“Advanced Concepts in Launching Girder”

LARSEN & TOUBRO LIMITED

P. S . N A R U K A ECC DIVISION, INFRA IC, EDRC & TECHNOLOGY
METROS AND SPECIAL BRIDGES
Erection Manager
(Kochi Metro Rail Project)
CONTENTS

 Methods For Segment Erection

 General Arrangement & Salient Features Of Launching Girder
 Fabrication Of Launching Girder.
 Assembly And Erection Of Launching Girder.
 Load Test (LG And Winch).
 Segment Lifting
 Segment Gluing
 Stressing Process
 Grouting
 Lowering Of Span On Permanent Bearings
 Auto Launching Of Launching Girder
 Design Tips, Operation And Maintenance Manual
 Safety In Segment Erection

2
Methods of Segment Erection

 Over Slung method

 Under Slung Method

3
Over Slung Erection Under Slung Erection

Sirsi Circle Flyover Bangalore

4
 Under Slung Erection

Over Slung Erection

MRTS Elevated Corridor - Delhi

5
Over Slung Erection Under Slung Erection

SVBTC Kolkata

6
Over Slung Erection

7
General Arrangement and
Components of LG

8
Launching Girder Configuration

Length of the L.G = 74m

Type of section = Box girder.

Depth of the section = 2.8m

Width of the section = 2m

Number of Modules of L.G = 8 (9.25m each)

Connection between modules are Bolted
connection (HT/HSFG Bolt, 10.9 grade).
Total Weight of LG Modules = 250 MT

9
10
Rear Trolley Rear Support Mid Support Front Support
Components of Front Support
Top beam - Transfers load from LG to
Top vertical leg

Top vertical legs - Fixed with top beam at top

and transfers load through
pin to telescopic leg

Telescopic legs - To adjust the height of

front support

Bottom beam - Transfers erection load

to pier cap

Jack supporting beam - Used to push up the Top

vertical leg, Top beam & L.G.

The front support is fixed at a distance of 2.5 m from the

front end of the Launching Girder.

12
13
Height Adjustment in Front support during auto launching

 Make sure that Load is completely transferred to Middle

support and Front support is ready for Auto launching

 Release the Turn buckle from the bottom beam

 Remove the Jacks from the bottom beam and pins
connecting telescopic leg. Fix the chain pulley of suitable
capacity to connect top beam and bottom beam
 Raise the bottom beam and Telescopic leg using chain
pulley till the front support attains its minimum height and
fix the pin
 After Auto launching, the Bottom beam and telescopic leg
shall be lowered and anchored with pier cap using the
chain pulley
 Place the jack over the bottom beam and raise the jacks
till the LG regains its position from the deflected shape
 Connect turn buckle and Pins. Now the LG is ready for
Erection of Next span
14
Components of Middle Support

1. Knuckle bearing - Specially designed bearing

to allow rotation of LG in
curvature
1
2. Cradle beams - Transfers load from knuckle 3
2
bearing to cross beam

3. Cross beam - Supports cradle beam and

provides anchor bracket to
anchor the support with pier 5
head segment during erection. 4

4. Side beams - Transfers load from cross

beam to jacks

5. Jacks - To allow vertical height

adjustment

The middle support should be seated on pier head segment during erection since most of the erection load is
carried by middle support.

15
Knuckle Bearing and cradle beam
16
Auto Launching Arrangement Connected to Middle Support

40T cap. Jack of Stroke 1200mm

Auto Launching Hydraulic Jack Breaking Arrangement

17
Components of Rear Support

1. Knuckle bearing - Specially designed bearing

to allow rotation of LG in
curvature
1
2. Cradle beams - Transfers load from knuckle 3
2
bearing to cross beam

3. Cross beam - Supports cradle beam and

provides anchor bracket to
anchor the support with Pre- 5
cast segment during launching. 4

