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Ppt of pre casting yard
1. The document presents information on the casting of U-girders for the Noida Metro Rail project, including the mix design, infrastructure, production cycle, prestressing, lifting, and launching. 2. It describes the casting of 1360 U-girders using a concrete mix with a compressive strength of 74.61 MPa, and details the fully automated production process including rebar fabrication, formwork, casting, curing, lifting, stacking, and stressing using high-tension cables. 3. The production cycle to cast 6 U-girders takes 10 days, after which the girders are loaded onto trailers and launched into position using 350-400 tonne
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Ppt of pre casting yard
- 1. Presentation on U-Girdercasting By RAVINDER SINGH Noida Metro Rail Project CEC-SAM-JV.
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- 4. Scope U-girder Scope ofWork 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 Gradeof 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-128*2= 56 2.Bay-2 28*2 56 3.Bay-3 23*2 46 Total 158
- 8. Casting Bed Preparation PCCfor casting bed
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- 11. Casting Bed Wall LongitudionalWall 300*1100 2800mm RCC Wall 1100*300 mm
- 12. Shutter Making Outer Shutter Bottom Shutter Outer Shutter Lifting hole Liftinghole 5050mm 3800mm 1850 mm
- 13. Lifting hole Lifting hole Innershutter Inner Shutter
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- 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
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- 25. Re bar cageplacing Rebar zig. Rebar cage
- 26. Pre Fab Rebar PreFab Rebar Rebar zig.
- 27. Cage lifter Wt. ofcage 10.2 MT Cage Lifting
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- 31. Cage Lifting U-girder cage27 mts long wt.10.12 MT
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- 36. Rebar cage Placing Rebarcage Bulk Head Shear Key Box
- 37. Cage Placing Re baris coated with inhibitor solution for corrosion protection
- 38. HT Coil despenser HTCoil despenser HT coil
- 39. HTS CABLE Cross section140 mm2
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- 41. Cable Threading Bulk head FloatingBeam 15.2mm dia . 7 ply LRPC Class-2
- 42. Stressing end 75mm diaMacalloy bar Wedge & Barrel
- 43. Grip for cable 15.2mm cable grip wedge 3 segmental Barrel 15.2mm dia HT cable
- 44. Prestressing 300MT Capacity hyd.Jack 600mm stroke
- 45. Prestressing 1. HT cable15.2mm 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 pack10 HP motor Stressing line Return line 700 bar cap. Hyd .hose
- 48. Washer plate 75mm dia macalloynut Hollow device Stressing jack Washer plate Nut 75mm dia Macalloy bar Stressing Mechanism 300MT cap. 600mm stroke
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- 50. Dead End Reaction wall 6500*1450*1200mm Cable grip
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- 52. Debonding tube 20 mmid HDPE pipe Debonded length 2175 mm both side Debonded tube
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- 54. Stressing End Washer plate& Nut. 75mm dia. Macalloy bar.
- 55. Concreteing by Boomplacer 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
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- 59. Load Transfer criteria After3 days of concreting with a minimum compresshive strength of conc. 35 Mpa.
- 60. Load Transfer ToConcrete
- 61. Pre cast piercap cage
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- 63. Pier cap Anchor cone 19T15 Anchorcone 12T15
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- 66. Rebar for Bearing pedestalRebar for seismic restrainer
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- 72. Bearing plate Anchor cone Groutvent Seathing pipe
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- 75. Girder Lifting Girder lifting& shifting
- 76. Girder Lifting FromBed Lifter 02 nos 40 mm dia Macalloy bar 4 nos
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- 78. Girder Lifting Washer plate 40mm dia Macalloy nut
- 79. Girder Lifter Girder Lifter 40mmDia. Macalloy Bar
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- 84. Girder Lifting Girder wt150 MT 100 MT Capacity EOT
- 85. Cable cutting byMechanical cutter Cable cutting
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- 87. Recess Filling withconbextra GP-2 Recess Filling
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- 89. Curing Curing period 21days from DOC
- 90. Girder Lifting &Stacking Girder stacking
- 91. TIME CYCLE FORU-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
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- 93. 200 MT CapacityTrailor
- 94. Loading For Launching Loadingfor launching
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- 96. Tieing with 04nos Belt Ready for Despatch
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- 102. section of NeopreneBearing. Steel Neoprene
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- 104. 350 MT Capacitytyre mounted crane. 400 MT Capacity crane
- 105. Position of craneduring lifting Behing pier cap Beside pier cap
- 106. Lifting for launching Straightlifting above pier cap
- 107. Lifting for launching 350MT cap. crane 400 MT Capacity crane
- 108. Swing for properposition
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- 113. Position of craneduring final lowering
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- 118. Launching 400 MT Capacitycrane 02 nos
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