C3ECV-U Girder Precast Method Statement

CHENNAI METRO RAIL LIMITED
Employer / Engineer
“CONSTRUCTION OF ELEVATED VIADUCT (APPROXIMATE LENGTH OF 10 KM),

NINE (9) ELEVATED METRO STATIONS AT SHOLINGANALLUR LAKE-I, SRI
PONNIAMMAN TEMPLE (SHOLINGANALLUR LAKE-II), SATHYABAMA
UNIVERSITY(SEMMEANCHERI-I), SEMMEANCHERI-II, GANDHI NAGAR, NAVALLUR,
SIRUSERI, SIRUSERI SIPCOT-1 AND SIRUSERI SIPCOT-2 AND STABLING VIADUCT
AT SIPCOT”.
(PROJECT PHASE 2, CORRIDOR 3)
TENDER No. C3/ECV-01/RT01
RAIL VIKAS NIGAM LIMITED

Company (Contractor)
“CONSTRUCTION OF ELEVATED VIADUCT (APPROXIMATE LENGTH OF 10 KM), NINE (9) ELEVATED
METRO STATIONS AT SHOLINGANALLUR LAKE-I, SRI PONNIAMMAN TEMPLE (SHOLINGANALLUR
LAKE-II), SATHYABAMA UNIVERSITY(SEMMEANCHERI-I), SEMMEANCHERI-II, GANDHI NAGAR,
NAVALLUR, SIRUSERI, SIRUSERI SIPCOT-1 AND SIRUSERI SIPCOT-2 AND STABLING VIADUCT AT
SIPCOT” C3/ECV-01/RT01
CHENNAI METRO RAIL LIMITED
Employer / Engineer
METHOD STATEMENT
FOR
PRECAST U GIRDER CASTING
CMRL – C3/ECV-01/RT01 PROJECT
“CONSTRUCTION OF ELEVATED VIADUCT (APPROXIMATE LENGTH

OF 10 KM), NINE (9) ELEVATED METRO STATIONS AT
SHOLINGANALLUR LAKE-I, SRI PONNIAMMAN TEMPLE
(SHOLINGANALLUR LAKE-II), SATHYABAMA
UNIVERSITY(SEMMEANCHERI-I), SEMMEANCHERI-II, GANDHI
NAGAR, NAVALLUR, SIRUSERI, SIRUSERI SIPCOT-1 AND SIRUSERI
SIPCOT-2 AND STABLING VIADUCT AT SIPCOT”
TENDER No. C3/ECV-01/RT01
RAIL VIKAS NIGAM LIMITED
Company (Contractor)
2 CHENNAI METRO RAIL LIMITED C3/ECV-01/RT01

Contents
1. PURPOSE ................................................................................................................................................. 4
2. SCOPE ...................................................................................................................................................... 4
3. REFERENCE DOCUMENTS ........................................................................................................................ 4
4. DEFINITIONS ............................................................................................................................................ 4
5. RESPONSIBILITIES .................................................................................................................................... 5
6. MATERIALS: ............................................................................................................................................. 8
7. MANPOWER: ........................................................................................................................................... 9
8. MACHINE, EQUIPMENT, TOOLS & TACKLES: .......................................................................................... 10
9. SEQUENCE OF WORKS: .......................................................................................................................... 10
10. WORK PROCEDURE: .......................................................................................................................... 11
10.1 GENERAL ARRANGEMENT OF CASTING YARD....................................................................................................... 11

10.2 PRECAST YARD MOULD .................................................................................................................................. 12
10.3 SOFFIT ASSEMBLY .......................................................................................................................................... 12
10.4 OUTER SHUTTER ASSEMBLY............................................................................................................................. 12
10.5 INNER FORM ASSEMBLY.................................................................................................................................. 13
10.6 PRE-TENSIONING SYSTEM ........................................................................................................................ 13
10.7 PRE-TENSIONING MATERIALS & EQUIPMENTS ......................................................................................... 15
10.7.1 HTS strand ......................................................................................................................................... 15
10.7.2 Pre-tensioning equipment’s .............................................................................................................. 15
10.7.3 Pre-Tensioning Anchorages............................................................................................................... 15
10.7.4 PRE-TENSIONING ACTIVITY AND PROCEDURE .................................................................................. 16
10.7.5 Casting bed and Placing Tendons ..................................................................................................... 17
10.7.6 Stressing: ........................................................................................................................................... 17
10.7.7 Prestressing Procedure:..................................................................................................................... 18
10.7.8 Transfer of Prestress: ........................................................................................................................ 19
10.7.9 Cutting of strands .............................................................................................................................. 20
10.8 TYPICAL CASTING SEQUENCE/ METHODOLOGY.................................................................................................... 20
10.9 CASTING CYCLE ............................................................................................................................................. 21
10.10 FABRICATION OF REINFORCEMENT CAGE .......................................................................................................... 23
10.10.1 Reinforcement ................................................................................................................................. 24
10.10.2 Cutting & Bending of Reinforcement .............................................................................................. 24
10.10.3 Transportation of Reinforcement .................................................................................................... 24
10.10.4 Placing of Reinforcement ................................................................................................................ 24
10.11 DETAILED PROCEDURE OF SURVEYING FOR BOX GEOMETRY CONTROL AT CASTING YARD............................................ 26
10.12 CASTING OF U-GIRDER ................................................................................................................................. 26
10.13 CURING ............................................................................................................................................. 31
10.14 STACKING ........................................................................................................................................... 32
11. MANDATORY SAFETY REQUIREMENTS: ............................................................................................. 33
12. TRAINING & EDUCATION: .................................................................................................................. 33

