NHSRCL Erects First Full Span 40M Box Girder for Mumbai-Ahmedabad HSR Corridor

This 40 meters 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

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NHSRCL Erects First Full Span 40 mtrs Box Girder for Mumbai-Ahmedabad High Speed Rail Corridor
Image Source: NHSRCL
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NEW DELHI, INDIA (Metro Rail News): National High-Speed Rail Corporation (NHSRCL) erected First Full Span Pre-Stressed Concrete (PSC) Box Girder of 40 meters span in a casting yard in Navsari district, Gujarat, today, in presence of Shri Satish Agnihotri, Managing Director, NHSRCL, Shri Miyamoto Shingo, Minister (Economic & Development), Embassy of Japan in India, Shri Saito Mitsunori, Chief Representative, JICA India Office, Shri S.V. Desai, Director, L&T and Shri Rajendra Prasad, Director (Project), NHSRCL.

This 40 meters 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 i.e. without any construction joint on 1st November 2021. 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 (MAHSR) 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 a high level of precision and expertise. The 40 meters Full Span Girder was then placed between Pier P11 and P12 at the Chainage 238 of the MAHSR corridor. The height of the piers is 13.4 meters 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 machinery over the cast Pier Caps.

Twenty-three (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 the High-Speed Rail Alignment. Planning of casting yards and heavy machinery for launching has been done in a way to meet the peak requirements of superstructure casting & erection.

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.

Mumbai Ahmedabad High-Speed Rail Project (MAHSR) is 508 km long. Out of 508 km, 352 km lies in the state of Gujarat (348 km) and Dadar & Nagar Haveli (4 km) and the balance of 156 km lies in the state of Maharashtra. Out of 352 km, the civil contracts of 343 km are already awarded. M/s L&T is the executing agency for 325 km length, through two packages awarded to them i.e. C4 (237 km) and C6 (88 km).

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