Construction Scheme

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
TABLE OF CONTENTS
1 GENERAL 1
2 SEQUENCE OF CASTING & ERECTIONS 1
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LIST OF FIGURES
Figure 1: Typical Details of Mould for Intermediate Segment 4

Figure 2: Typical Details of Lifting Arrangement of Segment 5
Figure 3: Typical Supporting Arrangement of Segment at Stacking Yard 6
Figure 4: Transportation of Segment on Low Bedded Trolley 7
Figure 5: Location of Lifting Point during Erection 8
Figure 6: Typical Details Overhead Launching Girder 9
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1 GENERAL
Salient features of the precast segmental construction technique as envisaged for the
project under consideration are indicated below:
The superstructure shall be constructed span by span sequentially, starting from

one end of station or special spans (if any) and finishing at the other end. The project
involves more than 3700 segments for the Box girder. Number of launching girder /
assembly truss therefore may be required so as to work on different stretches is taken
up simultaneously. The number of breaks is identified by station locations and or
number of special spans (if any).
The total number of segments types in the entire project is highlighted in table-1
below:
TABLE-1: NUMBER OF SEGMENTS

No. of Total
Horizonta No. of Pier Total No.
Span No. of intermediat number
l Segments of Pier
Length Spans e segments of 3m
Curvature per span Segments
per span segment
31 Straight 5 2 9 10 45
31 Curved 1 2 9 2 9
28 Straight 221 2 8 442 1768
28 Curved 33 2 8 66 264
25 Straight 81 2 7 162 567
25 Curved 28 2 7 56 196
22 Straight 12 2 6 24 72
22 Curved 5 2 6 10 30
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.
2 SEQUENCE OF CASTING & ERECTIONS
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
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next span and the sequence will continue.

The launching girder / assembly truss to be used for erection of precast segments
shall be capable of supporting the entire dead load of one span and transferring it to
the bearings over the pier. The governing weight of the precast segment will be of the
order of 35t -45t for the intermediate segments and about 40t for the pier segments.
The launching girder envisaged will be slightly greater than two span lengths and
must be able to negotiate curves upto 200 m radius. Launching girder is to be
designed for launching of segments by the contractor. The launching girder will be
erected on pier head at one end of the work. Segments shall be maintained in an
upright position at all times and shall be stored, lifted and/or moved in a manner to
prevent any undue stresses.
The various stages of operation are as described below:
Pre- Casting of Box girder Super Structure:
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 segments from the Casting beds:
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
Stacking of the segments in the pre-casting yard:
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
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supporting arrangement in stacking yard is shown in Fig. 3.0. A maximum of two

tiers stacking is envisaged at this stage. However a detailed proposal for stacking of
segments shall be prepared and got approved by the contractor before starting any
stacking of segments.
Lifting / Handling and transportation of segments in Pre-casting yard and to the

Erection site:
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.
Lifting of segments during Erection of spans:
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)
Temporary pre-stressing of segments during gluing:
A temporary Pre-stress shall be applied just after gluing of segments so that a

minimum of 0.3 Mpa compression is generated on the entire X sectional area of the
joint. It is envisaged that lifting frames attached to the top flange & steel frames
attached to the soffit slab will be made use for imparting temporary pre-stress. A
typical sketch showing holes for fixing steel frames for temporary prestressing of
segments is shown in Fig. 5.0. However a detailed scheme of Temporary pre-
stressing indicating exact steel frame details, vertical pre-stress force to fix the
frames and horizontal force at top and bottom locations shall be prepared by the
contractor and got approved.
Erection of segments:
Detailed erection scheme with complete details of supporting arrangement on pier

cap and already erected span shall be prepared by the Contractor based on
stipulations as envisaged in the design of permanent structure. Supports have to be
taken from the box-girder during the erection and launching of the girder. A typical
sketch for erection of girders is shown in Fig 6.0.
Stresses during transport, handling and erection of segments:
The stresses induced in the segments during any stages of construction shall not
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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.
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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
Figure 1: Typical Details of Mould for Intermediate Segment
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Figure 2: Typical Details of Lifting Arrangement of Segment
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Figure 3: Typical Supporting Arrangement of Segment at Stacking Yard
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Figure 4: Transportation of Segment on Low Bedded Trolley
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Figure 5: Location of Lifting Point during Erection
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Figure 6: Typical Details Overhead Launching Girder
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Construction Scheme

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Detailed Design Consultancy Services for Ten Elevated Metro Stations and

Viaduct between Baranagar (Km 4571.00) to Barrackpur (Km 17200.00) in

Figure 1: Typical Details of Mould for Intermediate Segment 4

Page ii| Rev : R0

The superstructure shall be constructed span by span sequentially, starting from

TABLE-1: NUMBER OF SEGMENTS

2 SEQUENCE OF CASTING & ERECTIONS

next span and the sequence will continue.

The various stages of operation are as described below:

Pre- Casting of Box girder Super Structure:

Lifting of segments from the Casting beds:

Stacking of the segments in the pre-casting yard:

supporting arrangement in stacking yard is shown in Fig. 3.0. A maximum of two

Lifting / Handling and transportation of segments in Pre-casting yard and to the

Lifting of segments during Erection of spans:

Temporary pre-stressing of segments during gluing:

A temporary Pre-stress shall be applied just after gluing of segments so that a

Detailed erection scheme with complete details of supporting arrangement on pier

Stresses during transport, handling and erection of segments:

Figure 1: Typical Details of Mould for Intermediate Segment

Figure 2: Typical Details of Lifting Arrangement of Segment

Figure 3: Typical Supporting Arrangement of Segment at Stacking Yard

Figure 4: Transportation of Segment on Low Bedded Trolley

Figure 5: Location of Lifting Point during Erection

Figure 6: Typical Details Overhead Launching Girder

Page 10| Rev : R0

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