1. PURPOSE
The purpose of this document is to describe the concreting sequence to be adopted for Casting of
Pre-tensioned U-Girder Spans.
2. SCOPE
To set out the requirements for Casting of Pre-tensioned U-Girder Spans for C3/ECV-01/RT01 Project
to meet all the contract requirements and RVNL standards for work operation, safety, quality and
environmental compliance..
3. REFERENCE DOCUMENTS
• Contract documents
• Good for Construction drawing of U girder.
• IS 456 for reinforced cement concrete
• IS 1786 for Reinforcement
• IS 1343 for Prestressing works
• Bar bending schedules as prepared by RVNL and approved by CMRL.
• SHE conditions of Contract.
• Health, Safety and Environment plan.
• Project Quality Assurance plan.
4. DEFINITIONS
For the purpose of this document the term:
• CMRL : Chennai Metro Rail Corporation

• RVNL : Contractor
• GFC : Good for Construction
• IS : Indian Standard
• ITP : Inspection and Test Plan
• OCS : Outline Construction Specification
• QA : Quality Assurance
• QC : Quality Control
• SHEVC : SHE verification checklist

5. RESPONSIBILITIES
The proposed Organization charts associated with this work are enclosed in Appendix 1.
Project Manager - Shall be responsible for the overall execution of Precast

U-Girder activity.
Dy. Project Manager - Reporting to the Project Manager.

- Liaison with Engineer/ Engineers representatives.
(Casting Yard Incharge) - Liaison with specialized agencies.
- Planning and arrangement of resources.
- Liaison between design department and site execution team.
- Liaison with internal departments like planning department, quality control
department, plant & machinery department, safety department, stores etc.
for effective progress.
- Safety & quality system implementation.
- Monitoring the program: Planned vs. achievement as per the target.
Planning Incharge - Reporting to the Project Manager.
- Interacting with Engineer’s representatives and internal departments.
- Daily review of program and progress with the project manager &
Construction Managers.
- Responsible for resources allocation.
- Projection of material requirement and arrangement for procurement.
- Preparation of monthly programs based on Erection / Master Program.
- Monitoring of the progress and updating.
- Documentation of all process related reports as per ISO requirements
Survey Engineer/Surveyor - Reporting to the casting yard In-charge.
- Interacting with the shifting in charges about the daily activities.
- Up keeping the survey instruments including calibration in consultation with
QC/QA section and safe custody.
- Documentation /protection of benchmark and survey points.
- Interacting with Engineer’s survey department representatives.

Construction Manager Ma
- Reporting to the Casting Yard Incharge.
- Interacting with Engineer’s representatives and internal departments.
- Daily review of program and progress with the project manager.
- Safe working condition and safe acts of all workman, machineries etc.

- Quality at all the stages shall be ensured.

- Responsible for resources allocation.
- Preparation of Daily & Weekly Program.
- Submission of requirement of materials & other resources for the next week/
month to the Casting Yard Incharge.
- Progress to be achieved as per the program.
- Responsible for lifting the U-Girder from bed, stacking and dispatching.
- Arranging required resource inputs for both shifts according to the activity
planned.
- Co-ordination between the shift engineers.
- RFI submission as per the systems according to the activities planned
- Documentation of all process related reports as per ISO requirements.
Quality Incharge - Reporting to the Project Manager.

- Material source approval
- Vendor development for construction materials
- Finalization of mix designs for concrete
- Review of CWP and get it approved
- Reviews Inspection plan & Test plan
- Implementation of QMS at site
- Involves in quality pep talks, periodical demonstrations of best practices in
work.
- Arranges routine testing for concrete, reinforcement, and other construction
material as per inspection and test plan.
- Checks for the use of right material at right place
Pre-stressing Agency - Reporting to the Casting Yard In charge.
- Getting approval from engineer for Prestressing system.
- Getting approval from engineer for hardware/ accessories for Prestressing.
- Fixing & Aligning of Sheathing Pipes in the U-Girder.
- Documentation as per ISO for prestressing systems.
- Getting approval from engineer for guide cone fixing.
- Responsible for proper up keep of prestressing material at yard.
- Preparation of Shop drawings and submission to Engineer via Project
Manager.
- The shop drawings shall be submitted as an addendum
Reinforcement - Reporting to the Casting Yard In charge.
- Responsible for Cutting, Bending & Tying of reinforcement cages for U-
Girder.
Fabrication Incharge - Interacting with Engineer’s representatives and internal departments.

