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TABLE OF CONTENTS
1 GENERAL 1
2 SEQUENCE OF CASTING & ERECTIONS 1
Page i| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and
Viaduct between Baranagar (Km 4571.00) to Barrackpur (Km 17200.00) in
Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line
LIST OF FIGURES
1 GENERAL
Salient features of the precast segmental construction technique as envisaged for the
project under consideration are indicated below:
The total number of segments types in the entire project is highlighted in table-1
below:
The Contractor shall be responsible for proper handling, lifting, storing, transporting
and erection of all segments so that without damage they are placed in position.
Design of any precast segmental structure is very much dependent upon the scheme
of construction, method of stacking, transportation, erection etc. Hence this report
gives brief details of the various sequences and methodology of construction as
envisaged by the Consultants for the detailed design.
Box girder segments shall be match cast at the casting yard and transportation to the
point of erection will be by appropriately designed low-bedded trailers (tyre
mounted). The segments can be lifted and erected using erection portal gantry
moving on launching girder or alternatively by cranes on the ground. The segments
will be lifted in sequence and will be dry matched while hanging from the launching
girder. After dry matching, the segments will be glued with epoxy and temporary
prestressing shall be done. Post-tensioned cables shall be threaded in-situ and
tensioned from one end. It is emphasized that for precast segmental construction
only one end prestressing shall be used. The girder will be lowered on the bearings
after prestressing. The launching girder will then move over the launched span to
Page 1| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and
Viaduct between Baranagar (Km 4571.00) to Barrackpur (Km 17200.00) in
Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line
For viaduct segmental precast construction requires a casting yard. The construction
depot will have facilities for casting beds, lifting & handling arrangements, curing and
stacking area, batching plant with storage facilities for aggregate and cement, site
testing laboratories, reinforcement steel yard and fabrication yard etc.
The pre-cast Box girder super structure is 3 m in lengths for intermediate segments
and 1.950m for Pier segments. Pre-casting of straight spans can be done by either
short line method or Long Line method as per contractors choice. However pre-
casting of Curved spans shall have to be done by Long line Method only. Short Line
method for Curved spans shall not be allowed due to shape of the structure, which
may lead to offsets on the exposed outer surfaces of the finished structure.
A typical mould drawing for the Box girder is shown in Fig. 1.0
Lifting of the intermediate segments from casting bed shall be done by attaching a
steel frame to the cantilever of the top flange (near web) of the box shaped segment.
The fixing of the steel frame shall be done with the help of HTS bars (such as Mac-
Alloy bars or Dywidag bars) of the suitable diameter on either flanges and than
attaching a lifting beam to these frames. Lifting of pier segments may be done from
the cantilever of the top flange (near web) by providing sleeved holes. However
detailed proposal of handling of the segments from casting bed shall be submitted by
the contractor before starting the pre-casting of the segments.
A typical lifting scheme for the intermediate segment and pier segment is shown in
Fig. 2.0
Location of the Support line for Stacking of the segments in pre-casting yard is very
important and must be practiced. An indicative sketch showing the location of
Page 2| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and
Viaduct between Baranagar (Km 4571.00) to Barrackpur (Km 17200.00) in
Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line
Location of lifting points during handling of segments in stacking yard shall be from
top flange as practiced during removal of segments from casting bed at a pre-
determined location shown in the sketch attached to this document. A maximum of 2
holes on either cantilever flange shall be allowed for the purpose of the entire
handling and temporary pre-stressing purposes. Support line during transportation of
segments on trailers shall be under the webs and shaped wooden slippers shall be
provided under both webs. A typical sketch of transportation of segments on low
bedded trolley is shown in Fig. 4.0. However a detailed scheme of handling tackles
and transportation scheme shall be prepared by the contractor and got approved.
Location of lifting points during erection of segments shall be from holes in cantilever
of top flange (near web) as explained above under handling in stacking yard. (Refer
Fig. 5.0)
Erection of segments:
The stresses induced in the segments during any stages of construction shall not
Page 3| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and
Viaduct between Baranagar (Km 4571.00) to Barrackpur (Km 17200.00) in
Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line
exceed 50% of the strength achieved at that stage. In addition, the following
limitations shall be observed:
i) The segment shall not be lifted from the casting bed till the concrete reaches
strength equal to that of concrete grade M25.
ii) The age of concrete shall not be less than 14 days at the time of its erection and
shall achieve its specified 28-day strength.
Page 4| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and Viaduct between Baranagar (Km 4571.00)
to Barrackpur (Km 17200.00) in Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line
Page 5| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and
Viaduct between Baranagar (Km 4571.00) to Barrackpur (Km 17200.00) in
Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line
Page 6| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and Viaduct between Baranagar (Km 4571.00)
to Barrackpur (Km 17200.00) in Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line
Page 7| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and Viaduct between Baranagar (Km 4571.00)
to Barrackpur (Km 17200.00) in Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line
Page 8| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and Viaduct between Baranagar (Km 4571.00)
to Barrackpur (Km 17200.00) in Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line
Page 9| Rev : R0
Detailed Design Consultancy Services for Ten Elevated Metro Stations and Viaduct between Baranagar (Km 4571.00)
to Barrackpur (Km 17200.00) in Baranagar-Barrackpur Corridor of Kolkata Metro Railway Line