Segmental Box Metro

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
Page i| Rev : R0
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
No. of Pier Total No.
Horizontal No. of intermediate number of
Span Length Segments of Pier
Curvature Spans segments 3m
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 next span and the sequence will
continue.
The launching girder / assembly truss to be used for erection of precast segments shall be
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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 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:
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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 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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Segmental Box Metro

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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

TABLE-1: NUMBER OF SEGMENTS

2 SEQUENCE OF CASTING & ERECTIONS

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:

Lifting of segments during Erection of spans:

Temporary pre-stressing of segments during gluing:

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

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