- Preparation of BBS based on approved drawings.
- Optimization of Scrap & Offcuts.
- Safe working condition and safe acts of all workman, machineries etc.
- Quality at all the stages shall be ensured.
- Submission of requirement of steel on monthly basis to the Construction
Manager.
- Co-ordination between the shift engineers.
- RFI submission as per the systems according to the activities planned.
- Documentation of all process related reports as per ISO requirements
Engineers - Reporting to the respective in-charge.
- Prepares micro planning schedule for the activities set by the Bay in–charge.
- Achieving targets as per the planned.
- Targeting for zero accidents.
- Quality check at all the stages of activities.
- Material wastages control like rebar, concrete, consumables etc.
- Inspection of prestressing works with Prestressing agency/Engineer/ internal
QA/QC section.
- Arrangement of necessary materials required for next shift.
- Updating the shift registers/records.
- Handing over & taking over with the counterparts.
- Tools and tackles periodical checks along with P&M and safety section.
P&M in Charge - Ensure continuous availability of P&M at the site.
- Ensure periodic preventive maintenance & timely breakdown repairs of all
machinery & electrical equipment as per their inspection manuals.
- Ensure operation of P&M as per company norms
Chief SHE Manager - Shall report to Project Manager.

- Shall be responsible for overall control of SHE Activity as per approved
Safety Methodology.
- Ensuring the approval of Method statement by the client.
- Responsible to Ensure to provide Risk Assessment involved in piling
activities.
- Monitoring of safety requirement and its compliances from time to time.
Sr. Safety Manager - Responsible for completing all the safety documents needed for U-Girder
casting activity.

- Responsible for provision of risk assessment.

- Responsible for ensuring safety norms to be followed in casting yard.
Jr. Safety Manager - Shall report to Sr. Safety Manager.
- Shall ensure accident prevention
- Shall ensure daily HSE activities fully complied.
Safety supervisor - Monitor Safety practices, persuade to minimize non compliance
- Reports incidents beyond control and unsafe occurrences to HSEO s
PROJECT HEAD
Dy. PROJECT
CHIEF SHE QA/QC
MANAGER PLANNING HEAD SURVEYOR P&M IN CHARGE
MANAGER MANAGER)
(Casting Yard)
Construction Prestressing Sr. SAFETY

ENGINEER
Manager Agency MANAGER
Reinforcement
Fabrication Jr. Safety Manager
incharge
Engineer
Safety Supervisor
6. MATERIALS:
Sl.No. Name Brand / Source Conforms Remarks

to
1 Concrete M55 grade Batching Plant at site IRS: CBC/Clause 1.5
of outline
specifications for
2 Water Construction water from Viaduct works
Clause 4.3 of IRS:
R.O. Plant CBC
3 As per Project
Debonding Tubes Specifications (GFC
Drawings)

Sl.No. Name Brand / Source Conforms Remarks

to
4 Shall be procured from
Anchorage Sets
approved manufacturers
only.
5 Fe 500D TMT – IS
Reinforcement steel SAIL/TISCON/RINL/JSW 1786
6 Annex. C Technical
Debonding agent Approved Brand
Specification & MTC
7 Approved Brand Annex. C Technical
Mould Releasing agent
Specification & MTC
8 Structural Steel for Approved Supplier Confirming to IS:
moulds 2062
9 GI Binding Wire Locally available IS 280 & IS 4826
10 Macalloy or equivalent
40mm Threaded Bars
1030 grade
11 Hessian cloth Locally available ------

12 Mould Release agent Approved Brand
13 Sponge Locally available
14 Putty Locally available
15 Nails Locally available
16 Curing pipe Locally available
7. MANPOWER:
Sl.No Category
1 Carpenters
2 Fitters
3 Masons
4 Helpers
5 Riggers
6 Khalacis
7 Gantry Crane Operators
8 Batching Plant operators
9 Safety Stewards
10 Equipment/ P&M helpers

8. MACHINE, EQUIPMENT, TOOLS & TACKLES:

Sl. No Description Quantity Remarks
1 100 MT Capacity Gantry 02 Nos.

2 Batching Plant Capacity 60Cum/Hr 01 No.
3 Transit Mixer 4/6 Cum Capacity 03 Nos.
4 Concrete Pump with Boom Placer/Concrete Pump 01 No.
5 Concrete Cube mould 150*150*150 mm Size 150 Nos.
6 Total Station With Accessories 1Sec Accuracy 02 Nos.
7 Auto Level 02 Nos.
8 Welding Machine 03 Nos.
9 Hydraulic jack With Power Pack 400T capacity 06 Nos.
10 Immersion Vibrator 6 Nos.
11 Mould Vibrator 20 Nos.
12 Casting Moulds – Straight bed 26 Nos.
9. SEQUENCE OF WORKS:
1. Cleaning of casting beds and oiling
2. Fixing of outer shutter
3. Placing of rebar cage
4. Threading of strands
5. Initial pre-stressing
6. Final pre-stressing of all strand
7. Placing of inner mould
8. Inspection by client
9. Pouring of concrete
10. Curing
11. Removal of inner shutters
12. Transfer of prestress
13. Cutting of strands
14. Lifting of girder
10. WORK PROCEDURE:

10.1 General Arrangement of Casting Yard
U-Girder shall be cast in precast yards located at Pushp Vihar, Delhi. For general layout showing casting
yard, refer sketch below. A well-equipped precast yard of length around 235 consisting of 2 parallel casting
beds shall be built-up for casting the precast elements with proper ground control for reinforcement,
shuttering, concreting & curing, stacking of U-Girder, drainage facility etc.
1) Light masts shall be provided for illuminating the casting area.

