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Ppt u girder casting by l.k.prasad
- 1. Presentation on U-Girder casting By L.K.Prasad Noida Metro Rail Project CEC-SAM-JV.
- 3. Casting Yard
- 4. Scope U-girder Scope of Work Sl no Package Nos of Girder 27 m standard span Non standard span Concrete Qty Steel Qty. 1 NC-01 656 460 196 38376 6667.58 2 NC-02 704 532 172 41184 7155.46 Total 1360 992 368 79560 13823
- 5. U-GIRDER MIX DESIGN Grade of Concrete:M55 Ingredients Sourcr/Brand Qty/M3 Cement(Kg) Ultratech OPC-53 450 Microsilica(Kg) Elkem/Comiche 25 20mm Aggregate(Kg) Kotputli 577 10mm Aggregate(Kg) Kotputli 532 Fine aggregate(Sand)(Kg) Bajpur 765 Free Water(Kg) Batching plant 141.66 Admixture(Kg) Don super flow PC-250 4.037 Slump after 2 hours retension(mm) 140 7days strength(Mpa) 61.55 28 days strength(Mpa) 74.61 W/C Ratio 0.31 U-GIRDER MIX DESIGN
- 6. CASTING YARD INFRASTRUCTURE 1. Total No of BAY-4. 2.U-girder bay-03 nos 3.Pier cap Bay-1 4. No of U-girder bed 36 (6 bed in each row). 5. Pier cap mould-16. 6. 100 MT capacity gantry 02 nos in each u-girder bay. 7. T ime cycle is 10 days FOR U-girder casting. 8. Peak Max production 6*6*3=108 nos u-girder per month
- 7. STACKING CAPACITY 1. Bay-1 28*2= 56 2.Bay-2 28*2 56 3.Bay-3 23*2 46 Total 158
- 8. Casting Bed Preparation PCC for casting bed
- 9. Casting Bed preparation Rebar fixing
- 10. C/Bed Wall
- 11. Casting Bed Wall Longitudional Wall 300*1100 2800mm RCC Wall 1100*300 mm
- 12. Shutter Making Outer Shutter Bottom Shutter Outer Shutter Lifting hole Lifting hole 5050mm 3800mm 1850 mm
- 13. Lifting hole Lifting hole Inner shutter Inner Shutter
- 15. Outer shutter Bottom shutter Outer form
- 16. Buffing of Shutter Buffing/cleaning of shutter
- 18. Automatic bar cutting & Bending M/c
- 19. Automatic bar cutting & Bending M/c Capacity 100 MT/Day
- 20. Automatic bar cutting & Bending M/c Format Line 12 12mm dia rebar coil
- 21. Format line 16
- 25. Re bar cage placing Rebar zig. Rebar cage
- 26. Pre Fab Rebar Pre Fab Rebar Rebar zig.
- 27. Cage lifter Wt. of cage 10.2 MT Cage Lifting
- 28. Cage Placing
- 29. Cage Placing
- 31. Cage Lifting U-girder cage 27 mts long wt.10.12 MT
- 32. Cage lifting from zig.
- 33. Outer Shutter 2500mm c/c Turn buckle
- 36. Rebar cage Placing Rebar cage Bulk Head Shear Key Box
- 37. Cage Placing Re bar is coated with inhibitor solution for corrosion protection
- 38. HT Coil despenser HT Coil despenser HT coil
- 39. HTS CABLE
- 40. Cable Threading HT Cable Bulk head
- 41. Cable Threading Bulk head Floating Beam 15.2mm dia . 7 ply LRPC Class-2
- 42. Stressing end 75mm dia Macalloy bar Wedge & Barrel
- 43. Grip for cable 15.2 mm cable grip wedge 3 segmental Barrel 15.2mm dia HT cable
- 44. Prestressing 300MT Capacity hyd. Jack 600mm stroke
- 45. Prestressing 1. HT cable 15.2mm dia 2. Load in each cable 195.5 KN/19.92 MT 3. Total load 1434.24 MT 4. Ram area of jack 529.2 sq.cm 5. Required pressure 460.55 kg/cm2 6. Modified elongation 1179mm Hydraulic hose 700 bar.