4. Side beams and - Transfers load from cross

supporting stool beam to jacks

5. Jacks - To allow vertical height

adjustment

Erection load should not be transferred through rear support since it is designed only to take loads from LG
during hauling

18
Components of Rear Trolley

1. Top beam - Connects rear trolley with LG

with Pin
1 6
2. Inclined column - Supports top beam at top
and bottom beam at bottom

3. Bottom beam - Provides provision to fix

wheel assembly of trolley 2

4. Wheel assembly - Used to haul LG during auto

3
4
launching

5. Rail track - Wheel assembly runs on rail

track laid over already erected
5
deck

6. Mono pull jacks - Fixed at top beam to side

shift LG in curvature.

The rear trolley is located at a fixed distance of 4.5 m from the rear end of the Launching Girder.

19
20
Anchor Bolt – Front Support

Front support anchoring hole location – Radius > 300m

Front support anchoring hole location – Radius 300m to 152m

FABRICATION OF LAUNCHING GIRDER

22
FABRICATION OF LAUNCHING GIRDER

Procurement of steel
Physical inspection of plates
Testing of steel plates
Cutting plan
Fit up procedure
Welding of joints

Welding Test Method Of LG

DPT Method
Ultra sound method

23
Fit up procedure

24
WELDING TEST METHOD

DPT Method:- Dye penetrant test is also called liquid penetrant inspection
(LPI) or penetrant testing (PT), is a widely applied and low-cost inspection
method used to locate surface-breaking defects in all non-porous
materials (metals, plastics, or ceramics). The penetrant may be applied to
all non-ferrous materials and ferrous materials.

Ultra Sonic Test Method:- Ultrasonic testing (UT) is a family of non-

destructive testing techniques based on the propagation of ultrasonic
waves in the object or material tested. In most common UT applications,
very short ultrasonic pulse-waves with center frequencies ranging from
0.1-15 MHz, and occasionally up to 50 MHz, are transmitted into materials
to detect internal flaws or to characterize materials.

25
Ultrasonic Test Method

Principle of ultrasonic testing.

LEFT: A probe sends a sound wave into a test material. There are two
indications, one from the initial pulse of the probe, and the second due to
the back wall echo.
RIGHT: A defect creates a third indication and simultaneously reduces the
amplitude of the back wall indication. The depth of the defect is
determined by the ratio D/Ep

26
Assembly And Erection Of Launching Girder

27
 Methods of LG Erection
Tandem Lift Method Single Lift Method

28
Procedure of LG Erection
1. Erection Of Front Support.
2. Erection Of Middle Support
3. Erection Of LG Boxes (S1 to S5)
4. Erection Of Crab Hoist Winch
5. Erection Of Segment Trollies
6. Load Test Of Winch And LG.
7. First Span Erection
8. Erection of Rear Support
9. Part Auto launch and Erection of S6 & S7 box
10.Erection of counter weight over S7 Box
11.Erection of rear trolley
12.Erection of S8 box
13.Placement of all counter weight at S8 box

29
Stage 1:- Erection Of Front Support
Stage 2:- Erection Of Middle Support

30
Mid support Temporary Stool for 1st span Erection

Temporary Stool

Anchor Bolt for

Temporary Stool
DIRECTION OF LAUNCHING
Stage 3:- Erection Of Box Assembly (Tandem Lift Method)

32
Stage3:- Erection Of LG Boxes (Single Lift Method)

33
Stage 4:- Erection Of Crab Hoist Winch
Stage 5:- Erection Of Segment Trollies

34
Stage 5:- Load Test Of Winch And Launching Girder

35
Crab Hoist Winch Load Test
• Before starting the Winch load test, Launching Girder is to be in segment
lifting position.
• Here the winch is finally tested by lifting 25% additional load of 50 T and it is
to be certified for its capacity of 80MT.