2) 2 Nos. electrically operated 100 MT Gantries shall be erected for handling the U-Girder formworks,
reinforcement cage and other miscellaneous works.
3) Sacking yard shall be equipped to stack 30 nos. of U-Girder in 2-tier stacking, refer Annexure ‘A’. for the
Stacking Arrangement of U-Girders.
4) Reinforcement yard is located adjacent to the casting yard, reinforcement jig shall be provided for the pre-
fabrication of reinforcement cages of running U-Girder. Reinforcement cages shall be handled by Gantry
with suitable lifting arrangements. Adjacent to running U-Girder, refer drawings in Annexure ‘A’.
5) Reinforcement cutting and bending shall be done at Casting Yard.

6) Access roads for plying the transit mixers and other vehicles shall be provided in between casting bays.

10.2 Precast Yard Mould

There are 8 moulds proposed in the casting yard, for casting U-Girder, each moulds consists the
following
I. Inner form assembly

II. Soffit assembly.
III. External side shutter (Outer form) assembly with supporting arrangement.
IV. Working platforms & access staircase.
The Details of Moulds arrangement has been shown in Drawings attached in Annexure-A
10.3 Soffit Assembly

Soffit for U-Girders shall be rested over a raised platform, with side shutters secured from Turnbuckles
as shown in the picture below. The Detailed arrangement of soffit has been shown in drawings attached
as Annexure-A
10.4 Outer Shutter Assembly

For mould two outer form assemblies shall be placed on either side of soffit i.e. LHS & RHS as per ref
drg. in Annexure A.
In order to support the outer web of the U-Girder to be cast, outer form of structure of panel type fixed at
the joint of soffit and side shutter, is supported by heavy duty turn buckles, it has a frame at the top of the
shutter and horizontal jacks fixed to it for adjustment in the horizontal direction. It is also held in position to
the soffit by locking arrangements to prevent movement due to vibrations during concreting.

10.5 Inner Form Assembly

The inner shape of U-Girder is ensured with the help of Inner Moulds. Alignment / adjustment & de-
shuttering of panels shall be carried out with the help of turnbuckles & hinges provided in panels to
resist concrete pressure load during concreting. For details ref. Drg. in Annexure A.
Fig: Inner form Shutter Assembly
10.6 PRE-TENSIONING SYSTEM
In pre-tensioning system, the high-strength steel tendons are pulled between two end abutments (also called
bulkheads) prior to the casting of concrete. The abutments are fixed at the ends of a prestressing bed.
Once the concrete attains the desired strength for prestressing, the tendons are cut and released from the
abutments.

The prestress is transferred to the concrete from the tendons, due to the bond between them. During the transfer
of prestress, the member undergoes elastic shortening.
The various Activities of the pre-tensioning operation are summarized as follows.
1) Anchoring of tendons against the end abutments

2) Placing of jacks
3) Applying tension to the tendons
4) Casting of concrete
5) Cutting of the tendons.
During the cutting of the tendons, the prestressing force is transferred to the concrete. The different activities are
shown schematically in the following figures.

10.7 PRE-TENSIONING MATERIALS & EQUIPMENTS
10.7.1 HTS strand

Strand shall be supplied in form of coils as per project specification. The steel strand to be used for the tendons
shall be (Low Relaxation Class-II). The tendons shall comprise of 15.2mm Diameter seven-wire strand. Each strand
shall have a minimum Characteristic Breaking strength of 260.7 KN with cross sectional area of 140mm2.
It is recommended to store HTS strand coils at about 300mm above the ground in a suitably
covered and closed space so as to avoid direct climatic influences and to protect them from
splashes from the cutting operation of an oxy-acetylene torch or arc welding process in the
vicinity.
10.7.2 Pre-tensioning equipment’s

Two jacks shall be used for tensioning strands by Jacks at one end. These specials jacks shall be of
sufficient capacity & sufficient stroke length to tension all cables at one time.
Jacks
The jacks are used to apply tension to the tendons. Hydraulic jacks are commonly used. These jacks work on oil
pressure generated by a pump. The load applied by a jack is measured by the pressure reading from a gauge
attached to the oil inflow.
All PT equipment’s delivered to site should be as per anchorage force and project requirement. All PT
Equipment’s delivered to site must be kept properly, covered & protected against physical damage, as it
may affect efficiency & accuracy of equipment’s/instruments. Following PT equipment’s are required for
this project.
I. Special Jacks along with accessories.
II. Monostand stressing Jack
III. Electrically operated Hydraulic Pump with pressure gauges.
IV. PT accessories & necessary instruments.
All Jacks & Pressure gauges shall have valid Jack efficiency/calibration certificates prior to start of pre-tensioning
work.
10.7.3 Pre-Tensioning Anchorages

All PT anchorage units are consisting of Monostrand anchorage & wedges. These components shall be handled
and stored well to prevent any mechanical damage and detrimental corrosion.