- 46. Stressing operation Power pack 10 HP motor Stressing line Return line 700 bar cap. Hyd .hose
- 48. Washer plate 75mm dia macalloy nut Hollow device Stressing jack Washer plate Nut 75mm dia Macalloy bar Stressing Mechanism 300MT cap. 600mm stroke
- 50. Dead End Reaction wall 6500*1450*1200 mm Cable grip
- 52. Debonding tube 20 mm id HDPE pipe Debonded length 2175 mm both side Debonded tube
- 54. Stressing End Washer plate & Nut. 75mm dia. Macalloy bar.
- 55. Concreteing by Boom placer Grade of conc. M55 with micro silica Cement content 450 kg. W/c Ratio 0.31 Admixture Don super flow PC-250 4.037 Kg/m3. Conc. Qty per girder 60m3 Concrete placing Boom Placer
- 58. Load Transfer
- 59. Load Transfer criteria After 3 days of concreting with a minimum compresshive strength of conc. 35 Mpa.
- 60. Load Transfer To Concrete
- 61. Pre cast pier cap cage
- 62. Precast pier cap cae
- 64. Cross Arm
- 72. Girder Lifting Girder lifting & shifting
- 73. Girder Lifting From Bed Lifter 02 nos 40 mm dia Macalloy bar 4 nos
- 75. Girder Lifting Washer plate 40 mm dia Macalloy nut
- 76. Girder Lifter Girder Lifter 40mm Dia. Macalloy Bar
- 77. Girder Lifting from Bed
- 79. Stacking
- 81. Girder Lifting Girder wt 150 MT 100 MT Capacity EOT
- 82. Cable cutting by Mechanical cutter Cable cutting
- 83. Recess Filling with conbextra GP-2.
- 84. Recess Filling with conbextra GP-2 Recess Filling
- 85. Double layer stacking Stacking stool
- 86. Curing Curing period 21 days from DOC
- 87. Girder Lifting & Stacking Girder stacking
- 88. TIME CYCLE FOR U-GIRDER Sl no Activity Day Duration in hours Total Hours Remarks 1 Cleaning of bed and shuttering oil applying 1 12 12 2 Fixing of outer shutter 10 22 3 Fixing of bulkhead & cage placing. 2 12 34 4 Threading of HT strand. 3 24 58 5 Initial prestressing 6 64 6 Final Prestressing 6 70 7 Sealing of debonding tubes 4 3 73 8 Inner shutter placing 5 78 9 Inner shutter Alignment 9 87 10 Inspection by Client. 4 91 11 Pouring of concrete 5 48 139 12 Curing 6,7,&8 72 211 13 Load transfer 9 6 217 14 Lifting of girder for stacking. 10 24 241 10.04167 Note: Time cycle for 6 U-girder casting 10 Days. Time cycle U-girder
- 90. 200 MT Capacity Trailor
- 91. Loading For Launching Loading for launching
- 93. Tieing with 04 nos Belt Ready for Despatch
- 99. section of Neoprene Bearing. Steel Neoprene
- 100. Wedge plate Steel wedge plate
- 101. 350 MT Capacity tyre mounted crane. 400 MT Capacity crane
- 102. Position of crane during lifting Behing pier cap Beside pier cap
- 103. Lifting for launching Straight lifting above pier cap
- 104. Lifting for launching 350 MT cap. crane 400 MT Capacity crane
- 105. Swing for proper position
- 108. Lowering on pedestal
- 110. Position of crane during final lowering
- 111. Final position
- 114. Launching view
- 115. Launching 400 MT Capacity crane 02 nos
- 116. Thank you