Test Type Lifting load Winch Movement

Segment+ 5T = 45T Vertical Up

NOMINAL LOAD TEST Vertical Down

(Capacity = 40T) 360 degree rotation

Segment + 1.25 times= 50T Vertical Up

Over Load test
(1.25 times Nominal =50T Vertical Down & 360
) degree rotation

36
37
Launching Girder Load Test

38
Segment Erection

39
Stressing Frame and Concrete Blisters for Temporary Stressing

Stressing Frame (Type 1) for

End segment

Stressing Frame (Type 2) for

Running segment

End Segment and Other Running segment

To Side Shift segment at 152 m radius of

curvature at Winch Location
40
Temporary Stressing of Precast Segments

Glue is to be applied at the surface of precast segment and a uniform stress of 3kg/cm2
is applied over the entire c/s area of the segment using macalloy bars and jacks
41
CHECKS BEFORE SEGMENT ERECTION
 Front anchored with the pier cap by using anchor bars.
 Middle supports, Rear support and Rear trolley are anchored with the Span by using
anchor bars.
 Supporting jacks of middle support are locked with lock nut provided in the jacks.

42
 Brakes are applied at Middle support using breaking assembly provided at their front
side.
 Middle support cradles are anchored using the HT stress bars provided over the
main beam so that it doesn’t move in transverse direction during erection of pre-cast
segments.

43
44
45
46
47
48
49
50
Segment Lifting and Side Shifting using Winch System <15m lift

Segment Trolley

Hoist Beam

Strong Back

Stressing frame

Position of Segment in Straight Span Position of Segment in Curved Span

51
Segment Lifting and Side Shifting using BID LIFT

Position of Segment in Straight Span Position of Segment in Curved Span

Segment
gluing

53
Dry Matching

 When the segment is positioned, it is to be joined with the existing segment.

Therefore, the segment was first dry matched with the already erected
segment. On completion of dry-matching, epoxy application is started.

Why Dry matching is required ?

Segments are dry matched to confirm the following points

 All segments are lifted as per serial number.

 Direction of all segments are as per match casting.
 Finishing of segment face done properly during dispatching of segments from
PC yard.

54
Epoxy Application on segment surface

Create 300mm gap between S1 segment and S2 segment for applying epoxy glue
between segments.
Apply epoxy glue (Sikadur 31SBA S-02) between segments S1 & S2.
Note: As per FIP (international pharmaceutical federation) Glue consumption is
3.2kg/m2 to 3.6Kg/m2
Do temporary pre stressing of the segments S1 & S2 by stress bars. Applied
pressure during gluing is 3kg/cm2.

55
56
 Temporary pre stressing in
between lifting frame of the
segment at top level

Temporary pre stressing in

between blister inside the
segment at soffit level

57
 Technical specification of Epoxy (Sikadur-31 SBA-02)

Sl. No Parameter FIP specefication

1 Glue consumption (kg/m2) 3.2 - 3.6
2 POT life at 45◦C in minutes 20-30 minutes
3 Open time at 45◦C in minutes 60-70 minutes
4 Compressive strength at 25◦C (N/M²), in 1 day 60 - 75
5 Compressive strength at 25◦C (N/M²), in 7 days upto 75
6 Tensile bending strength Concrete failure

58
59
 Checklist for Gluing

Span No. Epoxy Brand Name Batch No. Shelf life Upto

1) Epoxy Batch tested at site lab. & Found O.K. within last twelve Months
YES / NO / NA

2) Calibration report of pressure gauges for temporary Pre stressing available

YES / NO / NA

3) Pressure jacks are functioning well YES / NO / NA

4) Sufficient Trained manpower available for gluing and pre stressing. YES / NO / NA

5) Glue mixer is functioning well. YES / NO / NA

6) Stand by Glue mixer is available at site. YES / NO / NA

7) Dry matching of segment done & found O.K. YES / NO / NA

8) The matching surfaces of the segment are dry. YES / NO / NA

60
 Glue/Epoxy application format

S. Joint Date Temp Epoxy Batch No. Epoxy Harden Start End Theoret Actual POT Open
No. No (o C) Base Hardene Temp er Type time of time of ical Qty. consum Life time
Batch r Batch range gluing temp. of glue ption (Limit (Limit
No. (o C) pre (kg /Lit) (kg/Lit) 20 min) 60 min)
stressin
g