Anchoring Device
Anchoring devices are often made on the wedge and friction principle. In pre-tensioned members, the tendons are
to be held in tension during the casting and hardening of concrete. Here simple and cheap quick-release grips are
generally adopted. The following figure provides some example of anchoring devices. In this Project Barrel & Grips
suitable for 15.2mm strands shall be used.
The end abutments are kept sufficient distance apart, and several members are cast in a single line. The
shuttering is provided at the sides and between the members. This system is also called the Long Line Method.
The following figure is a schematic representation of the Hoyer system.
10.7.4 PRE-TENSIONING ACTIVITY AND PROCEDURE
There are Five beam of approx. 28-meter length to be Pre-tensioned. The entire length of strand is approx.
142.00 meter. Step by step procedure for pre-tensioning of beams is as below:

10.7.5 Casting bed and Placing Tendons
It is essential to design the pre-tensioning bed to additional 20 per cent capacity as the prestressing force on
reaction abutment will increase due to “long line bench effect” after casting of concrete, due to shrinkage and
temperature variation between the duration of casting of concrete and de-tensioning. Prior to de-tensioning in the
casting yard, the strands can be stressed up to maximum 85 % of UTS. Due to the shrinkage of concrete clubbed
with reduction in temperature, shrinks the concrete along with the strands in the bonded length thereby elongating
and inducing further stress in the un-bonded length. If the increase in stress in un-bonded length before de-
tensioning is beyond UTS, the strands in some cases may even start snapping. The increase in the stress of the
unbonded tendon is directly proportionate to the ratio of the length of the embedded strands to that of total strand
length. This is also affected by curing time and is more severe when the ambient temperature during stripping is
low. Hence care shall be taken while de-tensioning of strands.
HT strands shall be cut to required length and stacked over raised platform along the line of casting bed. While
opening the coil, HT strands shall be passed through water tank to remove protective coating if any exist over
strand. The cables shall be threaded manually inserting through 20 mm dia ‘PVC’ pipes of required length meant
for debonding as mentioned in drawing. After fixing up the anchorages, the cables shall be prestressed from
stressing end in predetermined sequence. The de-bonding pipes were positioned and sealed with epoxy and tapes
as per the drawing after the stressed cables are anchored.
The tendons shall be placed across bulkheads as shown on the Drawings and secured such that it shall not shift
during concrete pouring. In placing the tendon, attention shall be given so that the tendon shall not touch the
lubricating on the formwork. If the tendon touches the lubricant, it shall be cleaned immediately using kerosene or
other suitable material. If possible, tendon stressing shall be carried out before lubricating the formwork.
10.7.6 Stressing:
After tendons are layed, then all strands are kept in proper alignment. Force shall be applied as mentioned in the
drawing. The jacking force applied shall allow for any anticipated slip at the anchorage devices, wedge draw-in,
and friction losses.
The method of tensioning shall ensure that the required force is produced in all tendons at the middle of all units,
especially where more than one tendon or one unit is tensioned in the one operation. Elongation measurement
may be used only after the Engineer has examined the calculations and determined that the system meets the
requirements. Jack pressure readings shall be used as a comparison with elongation measurements. If the jack
pressure reading and the elongation measurement differ by more than 5%, the Engineer shall be informed prior to
starting the concrete pour and, if considered necessary, the tendon shall be tested and the equipment shall be
calibrated as directed by the Engineer.
Please refer Appendix-I for example pressure & Elongation calculations. Actual data of strand & Jacks etc. shall
be used while preparation of pressure & elongation calculation of each girder.
10.7.7 Prestressing Procedure:

The tensioning operation shall be performed only by personnel trained and experienced in this type of work. The
tensioning force shall be applied and released at a uniform rate. In order to remove slack and to lift tendons off
the bed floor an initial force of 750 kg or as otherwise approved by the Engineer shall be applied to the tendons.
Allowance shall be made for this force in calculating the required elongation.
Initial force of approx 1860 Kg shall be applied to each strand by Monostrand Jack in order to remove slackness and to keep
all strands at equal force, prior to stressing all strands at a time.
No. of Strands: 1
Total Jacking Force: 1860.00 Kg
Jack Model: SC-2
Stressing Area: 37.2 cm2
Jacking
Design Pressure = Force 1860.00
=
Stressing
Area 37.2
= 50 kg/cm2
Hence an initial Pressure of 50 kg/cm2 shall be applied to all strands in order to remove slackness prior to
stressing & elongation measurement.
Tensioning (applying required force to girder) & De-tensioning of girders can be done by this methods, i.e. (I)
Tensioning & De-tensioning by Solid hollow jack of all individual strands
(I) Tensioning & De-tensioning by solid hollow jack of all individual strands
In this method strands (bottom & Top) strands both shall be stressed by solid hollow Jack and also de-tensioned
by same jacks individually in a sequential manner specified by engineer.

