Girder

launching and
Re girdering
Launching: Introduction
Launching : Placement of Super structure on Sub-structure

Undertaken for Construction of new line or doubling hence time

of construction is not very tight. unlike in “Regirdering”, which is
undertaken in open line under very tight time schedules.
Regirdering:
introduction
 Replacement of the Old girder with New Girder
 Additional features than Launching
◦ Work to be done in traffic block normally
◦ Girder to be fully ready before launching
◦ Additional activity of Removal of existing Girder
◦ Issues of change in the Rail Level
◦ Issues of Safety of Traffic on adjacent Line(s)
Preliminaries
Transportation of girders to site:
◦ Span upto 12.2 m assembled in workshop and Transported to site by BFR
◦ Longer plate girder spans transported in pieces and assembled at site
◦ Can be transported over trailers also

Fabrication / casting of Span: Girders are assembled/ cast on Bridge

approach or in situ.
Scheme
The “Brain” of the entire exercise
It Decides
◦ Success or failure of the scheme
◦ Success or failure of the work
◦ Time of the project
◦ “Headache” to the supervisors at site
 Essential Feature of
Scheme

Safety
◦ Safe handling of span as well as men and equipment used.
◦ Checking the erection stresses in each member of span during
launching and if required temporary strengthening is to be provided.
◦Steel girders need careful handling to avoid damage to
connections.
◦Concrete girders cannot be handled at any point. Depending on the
design, only load may be applied at nominated locations only.
◦ While providing temporary arrangements, proper care should be taken.
Desirable Features of
Launching Scheme
 Features of Launching
Scheme
Speed
◦ Completion of the work as per laid
down time frame of project.
◦ Project should not get delayed on
account of bridge construction.
Features of Launching
Scheme
Economy
◦ Scheme selected shall preferably be with available
equipment and supporting false work .
◦ Quality of construction to be maintained as per laid
down specification.
◦ Bridge girders are very costly asset and difficult to repair
during service .
◦ For sake of economy, safety cannot be compromised .
 Selection of Suitable
Method

Particulars of Bridges and Span

◦ Length, width, height and weight of girder
◦ Number and type of spans
◦ Steel or concrete or composite
◦ I section or BOX girder etc
◦ Height and width of piers/abutments
◦ Space available
◦ Skew or square span
 Selection of Suitable
Method

Site Conditions
◦ Height of opening
◦ Wet, dry or partly dry ground/river bed
◦ Depth of water and velocity
◦ Vulnerability of river to flash floods
◦ Condition of approaches - high banks or cuttings
◦ Access to site
◦ Road, rail or water access
 Selection of Suitable
Method
Other Conditions
◦ Experience of the contractor
◦ Experience of the supervisors
◦ Availability of bridging equipment and materials
◦ No of spans
◦ Estimated cost
◦ Erection of girders is sometimes as costly as the main bridge
Avoid complicated and extensive staging or auxiliary girders in erection
work.
◦ Simplicity avoids mistakes at site
Design of a Scheme
Girders should be designed/ checked for erection
and handling stresses.
◦ Scheme shall ensure that the girder does not get hit/
damaged during erection
Design of temporary work/false work used in
erection is very important
◦ Adequate extra factor of safety shall be there
◦ Shall cater to mistakes and minor accidents
◦ Shall cater to the “actual site conditions” i.e. loose bolts,
wear and tear etc
 Preliminary Arrangements
Before Start of Work
Plan sequence of erection work
Move girder materials to site
◦ Make yard arrangements on one bank or nearby station

Arrange plant and equipment required for launching along with spans
◦ Testing all equipment

Arrange for supervision, skilled and unskilled staf

◦ Provide camp facilities for labour force.
Preliminary Arrangements
Before Start of Work
Discuss scheme at site with the railway and contractor
supervisors
◦ Also discuss with the contractor’s artisans about the scheme

Visualize failures
◦ Have “Plan B” ready

First Aid and Communication at site

Arrange consumable stores
Schemes as
per site
conditions
Site Condition
#1
Site condition #1:
features
Plain terrain
Accessible by road
Medium to low height
No water in river in some period of the year
◦ Easy site
Site condition #1:
options
In situ erection
Side Slewing
◦ On CC crib
◦ On trestles
◦ By portal crane