01

02

03

04

05

06

07

08

09

10

11

61
Stressing method

62
STRESSING METHOD

 Pre-stressing is a technique of construction in which internal stresses of

suitable magnitude and distribution are introduced in a member, so that the
stresses resulting from external loads are counteracted to a desired degree.
Post- tensioning is a method; the pre-stressing force is imparted to the
concrete by the bearing.

 Following are the properties of 15.2Φ Low Relaxation High Tensile Strands
Conforming to IS: 14268 LRPC Class- II.

 Nominal Area of Strand - 140.0mm²

 Minimum Breaking Strength - 260.7KN
 Nominal Weight of Strand - 1.102Kg/m

63
STRESSING EQUIPMENT DATA

 12K15 and 19K15 Live and Anchorage System

Tube Unit (Guide)

The basic raw material for manufacture of tube unit is gray cast iron. It allows the transfer of
pre stressing force from the bearing plate to the concrete. The tube is embedded in
concrete and can be easily fixed to the MS cone box by means of bolts and nuts. The design
of Tube Unit allows uniform flaring of H.T. Strands and free access to the injection of Grout.

Anchor Head (Bearing Plate)

The basic raw material for manufacture of bearing plate is Steel casting/forged steel. The
conical holes facilitate the seating of wedges and holding the strands in stressed condition.

Wedges
The basic raw material for manufacture of wedges is alloy steel. The individual high tensile
strands passing through the bearing plate is anchored by the wedges. The 3 segments of the
wedges are held together around the strand by means of special wire circlips for better
functioning, easy placement and storage.

64
Multi strand jack and Power pack unit

65
Storage of pre stressing Materials

 All pre stressing steel, sheathing, anchorages and couplers shall be protected during
transportation, handling and storage. Following are the precautions to be taken.

 High Tensile strand in the coil form shall be handled by crane using wire slings.
 Sheathing ducts are flexible and hence should be handled with care to avoid any damage
against deformation due to mis- handling.
 Pre stressing materials like sheathing ducts, anchorages shall be kept in stores under dry
and covered place. They should be stored at least 100mm above the ground level to
avoid corrosion.
 Jacks & Pumps, hoses shall be kept under cover.
 High tensile strand shall be stacked over raised platforms more than 300mm and
covered.
 Strand dispenser is to be used while uncoiling the HT Strand coil to avoid accidents & an
abrasive cutting wheel mounted on a grinder is to be used for cutting strands as per
required lengths.

66
STRESSING OPERATION

 Once the segments are glued and span is ready for stressing, strands will be threaded
individually into the ducts.
 Anchor heads are assembled on both sided and strands are threaded on to the same by
securing strands with compact wedges.
 Multi strand jack will be fixed at the one end and stressed to design force.
 Since the elongation to be achieved is above 200 mm, stressing will be done in two
stages.

67
 In 1st stage the stress will be applied to approximate 50% of total pressure ~ 200 Kg/cm²-
During this operation elongation of tendon shale be noted at intervals of 50, 100, 150
and 200 Kg/cm².
 After applying a pressure of 50 Kg/cm², a mark at distance of 100 mm shall be done on
passive end to measure the wedge draw in.
 Then the tendon will be locked and the ram will be retracted.
 After retraction of ram, the master heads of jacks shall be fixed back to ram and stress
will be continued until the pressure reached previous force of 200 Kg/cm².
 After noting down the ram readings at 200 Kg/cm², the balance force shall be applied in
equal increments of 200, 250, 300, 350 , and final pressure depends on the (type of
tendon or ) serial number of tendon.