Tensioning:
After Initial Pressure of 50 kg/cm2 applied, as mentioned above for removal of slackness, Pressure at interval of
50 kg/cm2 shall be applied till final pressure and record elongation. In case of stroke of jack is finished use following
steps for stressing in multiple stages:
1. Apply initial pressure 50 kg/cm2 till complete stroke of the jack (use safe limit of stroke of jack) and record
elongation between each Pressure interval.
2. Lock the strand once stroke is over, release pressure and return jack.
3. Again apply same pressure (attained previously) and record the new reading on piston, which will be new
reference reading for second stage of stressing. Increase the pressure to next increment of 50 kg/cm2 and
record elongation between each Pressure interval.
4. If stroke is over again repeat steps 2-3 till final pressure is achieved.
5. Calculate total elongation, compare with required elongation and apply required pressure.
We can keep additional steel or RCC blocks over length of piston of both jacks in between jack & reaction beam
(which are safe to hold forces in all strands at all times till de-tensioning) to make sure that there shall be no loss
in strand force/elongation due to any oil leakage in jacks or any other reasons. Due care shall be taken to avoid
any damage to piston of jacks. Once these jacks are placed, tensioning of strands can be done of all strands.
De-tensioning:
After required strength of casted girder has been achieved, strands can be de-tensioned. Following steps shall be
taken to de-tension strands in this method.
1. Remove the packing (RCC/Steel blocks) in between jack & reaction beam.
2. Release pressure simultaneously in both jacks slowly at approximately constant rate till force in strands
becomes zero, which can be confirmed by pressure in hydraulic pump.
3. Cut strand by abrasive disc in between girders to de-tension strands.
10.7.8 Transfer of Prestress:

Concrete Strength Requirements: No tendon shall be released before the concrete has attained a compressive
strength 40Mpa of the specified 3-day strength shown on the Drawings or as suggested by engineer.
Procedure: The tendons shall be examined prior to being released to ensure that no tendons are loose. If there
are any loose tendons the Contractor shall immediately inform the Engineer who shall inspect the unit and decide
whether the unit shall be used or replaced. Each tendon shall be marked on both ends of the prestressed beam,
so it is possible to record slippage or draw-in whenever these occur. Release of the tendons shall be done gradually
and shall not be interrupted.
10.7.9 Cutting of strands

The transfer of prestress in between girders shall be induced by cutting strand by abrasive cutting disc after
concrete achieved desired strength. Concrete sample should be taken for every new mix so that strength obtained
may be determined before cutting the tendons releasing the stresses onto the concrete.
The pre-tensioning strands shall be released by cutting them, quality control and testing of concrete samples shall
be performed.
10.8 Typical Casting Sequence/ Methodology

The step by step casting sequence of U-Girders has been shown in Drawings attached as per
Annexure-A,
A. Sequence for Casting of U-Girder
1. Leveling the form work free / fixed end and support for bearing outstand
2. Closing the external form work of U-Girder
3. Application of shuttering oil or form work releasing agent
4. Lifting and placing of reinforcement cage
5. Threading & Installation of Prestressing Tendons
6. Initial Stressing (Slack Removal) of prestressing Tendons.
7. Final Prestressing of Tendons
8. Installations of all inserts to the inner Moulds.
9. Aligning & setting of internal Moulds in position
10. Jacking and fixing up of internal form work
11. Laying, compacting & finishing of concrete for U-Girder
12. Release of inner moulds after 16-24 Hr. of Casting.
13. Allow setting of concrete for release of prestressing force. Curing to be done during setting.
14. Transfer of Prestress.
15. Cutting of strands, b/w different cast Girders.
16. De-shuttering of Outer Form.
17. Shifting of U-Girder to Stacking Yard

10.9 Casting Cycle
Stage-1 Reinforcement Cage Lifting / Placing Inner & Moulds Fixing in BAY-01
Stage-2 Concreting BAY-01

Stage-3 Lifting of U-Girder for Stacking BAY-01
(a) 2 nos. 100 MT equal capacity Gantry will be used for tandem lifting of U-Girders.
(b) 2 Lifting points has been provided as per design.
(c ) 1 no. spreader beam will be used for each gantry crane.
Detail of Lifting Beam For Casting Yard

Detail of Lifting Beam For Casting Yard
10.10 Fabrication of Reinforcement Cage

NOTE – Gantry Erection is in commissioning stage once the commissioning is completed, Third Party
Inspection for Load test of Gantry shall be done.