Road crane
In situ
erection
In situ erection
Space under the girder is occupied by formwork
Superstructure work starts after sub structure work is completed
Lowering of girder to proper position to be done
In situ erection: All the
space can be used
In situ erection: All the
space can be used
In situ erection: Even in
slightly difficult site
With pre-cast concrete
units
Pieces are cast in yard and transported to site
On scaffolds, all pieces are placed
Stressing is done
◦ Site is occupied for minimum time
◦ Quality is maintained
◦ Speed of work is good
Derrick
Derrick for steel girders
Derrick
A column properly founded and guyed
Has freedom of movement in only one direction: vertical
Difficult to maneuver girder too much in lateral directions
Useful for
Relatively smaller spans
Lesser no of spans

Shockwave Flash
Object
Launching by derrick
Service span pulled
over opening using
Derrick
PSC girder launching using
derrick
PSC girder launching using
derrick
Side slewing
Side slewing
Mostly used for regirdering
For launching, Superstructure can be cast/ fabricated at approach,
pulled in position and slewed in
Slew – in slew – out
method

TRANSPORT NEW GIRDER IN RIVER BED TO THE SPAN LOCATION

 Slew – in slew – out
method IN BLOCK
WITHOUT BLOCK

SHIFT THE
STAGING
TO NEXT
SPAN

REGIRDERING IS NOW COMPLETE

Side Slewing With C C Crib
Side Slewing With C C crib
Support
Cast/ fabricate at
approach and side slew:
manual method
I II III

GIRDER
Launching of Girders by road
Cranes
Movement
◦ Crawler mounted
◦ Tyre mounted
Boom
◦ Hydraulic
◦ Mechanical
Crawler Mounted Mechanical
Crane
Tyre Mounted Hydraulic
Crane
Launching of Girders by Cranes
Choose adequate capacity crane depending on the total load, radius at
which the load is to be handled
Choose well maintained cranes
Plan the site layout and movement of cranes
Have sufficient standby
Well designed lifting girder
Site Condition
#2
Site condition #2:
features
Difficult terrain
◦ Not accessible by road OR
◦ Height is great

Water in river all round the year OR

Multiple lines having no space
AND
Isolated work for one/ two spans and moderate span length
Very difficult site
Site condition #2:
options
Railways’ 140 T Crane
◦ Girder on BFR
◦ Girder at bridge approach

Use of rail mounted methods

◦ Gantry Method
140 T breakdown crane
Requires more block with OHE grounded, but the best option in
emergency or where the site is very difficult
Work to be done after taking approvals
Mechanical department responsible
140 T breakdown crane
Schematic drawing for replacing
girder using 140 T crane
Track mounted steam
crane
140 T crane: handles
upto 18.3 m steel
spans
140 T crane: Moving
with the span
 Gantry Method method
PREPARATIONS WITHOUT BLOCK

PROVIDE GANTRY STOOLS ON PIERS

PROVIDE GANTRY ON APPROACH

TRANSPORT NEW GIRDER TO THE

BRIDGE APPROACH AND RAISE TO
THE CESS LEVEL
 Gantry method
WORK IN BLOCK

LOAD GANTRY CARRIER ON TRACK

LOAD NEW GIRDER ON TRACK

LEAVE GANTRY ON STOOLS

ALREADY FIXED ON PIERS
TRANSPOSRT NEW GIRDER TO THE
SPAN LOCATION
 Gantry method
WORK IN BLOCK
LIFT OLD GIRDER ON CHAIN PULLEY BLOCKS

REMOVE DIP LORRIES

REMOVE OLD TRACK

WIDEN THE LEAVES AND LET THE

BRACING FALL DOWN

LOWER THE GIRDER TO THE PROPER LEVEL

 Gantry Method method
WORK IN BLOCK

LOAD THE GANTRIES ON CARRIER

UNLOAD THE GANTRY CARRIER OUTSIDE THE TRACK

REMOVE OHE BLOCK, LINK TRACK AND REMOVE ENGG BLOCK

REGIRDERING IS NOW COMPLETE

 Gantry Method Method
WORK AFTER BLOCK SHIFT STOOL TO
NEXT SPAN

REMOVE
AFTER THE
COMPLETE
WORK IS
DONE
DELAUNCH OLD GIRDER
LEAVES TO RIVER BED OR
APPROACH
ARRANGEMENTS READY FOR SIDE
MOVEMENT OF NEW GIRDER AND
GANTRIES
3-1/2 HRS BLOCK
GRANTED FOR DN
LINE
SR 30 Kmph FOR UP
LINE