68
 Initial reading of 2nd stage will be considered as starting reading to calculate cumulative
elongations. Elongations will be checked for any variance after applying actual young’s
modulus and cross sectional area of strands.
 After removal of jack a mark will be done on strands at distance of 100 mm to observe
24 hours – for any further wedge draw-in.
 Once the stressing is completed, strands are cut & the tendon prepared for grouting.

69
DON’Ts of Stressing

 DON’T stress any tendon which contains concrete slurry inside the anchor cavity.
 Concrete slurry in the anchor cavity will prevent proper seating of the wedges.
 DON’T use the jack when it is not positioned properly on the face of the anchor.
 DON’T overstress tendons in order to achieve proper elongation.
 DON’T allow obstruction in the path of the jack extension.
 DON’T use extension cords longer than 100 ft. (30 m), 2 wire cords or cords less than 12
gauge.
 DON’T continue stressing if you suspect that something is not working properly.
 DON’T stand in the immediate vicinity of the jack, or between the jack and pump during
stressing or DE tensioning.
 DON’T permit other workman in the immediate area of the jack, or pump, or along the
tendon during stressing application.
 DOESN’T hammer or beat on the jack or jack cylinders.
 DON’T activate equipment if you are not sure.

70
 WORK SHEET
Stressing calculation for Tendon-1
Values as per drawing
• Capacity of jack:- 415t
• Effective Ram area:- 659.7 cm2
• Efficiency of jack:- 98%
• Theoretical area of strand:- 140 mm2
• Theoretical modulus of elasticity of strand (E):- 1.95 x 105 Mpa
• Theoretical elongation:- 204 mm
• Load for Tendon-1 :- 239t
• Slip = (10mm at live end, 3mm at dead end)

 Pressure calculation (Modified pressure is applied on each tendon)

Modified pressure (kg/cm2) = [Load (ton) X 1000] / [Effective ram area(cm2) X Jack
efficiency]

 Elongation calculation (Modified calculation is applied on each tendon)

Modified elongation (mm) = [Theoretical elongation X Theoretical Area X Theoretical
E]/ [Actual area X Actual E]

 Net Elongation = Total elongation – Slip

 Percentage variation of Elongation =

{ [Net elongation - modified elongation] /modified elongation} x 100

71
Stressing Record format

Bridge data : Strand data : Jack data :

Span No : Coil No: Capacity : 415 tons

Cable No : Design UTS : Ram area : 659.7 mm
Date of Stressing : Actual C/S Area : Efficiency : 98.00%
No. of Strands : Actual 'E' value :

Data corrected for Strand and Jack used :

(Refer stressing Modification calculation sheet)

Required Modified Pressure : Max (+5%): Min (-5%):

Required Modified Elongation : Max (+5%): Min (-5%):

Elongation in mm
Applied
Cable no: Cable no:
Pressure
Reading Difference Cumulative Reading Difference Cumulative
(kg/ Remarks
(mm) difference (mm) difference
sq.cm)
(mm) (mm)

Total Elongation :
Slip (Live end + Dead end) :
Net Elongation :
Percentage variation of Elongation :

72
73
Stress calculation (Modified pressure is applied on each tendon)

Modified pressure (kg/cm2) = [Load (ton) X 1000] / [Effective ram area (cm2) X Jack
efficiency]
= [239 x 1000]/ [659.7 x 0.98]
= 369.67 kg/cm2
Maximum (+5%) = 388.16 kg/cm2 Minimum (-5%) = 351.18 kg/cm2

Elongation calculation (Modified elongation is applied on each tendon)

Modified elongation (mm) = [Theoretical elongation X Theoretical Area X Theoretical E]/

[Actual area X Actual E]
= [204 x 140 x (1.95x 105)] / [141.55 x 1.9876]
= 197.94 mm
Maximum (+5%) = 207.84 mm Minimum (-5%) = 188.04 mm

74
Bridge data : Strand data : Jack data :

Span No : Coil No: Capacity : 400 tons

Cable No : Design UTS : Ram area : 1025.70 sq.cm
Date of Stressing : Actual C/S Area : Efficiency : 98.02%
No. of Strands : Actual 'E' value :

