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    Noida Metro Rail Project Cec-Sam-Jv.: Presentation On U-Girder Casting by L.K.Prasad

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    LOHITH N
    The presentation summarized the scope of work for casting U-girders for the Noida Metro Rail project. 1360 U-girders will be cast in total, with a standard span of 27 meters. The concrete mix design for the girders was M55 grade with a water-cement ratio of 0.31. The casting yard has 4 bays and infrastructure to cast up to 108 girders per month. The time cycle for casting a single U-girder is 10 days, involving fixing reinforcement cages, stressing strands, pouring concrete, and curing.

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    Noida Metro Rail Project Cec-Sam-Jv.: Presentation On U-Girder Casting by L.K.Prasad

    Uploaded by

    LOHITH N
    391 views116 pages
    The presentation summarized the scope of work for casting U-girders for the Noida Metro Rail project. 1360 U-girders will be cast in total, with a standard span of 27 meters. The concrete mix design for the girders was M55 grade with a water-cement ratio of 0.31. The casting yard has 4 bays and infrastructure to cast up to 108 girders per month. The time cycle for casting a single U-girder is 10 days, involving fixing reinforcement cages, stressing strands, pouring concrete, and curing.

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    pptu-girdercastingbyl-170906100206

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    The presentation summarized the scope of work for casting U-girders for the Noida Metro Rail project. 1360 U-girders will be cast in total, with a standard span of 27 meters. The concrete mix design for the girders was M55 grade with a water-cement ratio of 0.31. The casting yard has 4 bays and infrastructure to cast up to 108 girders per month. The time cycle for casting a single U-girder is 10 days, involving fixing reinforcement cages, stressing strands, pouring concrete, and curing.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    391 views116 pages

    Noida Metro Rail Project Cec-Sam-Jv.: Presentation On U-Girder Casting by L.K.Prasad

    Uploaded by

    LOHITH N
    The presentation summarized the scope of work for casting U-girders for the Noida Metro Rail project. 1360 U-girders will be cast in total, with a standard span of 27 meters. The concrete mix design for the girders was M55 grade with a water-cement ratio of 0.31. The casting yard has 4 bays and infrastructure to cast up to 108 girders per month. The time cycle for casting a single U-girder is 10 days, involving fixing reinforcement cages, stressing strands, pouring concrete, and curing.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 116

    Presentation on U-Girder casting

    By
    L.K.Prasad

    Noida Metro Rail Project


    CEC-SAM-JV.
    Project Route Map
    Casting Yard
    Scope U-girder

    Scope of Work

    27 m standard
    Sl no Package Nos of Girder 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


    U-GIRDER MIX DESIGN

    U-GIRDER MIX DESIGN

    Grade of Concrete:M55

    Ingredients Sourcr/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


    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


    STACKING CAPACITY

    1. Bay-1 28*2= 56

    2.Bay-2 28*2 56

    3.Bay-3 23*2 46

    Total 158
    Casting Bed Preparation

    PCC for casting bed


    Casting Bed preparation

    Rebar fixing
    C/Bed Wall
    Casting Bed Wall

    RCC Wall 1100*300 mm

    Longitudional Wall
    300*1100

    2800mm
    Shutter Making

    5050mm

    Outer
    Shutter Outer
    Shutter
    3800mm

    1850 mm Lifting hole


    Bottom Lifting hole
    Shutter
    Inner Shutter

    Inner shutter

    Lifting hole

    Lifting hole
    Outer Shutter

    Outer shutter
    support
    Outer shutter

    Outer form

    Bottom shutter
    Buffing of Shutter

    Buffing/cleaning
    of shutter
    Girder Mould

    Applying shuttering
    oil(Reebol)
    Automatic bar cutting & Bending M/c
    Automatic bar cutting & Bending M/c

    Capacity 100 MT/Day


    Automatic bar cutting & Bending M/c

    Format Line 12

    12mm dia rebar coil


    Format line 16
    Bending upto 32mm
    Bending upto 32mm
    Re-bar zig

    Rebar zig
    Re bar cage placing

    Rebar cage

    Rebar zig.
    Pre Fab Rebar

    Pre Fab Rebar

    Rebar zig.
    Cage Lifting

    Cage lifter
    Wt. of cage 10.2
    MT
    Cage Placing
    Cage Placing
    Cage Lifter

    Cage Lifter
    Cage Lifting

    U-girder cage 27
    mts long
    wt.10.12 MT
    Cage lifting from zig.
    Outer Shutter