GANTRIES TO BE PUT
ON TRACK
GANTRIES TOO FIND THEIR
GROUND (ON LORRIES)
NEW GIRDER AS WELL AS GANTRIES
READY TO MOVE OVER THE BRIDGE
CROSS FRAME OF TWO LEAVES OF
EXISTING GIRDER CUT AT PLACES
BEFORE BLOCK
DISMANTLING OF TRACK STARTED
BUT FULL DISMANTLING CAN BE DONE
ONLY AFTER BRINGING GANTRIES AND
NEW GIRDER
GANTRIES REACHING THE SPAN TO BE
TACKLED
ARRANGEMENT ON PIERS FOR FIXING
THE TWO GANTRIES
GANTRIES IN POSITION ON PIERS –
WAITING FOR GIRDER
GIRDER REACHING THE TARGET SPAN
 GIRDER HANGED ON THE GANTRIES
 TRACK CAN NOW BE DISMANTLED
TRACK
DISMANTLED
TWO LEAVES OF
OLD GIRDER TO
BE SEPARATED
NEW GIRDER TO
BE LOWERED
LEAVES OF OLD GIRDER SEPARATED
REMAINING BRACINGS BEING
KNOCKED DOWN
NEW GIRDER BEING LOWERED
NEW GIRDER IN
POSITION
HOOK ARRANGEMENTS FOR HOLDING
RELEASED GIRDER’S LEAVES
GANTRY RELEASED FROM IT’S
SUPPORTS ON PIERS
ONE GANTRY MOVED TOWARDS THE
OTHER
BOTH GANTRIES BEING PLACED ON
THE LORRIES
TRACK LINKED AND GANTRIES
PLACED OUTSIDE THE TRACK
LIFTING OF LEAVES OF RELEASED
GIRDER
RELEASED LEAF READY TO BE MOVED
GANTRY WITH GIRDER LEAVES BEING
PULLED TO THE BANK
LEAF BEING PLACED ON CESS FOR
DISPOSAL
Site Condition
#3
Site condition #3:
features
Water in river to depth 4-5 m
Water current is not much
Use of water force for launching
Site condition #3:
options
Barge mounted crane
Launching using tidal variations
Barge
mounted
cranes
Barge mounted crane
Barge Mounted Crane for
Mandvi Bridge (KRCL)
Barge mounted cranes
Used on Konkan Railway for launching of 122 m span
Control of the barge important
Efforts lot less than the transportation of the girders over dip lorries etc
Work similar to the launching of the well curb etc
Slewing in on
barge
Slewing in on barge
Slewing in on barge can be done where
◦ Water 4-5 m is there
◦ Current is not high
◦ Pier not very high above the water
◦ Only jacking involved
◦ Very convenient as weight and height of CG reduces
Slew in with tidal
variations : Vasai Creek
Bridge
INNOVATIVE !!
NO JACKING TO BE DONE
Transportation of girder
by barge
Transportation of girder over
barge: Temporary stressing done
TEMPORARY STRESSING
Lowering by tidal
variations
Site Condition
#4
Site condition #4:
features
River bed not so inaccessible OR
Water in river all round the year BUT
◦ Depth is less

Height not very high, say less than 10-15 m

Supports possible in between
Not easy but not so difficult site
Site condition #4:
options
Launching over temporary girder laid over few supports in the span
Casting/ erection over supports
Casting/
erection over
supports
In situ fabrication over few
trestles
Trestles reduce the cost of
the temporary girder
Special Site
Condition
ROAD OVER BRIDGES
Road Over Bridge: Site
conditions
No water
Road access available
Rail traffic underneath
Easy site, however
◦ Safety of trains to be ensured
◦ Outsiders working, not know the train working
◦ Nothing shall fall on the tracks, especially under vibrations when the trains
pass
◦ Proper protections to be taken at all times
Launching of girders for
Road Over Bridges
Cast in situ
◦ Lowered by jacking
◦ Lowering by gantry