Data corrected for Strand and Jack used :

(Refer stressing Modification calculation sheet)

Required Modified Pressure : 369.67 kg/cm2 Max (+5%): 388.16 kg/cm2 Min (-5%): 351.18 kg/cm2

Required Modified Elongation : 197.94mm Max (+5%): 207.84 mm Min (-5%): 188.04 mm

Elongation in mm
Applied
Cable no: Cable no:
Pressure
Reading Difference Cumulative Reading Difference Cumulative
(kg/ Remarks
(mm) difference (mm) difference
sq.cm)
(mm) (mm)
50 44
100 75 31
150 105 30 61
200 139 34 95
Avg. 31 126
200 30
250 55 25 151
300 78 23 174
350 100 22 196
360 114 14 210
370 120 6 216
380
Total Elongation : 216 mm
Slip (Live end + Dead end) : 10+3= 13 mm
Net Elongation : 216-13 = 203 mm
Percentage variation of Elongation : 2.56%

75
GROUTING

76
CABLE GROUTING

 The purpose of grouting is to provide a permanent protection to the high tensile steel
against corrosion and develop bond between pre stressing steel and surrounding
concrete. The grout ensures encasement of high tensile steel for corrosion protection &
fills the duct space to prevent ingress of water or air.

Grouting Operation

 Grouting should be performed as soon as the stressing operation completes.

 Grout vents are provided at anchorages for each cable.

 The anchorage pockets should be capped with concrete or suitable capping material
prior to grouting operation

 After the anchorage has been capped the tendon shall be water flushed through the
grout hole which projects from the top of the duct

 As soon as flushing is completed the grout operation shall start.

 Grout mix shall have the mix proportion of water/cement ratio as specified by the
weight. The additive admixture is mixed with cement in proportion as recommended by
additive manufacture.
77
Typical proportions of grout mix are as follows.

 Water cement ratio = 0.40% by weight. Admixture used is Cebex-100 ( 1 pack per
bag of cement, 200gm) is mixed to Cement of weight 50 kilograms, Tap water (w)
20 liters is added to the grouting cement.

 Grout samples shall be collected and tests to be carried for compressive strength
at7 days and 28 days and the results should satisfy 17 N/mm2 and 27 N/mm2
respectively.

 After completion of grouting the projected portion of grout vent shall be cut flat to
the top of segment level by means of abrasive disc.

78
Lowering of Span to Permanent Bearings

Transferring the segment loads to permanent bearings

(Elastomeric bearing) from Launcher

 After completion of temporary stressing, Place the span jacks

on the pier cap in position such that the pier head segment
(diaphragm) rests over the span jacks
STRESSED CABLES

 Using Span Jacks Deck shall be lifted and suspenders are

loosened. Thus the segments are relived from launching
girder

 Reliving of suspenders shall be made from center

towards supports.

LOADED SPAN JACKS

79
Lowering of Span to Permanent Bearings

 If permanent bearings are available, place the bearings in

position and grout the gap between down stand and
bearings.

 Once the grout attains strength, lower the superstructure

with span jacks till load is transfer to permanent bearings.
LOAD TRAFERRED TO STEEL STOOL
 If permanent bearings are not available Place the temporary
bearings (steel stools) over the bearing pedestal.

 When permanent bearings are ready, the superstructure

shall be lifted with lifting jacks and the temporary bearings
shall be replaced with permanent bearings.

TEMPORARY BEARING / STEEL STOOL

80
Auto launching of
launching girder

81
Check before Auto launching

 At front support
 Front support should be detached from pier.
 Lift the bottom beam of front support up to 1.2m or required height and insert pin in
telescopic leg.
 Remove all the loose material from front support.