10.10.1 Reinforcement
• TMT Fe 500D steel bars of approved vendor shall be used.
• Reinforcement steel shall be supplied to steel bending yard directly from manufacturer.
• Unloading of reinforcement will be done either manually or using Hydra Crane of adequate capacity
considering all safety parameters.
• Reinforcement Cutting Bending shall be done at Casting Yard Pushp Vihar.
• Reinforcement shall be marked batch wise and tested as per Inspection and test Plan.
• Reinforcement which confirms to the requirements shall be used for cutting and bending.
• Approved BBS shall be used for cutting and bending.
• Reinforcement shall be protected from rusting, mortars, mills scale, grease oil or paints by covering with
tarpaulin sheets as per the requirement in site.
• Handling of reinforcement shall be in such a way so as to prevent damage or unwanted bending.
• Reinforcing bars will be projected in the crash barriers and coated with cement slurry for protection. If at
all any rusting starts it shall scrubbed with and wire brush.
• Relevant tests on reinforcement shall be done as per the test plan.
10.10.2 Cutting & Bending of Reinforcement

• Reinforcing steel shall conform to the dimensions and shapes given in the approved Bar Bending
Schedules.
• Reinforcement steel shall be fabricated through automatically operated machines and mandrels
confirming to IS1786:2008.
• Quantity of Reinforcement steel fabrication shall be as per the Production schedule.
• Cut and bent reinforcement shall be stacked on sleepers and protected to prevent rusting by covering
with tarpaulin sheets.
10.10.3 Transportation of Reinforcement

• Cut and bent reinforcement shall be transported to place of work on trucks /trailers.
• Unloading of reinforcement at site shall be done either manually or by crane.
• Reinforcement shall be stacked on elevated blocks in clean and dry condition.
10.10.4 Placing of Reinforcement

• Reinforcement tying shall be done in specially fabricated reinforcement jigs. Typical jig is shown in
the below sketch. Refer drawings in Annexure-A, for details.

• Reinforcement shall be tied together at every intersection with GI Binding wire.

• Lap length shall be as given in the GFC drawing and shall be staggered.
• Couplers may be also be used. Wherever used, couplers shall be staggered at least by the
distance of lap length shown in drawings.
• Suitable cover block shall be placed at suitable locations to maintain clear cover.
• G.I. binding wire shall be used for tying the bars. Cover blocks of required dimension & shape shall
be used.
• Reinforcement steel shall be tested & record shall be maintained as per Inspection Test Plan (ITP).
After completion of the cage fabrication, the same shall be offered for inspection to Engineers
Representative. Once it is cleared, it shall be lifted by the lifting frame & placed inside the moulds.
The lifting frame drawing is attached in Annexure ‘A’.

10.11 Detailed Procedure of Surveying for Box geometry control at casting Yard
I. Specialized equipment
Advanced total station capable up to 1sec accuracy & auto level capable to read up to 1mm shall be used
for geometry control surveying. The tolerance of survey control points will be aimed at the minimum
values attainable with these instruments.
II. Survey Tower

Two Survey towers will be constructed at both ends of each bay to control alignment of U-Girder.
III. Setting out with total station

Before starting the construction at site, the survey department has already established a system of station
(on each survey tower/target tower at both side of mould). The co-ordinates (for 1st cast and match cast
U-Girder) of the design point are pre calculated and recorded in the memory of total station. Setting out
works shall be done from the closest station, (survey tower), unless for any reason (e.g. Obstructions)
the orientation shall be observed from minimum two stations, to avoid mistakes and to check the actual
accuracy of the instrument.
IV. Survey checking before casting of U-Girder :

The marking of both axis lines shall be given before starting of any activity on each mould .
The surveyor from survey tower/ target tower will check with the total station and the target (prism) in to
the stressing end position (fixed and temporary both) of 1st cast U-Girder and confirm that the position
and level of stressing end are in right position. Surveyor will also check the soffit position and level as
per pre-calculated level and co-ordinates and accordingly if necessary soffit levels and position will be
adjusted.
V. Survey checking after casting of U-Girder

After casting of U-Girder the surveyor from survey tower with his instrument and prism will check the
stressing end position at center. The whole set of data taken for U-Girder will be given input into the
worksheet to calculate the twist error.
10.12 Casting of U-Girder

• Once erection & alignment is over, survey checking shall be carried out as per survey checking
procedure described in section 9.12, after alignment of all moulds parts, all minor gaps shall be filled
up by putty to prevent leakage of slurry. On completion of all activities at moulds thorough cleaning
shall be done by compressed air. Finally the U-Girder shall be offered for checking to Engineers
representative’s supervision team. Upon clearance casting shall be done.

• The concrete shall be placed before setting has commenced and shall not be subsequently disturbed.
Concrete shall be so placed as to avoid segregation of the materials and displacement of reinforcement. Placing
of Concrete shall be as per IRS Concrete Bridge Code Clause No 8.2, 8.2.1 and 8.2.2. Concreting will be carried
out with client's approval. Concrete of specified mix will be prepared in the batching plant and transported to
the site location with the help of transit mixer. Approved Concrete Mix as per Drawing shall be placed as per
concrete pouring plan with pump able slump (125 ±25) and concrete temp. shall not more than 32° C and not
less than 5° C at time of placing. Concrete pump with pipeline shall be used for pouring of concrete to the pour
area. A flexible hose shall be attached to the end of the concrete pipeline to deposit concrete as nearly as
practicable in its final position. Alternatively, a concrete placing boom can be use "’’Prior to the commencement
of pumping of concrete by concrete pump, 0.3 -1.0 m3 of cement slurry/Slurry Pouch of the same grade shall
be pumped for lubricating the pipelines. Once the Cement Slurry is pumped, after this, Concrete shall be taken
in the Pipeline. Slurry coming out of Pipe shall be discarded and the concrete shall be poured inside the
Formwork. Concrete shall be placed in final position and after that, adequate vibration shall be given for
consolidation.
• The top surface of the concrete shall be leveled and worked to produce the required surface finish. It will
be ensuring that Surface is not dried up before finishing. Maximum free-fall of concrete will be limited to 1.5mtr.
• Concrete Pour card shall be filled during the pouring of Concrete.
• The different stages of concreting are shown in the below sketch.
STAGE-01
1. Concreting of Bottom Slab
for 1st 14 m shall be done.
2. Qty of Concrete – 18.2 m3
3. Time for Concreting –
Approx. 25 Min.- 30 Min