Pre cast
◦ Launched using launching truss
◦ Launched by crane
◦ Launched using derrick
Cast in place:
Lowering by
jacking
Cast in place on
scaffolding
Jacking for lowering of
girders
Cast in place:
Lowering by
gantry
Casting inside
Launching truss
PSC Girder inside
Launching Truss
Launching truss for
precast girder
A different launching
truss: service span also
used
Launching
using road
crane
Crane from approaches
Launching by
derrick
Service span pulled
over opening using
Derrick
Lowering using derrick
Site Condition
#5
Site condition #5:
features
Difficult terrain
River bed not accessible OR
Water in river all round the year
◦ Heavy flow
◦ Depth of water is less (cannot support the barge)
◦ No support possible in the water

Difficult site
Site condition #5:
options
Launching over service span
End launching
Cantilever erection
Other erection methods e.g. Launching using ‘launching gantry or
launcher, ropeway etc
Erection on
service span
 Skidding on rail cluster
Lesser span lengths are possible
Dip lorry used for rolling on launching girder/ rail cluster
◦ Friction is lower
◦ Lowering requirement is higher

Alternately rollers can be used

◦ Rollers are required to be handled expertly else they can get
derailed and will require jacking
 Launching on service
span
Lighter service span is launched and span is
fabricated or launched using the same
Transportation of new
girder
Dip Lorry
arrangement for
transportation
Girder jacked up for
lowering
TRACK OVER THE
SERVICE SPAN

GANTRY
PORTAL

Service span for launching of

THE EXTENDED AND CONTRACTED POSITION OF GANTRY LEGS

Expanded Position
(before girder entry)
Contracted Position
(After girder entry)
 TROLLEY FOR
GANTRY MOVEMENT
PORTAL OF GANTRY
 STEEL LAUNCHING GIRDER OF 72M LONG

DIRECTION

1. Launching Girder Fabricated in Pieces of 12m long to facilitate

transportation.
2. 1st 36m length designed to bear the weight of PSC box Girder
and hence steel sections used in this portion are heavier than
remaining 36m length which is meant for supporting and
counter weight.
3. Approximate Weight of launching truss is 125 MT.
5MT WINCH TROLLEY FOR MOVEMENT OF
STEEL LAUNCHING GIRDER
COUNTER WEIGHT TROLLEY

During movement of launching

to next span, counter Weight
trolley should move in opposite
direction
Lowering of girder in
stages of 350 mm
Launching of PSC girder using launching
girder and counter weight

P- 5 P– 4 P– 3
Final Bridge after
launching
Another case: Girder
over service span
Lowering using tendons
Side service span
End launching
 End launching
Girders tied together on approach
No need to go to the river bed
Connection between girders shall be properly designed
Front portion acts as counter weight
Front portion droops due to load
Front portion shall have lesser load
Cantilever Launching: girders
under fabrication
End Launching: girders
connected for launching
End Launching: girders
connected for launching
End Launching: girders
connected for launching
End Launching: girders
connected for launching
End Launching: Rails as beam
on bottom
End Launching: rolling
arrangement
End Launching: Rolling
arrangement
End Launching: pulling
arrangement
End Launching: pulling
arrangement
End Launching:
Launching nose
End Launching: girder
pulled half way
Cantilever Launching: girder
nearing launching
Launching in progress
Launching in progress
Cantilever
erection
Cantilever casting
Cantilever erection: steel
open web girders
Most difficult method
Used for very long spans
Light crane used on top boom for
incremental erection
Difficult to provide camber
Cantilever erection
Cantilever erection
Cantilever erection
Cantilever erection
Cantilever erection
Other
spanning
arrangements
Other launching
methods
Launcher
Ropeway
Launcher
LAUNCHING OF
I/T/Box CONCRETE
GIRDERS
Less High Tech ‘Launcher’
Girder Launcher
Can be used for
◦ Complete precast girder
◦ Precast units, held together on scaffolds and then stressed together before
launching
Ropeway
Launcher/ Ropeway
Feasible only where large number of spans are there.
Initial cost is very high
◦ Working is very fast and safe afterwards

Rope way requires stable hills on either side of site

Girder launching
Methods are not exclusive
As per site conditions, combinations can be used
Scheme shall be safe, simple, fast enough
◦ Shall be economical too
Innovation is the key
No limit on imagination