 At middle support
 Middle support must be aligned properly.
 Both knuckle bearing of middle support should be water levelled.
 Knuckle bearing should be locked at 1.7m c/c by clamp plate bolts at bottom and by Mac
alloy bar at middle.

82
 Knuckle top clamp anchoring with LG
Box girder should be removed.
 Remove pin from braking assembly of
support.
 Middle support should be anchored
properly with the pier head segment by
32mm dia Mac alloy bars.

83
  At Rear trolley

 LG box girder should be positioned at the centre of rear trolley.

 Provide pin inside S8 box in the mating hole of rear trolley.

 Anchor the rear trolley with LG box girder by mac alloy bars.

 Splicing of rails should be proper and maintain a proper gauge 4.7m c/c between the
rails.
 While crossing over expansion joint, provide proper packing at bottom of rails.

84
 Slider beams
 All Slider beams should be moved at rear end of launching girder before auto launching.

85
 Auto launching equipment's.

 Launching girder is pulled by a fixed hydraulic jack mounted on middle support and a
pulling bracket hanging in monorail of launching girder.
 Details of hydraulic jack.
 Capacity – 40t
 Stroke length – 1200mm
 Closed length – 1500mm
 Power pack – Double acting (5HP).

Detail of monorail
 Monorail is a I-section beam which is welded at bottom center of LG Girder along the
length.
 55mm dia holes @500mmc/c are provided in monorail for fixing 50mm dia pin in pulling
bracket for LG movement.

86
 Auto launching operation:

 Connect the hydraulic jack (40t) with power pack (5HP) unit.
 Forced out/push the ram of jack outside along with connected pulling bracket up to 1m.
 Match the hole of pulling bracket with monorail hole and insert 50mm dia pin with split
pins.

 Apply lubricant (silicon grease) at the sliding surface of launching girder.

 Pull the launching girder up to 1m (closed length of jack).

87
 Remove the 50mm dia pins from pulling bracket
and again Forced out/push the ram of jack
outside along with connected pulling bracket
upto 1m.
 Continue this operation up to 20m auto
launching.
 At 20m Stop auto launching process and insert
pin in braking assembly and fix wedges in rear
trolley wheel.
 Release load from Rear support and shift it at S3
segment near middle support.
 Fix and anchor the rear support properly as done
before.
 Before start auto launching process remove pin
from braking assembly and wedges from rear
trolley wheel.
 Start auto launching again and continue it until
front support reaches at next pier.
 Anchor the front support with pier cap.

88
A u to L a u n c h i n g a n d
S e g m e nt E re c t i o n i n
Curved Span

89
 CURVED SPAN LAUNCHING

Complete the erection of span by transferring the load to temporary bearings

Jack up the rear support and release middle support
Shift the middle support as shown over the erected span
Shift the Rear support over the end segment

Segment Trolleys are not shown for clarity

90
 CURVED SPAN LAUNCHING

Jack up Rear support and shift middle support over pier head segment of the erected span
Jack up the Middle support and Release Front support

91
 CURVED SPAN LAUNCHING

Rotate the LG with Middle support as a pivot

using jacks in rear trolley

92
 CURVED SPAN LAUNCHING

Start Auto launching till rear trolley reaches Rear Support

93
 CURVED SPAN LAUNCHING

Shift Rear Support behind Middle support over the erected span
Continue auto launching till LG reaches the next Pier

94
95
96
 CURVED SPAN LAUNCHING

Rotate LG and align with the span to be erected

Raise the Telescopic leg and connect with anchor bolts
Now the LG is ready for next span erection

97
98
99
 CURVED SPAN ERECTION

Erection of segments in curved span differs from straight span

Segments should be rotated and side shifted using segment trolley
to align with the curvature

100
 CURVED SPAN ERECTION

Lift the segments as per the sequence

The segments are rotated and side shifted using 4 no of
Transverse jacks in segment trolley
Longitudinal slope and transverse slopes are adjusted with
Vertical central hole jacks