    2500mm c/c

    Turn buckle
    Shutter vibrator

    Shutter vibrator
    Shutter vibrator

    Shutter vibrator
    Rebar cage Placing

    Rebar cage

    Shear Key Box

    Bulk Head
    Cage Placing

    Re bar is coated with inhibitor


    solution for corrosion protection
    HT Coil despenser

    HT Coil despenser

    HT coil
    HTS CABLE
    Cable Threading

    Bulk head

    HT Cable
    Cable Threading

    15.2mm dia . 7 ply


    Bulk head LRPC Class-2

    Floating Beam
    Stressing end

    Wedge & Barrel

    75mm dia Macalloy bar


    Grip for cable

    Barrel

    15.2 mm
    cable grip
    wedge 3
    segmental

    15.2mm dia HT cable


    Prestressing

    300MT Capacity hyd. Jack


    600mm stroke
    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.
    Stressing operation

    700 bar cap. Hyd


    .hose
    Power pack 10 HP motor

    Return line

    Stressing line
    Stressing Mechanism

    75mm dia Macalloy


    Stressing jack bar

    Washer plate

    75mm dia Nut


    macalloy nut

    300MT cap. 600mm stroke

    Hollow device
    Washer plate
    Prestressing

    Stressing line

    Washer Return Line

    Piston

    Nut
    Dead End

    Reaction wall
    6500*1450*1200 mm Cable grip
    Cable Threading

    Debonding
    tube

    Drainage
    spout
    Debonded tube

    Debonded length 2175 mm both side

    Debonding
    tube 20 mm id
    HDPE pipe
    Stressing End

    Bulk head

    Floating
    Beam
    Anchorage/Grip

    HT strand
    Stressing End

    Washer plate & Nut. 75mm dia.


    Macalloy bar.
    Concrete placing

    Boom Placer

    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
    Concreting

    Boom Placer
    Concreting

    Transit Mixture
    Load Transfer
    Load Transfer criteria

    After 3 days of
    concreting with a
    minimum
    compresshive
    strength of conc.
    35 Mpa.
    Load Transfer To Concrete
    Pre cast pier cap cage
    Precast pier cap cae
    Pier cap

    Anchor cone
    Cross Arm
    Anchor cone

    Anchor cone
    Stressing

    Multipull stressing jack


    Girder Lifting

    Girder lifting &


    shifting
    Girder Lifting From Bed

    Lifter 02 nos
    40 mm dia
    Macalloy bar 4
    nos
    Girder Lifting

    Lifting hole
    Girder Lifting

    40 mm dia Macalloy
    nut

    Washer plate
    Girder Lifter

    40mm Dia. Macalloy Bar


    Girder Lifter
    Girder Lifting from Bed
    Double layer Stacking
    Stacking
    Girder Stacking

    Girder stacking
    Girder Lifting

    100 MT
    Capacity EOT

    Girder wt 150 MT
    Cable cutting

    Cable cutting by Mechanical cutter


    Recess Filling with
    conbextra GP-2.
    Recess Filling with conbextra
    GP-2

    Recess Filling
    Double layer stacking

    Stacking stool
    Curing

    Curing period 21 days from


    DOC
    Girder Lifting & Stacking

    Girder stacking
    Time cycle U-girder

    TIME CYCLE FOR U-GIRDER

    Sl no Activity Day Duration in Total Hours Remarks


    hours
    1 Cleaning of bed and shuttering oil applying 12 12
    2 Fixing of outer shutter 1 10 22
    3 Fixing of bulkhead & cage placing. 2 12 34
    4 Threading of HT strand. 24 58
    5 Initial prestressing 3 6 64
    6 Final Prestressing 6 70
    7 Sealing of debonding tubes 3 73
    8 Inner shutter placing 5 78
    4
    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.
    Loading for Launching
    200 MT Capacity Trailor
    Loading For Launching

    Loading for launching


    Loading For Launching
    Ready for Despatch

    Tieing with 04 nos Belt


    Positioning gor lifting
    Lifting From Trailor
    Lifting for launching
    Neoprene Bearing.
    Denka chloroprene

    Denka chloroprene
    section of Neoprene Bearing.

    Steel Neoprene
    Wedge plate

    Steel wedge plate


    400 MT Capacity
    crane

    350 MT Capacity tyre


    mounted crane.
    Position of crane during
    lifting

    Beside pier cap

    Behing pier cap


    Lifting for launching

    Straight lifting above pier cap


    Lifting for launching

    350 MT cap. 400 MT Capacity


    crane crane
    Swing for proper position
    Lowering on bearing
    pedestal
    Lowering on bearing
    pedestal
    Lowering on pedestal
    Position of crane during
    final lowering
    Final position
    Launching view
    Launching

    400 MT Capacity crane


    02 nos
    Thank you

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