Girder Stacking
Girder stacking

84. Girder Lifting
Girder wt 150 MT
100 MT
Capacity EOT

85. Cable cutting by Mechanical cutter
Cable cutting

86. Recess Filling with
conbextra GP-2.

87. Recess Filling with conbextra
GP-2
Recess Filling

88. Double layer stacking
Stacking stool

89. Curing
Curing period 21 days from
DOC

90. Girder Lifting & Stacking
Girder stacking

91. TIME CYCLE FOR U-GIRDER
Sl no Activity Day Duration in
hours
Total Hours Remarks
1 Cleaning of bed and shuttering oil applying
1
12 12
2 Fixing of outer shutter 10 22
3 Fixing of bulkhead & cage placing. 2 12 34
4 Threading of HT strand.
3
24 58
5 Initial prestressing 6 64
6 Final Prestressing 6 70
7 Sealing of debonding tubes
4
3 73
8 Inner shutter placing 5 78
9 Inner shutter Alignment 9 87
10 Inspection by Client. 4 91
11 Pouring of concrete 5 48 139
12 Curing 6,7,&8 72 211
13 Load transfer 9 6 217
14 Lifting of girder for stacking. 10 24 241
10.04167
Note: Time cycle for 6 U-girder casting 10 Days.
Time cycle U-girder

92. Loading for Launching

93. 200 MT Capacity Trailor

94. Loading For Launching
Loading for launching

95. Loading For Launching

96. Tieing with 04 nos Belt
Ready for Despatch

97. Positioning gor lifting

98. Lifting From Trailor

99. Lifting for launching

100. Neoprene Bearing.

101. Denka chloroprene
Denka chloroprene

102. section of Neoprene Bearing.
Steel Neoprene

103. Wedge plate
Steel wedge plate

104. 350 MT Capacity tyre
mounted crane.
400 MT Capacity
crane

105. Position of crane during
lifting
Behing pier cap
Beside pier cap

106. Lifting for launching
Straight lifting above pier cap

107. Lifting for launching
350 MT cap.
crane
400 MT Capacity
crane

108. Swing for proper position

109. Lowering on bearing
pedestal

110. Lowering on bearing
pedestal

111. Lowering on pedestal

113. Position of crane during
final lowering

114. Final position

117. Launching view

118. Launching
400 MT Capacity crane
02 nos

119. Thank you