101
Transverse Side shifting of Segment during Curved Span Erection

Segment trolley

12T cap. Push pull

L.G Jack, 1200mm Stroke

Segment

Segment Lifted position Segment side shifted position

102
103
104
D e s i g n co n c e p t o f
L a u n c h e r p a r t s fo r
S e g m e nt E re c t i o n

105
Design Concepts – General Components

 Size of Box Girder

 Fixed based on the weight of segments, span length & curvature

 Length of Box girder

 Depends on the span length (Auto launching)

 Counter Weight
 Counter weight is provided to counter balance the girder during Auto launching. The
counter weight is fixed based on the net possible uplift at rear trolley location.

 Segment Trolley
 Size and Self weight of segment
 Minimum curvature in the alignment
 Space available to occupy the segment trolley during erection
• The width of segment trolley has to be fixed considering the Size of the strand
wedges which occupies space of about 150mm between two adjacent
segment trolleys.

106
Design Concepts – General Components

 Temporary Stressing frame

 Top
 The corresponding segment self weight
 Temporary stressing force to be applied during glue matching at top
 Segment lifting hole location
 Lifting arrangement in segment trolley and Strong back
 Bottom
 Temporary stressing force to be applied during glue matching at bottom
 Stressing frame attachment hole at bottom
• Concrete blisters can also be used for bottom temporary stressing when holes
are not preferred at soffit slab

 Winch system
 The capacity of winch is fixed considering the maximum weight of segment and
corresponding stressing frame self weight

107
Design Concepts – LG supports

 Front Support

 The front support will be connected to launcher with bolts and moves along with
launcher during Auto launching
 Designed to take maximum reaction to be transferred during segment erection of the
maximum span length over the entire alignment
 The torsion generated in girder during erection of curved spans (Eccentricity in load at
segment trolley) is also considered for design
 Anchor slots in bottom beam has to be fixed based on the minimum curvature and the
dimension of the pier
 The maximum height of telescopic leg should be finalized considering the Height of
bearing pedestal, segment height and the height of rear trolley
 The minimum height of front support should be such that the bottom of front support
should not touch the shear key in pier cap or the inserts provided in pier cap during
Auto launching
• Deflection at Front support location during auto launching to maximum
span length should also be considered to fix the minimum height of Front
Support

108
Design Concepts – LG supports

 Front Support (cont..)

 The space between the inner face of front support and the End segment should
be considered in designed based on the available post tensioning jack
dimensions.
 The Inserts provided in pier cap to anchor front support shall be of two types
• Sleeve with threads anchored inside the pier cap and removable bolt
screwed into the sleeve (Sleeve to be filled after erection)
• Fixed bolt anchored inside the pier cap (Should be removed after erection)

109
Design Concepts – LG supports

 Middle Support

 Middle support is designed to take care of maximum support reaction generated

during segment erection
 The knuckle bearing at top of Middle support acts as a hinge to releases moment
generated during segment erection. The Knuckle bearing also rotates with
respect to cradle beam during side shifting of LG
 The middle support deign considers the torsion generated in LG during curved
span erection.
 The movement of Middle support is arrested with anchor bars which connects
middle support to precast segment

 Rear Support

 Rear Support is designed similar to middle support.

 The load considered in design of rear support will be minimum since rear
support will be active only during Auto launching.

110
Design Concepts – LG supports

 Rear Trolley Counter Weight

 The rear trolley will be subjected to maximum

reaction only at the first stage of Auto launching
 After erection of segments the slider beams
will be moved to rear end and also the LG will
be at an eccentricity if curved span is being
erected.
 Rear trolley should be checked for reaction at full
cantilever and suitable counter weight has to be
provided to counter the uplift (57t counter weight
for an uplift of 26MT – Chennai Metro)

 Also the reaction in wheels of rear trolley should be

checked for uplift (Transverse direction) during side
shifting of LG. Counter weight also shall be placed
over the top beam of rear trolley to resist the uplift
reaction

111
THANK YOU
112