STAGE-02
4. Left Side Walls upto Half
height
STAGE-03
7. Right Side Walls upto

Half height
STAGE-04
10. Concreting of 2nd Bottom
Slab for 14m shall be
done.
STAGE-05 13. Left Side Walls upto Full

height (1st Bottom)

STAGE-06
16. Right Side Walls upto Full

height (1st Bottom)
STAGE-07
19. Left Side Walls upto Half

height (2nd Bottom)
STAGE-08
22. Right Side Walls upto

Half height (2nd Bottom)
23. Qty of Concrete – 3.44
m3

STAGE-09
25. Left Side Walls upto Full

height (2nd Bottom)
STAGE-10
28. Right Side Walls upto Full

height (2nd Bottom)
NOTE :-
• Bottom slab & top of wall concrete shall be finished by an aluminum box ruler; the top surface shall be
smooth finished.
• All types of construction joint and shear key shall be tooled and made free from any loose
mortars/concrete.
• Before transportation the joint shall free of any loose particles/ debris.
• Casting of PT Recess in Stacking Area,

Note :- The PT Recess shall be cast after completion of curing period for U-Girder. The Epoxy bonding
compound will be used of approved Manufacturer.
Compaction of Concrete:
Concrete Compaction shall be done as per IRS Concrete Bridge Code Clause No.8.3, 8.3.1; 8.3.2 and
8.3.3. Concrete shall be compacted during placing by using shutter vibrator/Needle Vibrator. The vibrator
shall be withdrawn slowly to avoid the formation of voids. During the compaction, care shall be taken to
avoid the displacement of reinforcement, formwork, pre-fixed pipes, inserts etc.
Concreting in Hot Weather
When depositing concrete in hot weather, precautions shall be taken so that the temperature of wet
concrete does not exceed 32°C while placing. This shall be achieved by using Chilled mixing water,
wrapping of hessian cloth over the TM and water sprinkling over hessian cloth, shading stock piles of
aggregate from direct rays of the sun and sprinkling the stock piles of coarse aggregate with water to
them moist, Start curing before concrete dries out and restricting time of concreting as far as possible to
finish early morning and start late evenings.
10.13 Curing
Water Curing shall be done on the top surface of sidewalls as soon as the concreting is finished by water sprinkling.
The top of slab shall be covered with the hessian cloth and it shall be made sure that the hessian cloth is kept wet
all the time. After removal of inner moulds the walls shall be draped in hessian cloths and kept wet for the curing

purpose. The same method shall be adopted for curing after removal of outer shutters. The U-Girders shall be
water cured for a period of 21 days from the date of casting as per OCS Clause No.3.20(e).
10.14 Stacking
While transporting the U-Girder from the casting yard to the stacking yard, two riggers shall be moving
along with the gantry rail by using guide rope for safe movement
• Before lifting of every U-Girder, care shall be taken such that the U-Girder is attained required
strength as per the specifications. For U-Girder lifting purpose, suitable lifting beam shall be used
as per the sketch shown below.
Fig; Details of Lifting Beam for U-Girder at Casting Yard

Fig; Details of Stacking U-Girder at Casting Yard
11. MANDATORY SAFETY REQUIREMENTS:

• Every workman must be engaged after Screening, Safety induction & medical test with a valid ID
card.
• Appropriate PPE shall be used at all times.
• Work shall be executed in competent and continuous supervision.
• Any un-authorized activity shall be strictly prohibited.
• There should be proper co-ordination and communication between teams/workmen at all times.
• Proper housekeeping shall be maintained.
• Required inspections shall be carried out prior to start work.
• Proper illumination shall be maintained during night work.
• Permit system shall be followed for activities such as height work, night work and hot work.
• TBT shall be conducted before starting work.
12. TRAINING & EDUCATION:

10.8 Daily safety pep talk shall be given by Construction Manager to the staff and workmen.
10.9 Before commencement of the work, Construction Work Procedure shall be explained to the staffs.


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CHENNAI METRO RAIL LIMITED

“CONSTRUCTION OF ELEVATED VIADUCT (APPROXIMATE LENGTH OF 10 KM),

(PROJECT PHASE 2, CORRIDOR 3)

TENDER No. C3/ECV-01/RT01

RAIL VIKAS NIGAM LIMITED

CHENNAI METRO RAIL LIMITED

CMRL – C3/ECV-01/RT01 PROJECT

“CONSTRUCTION OF ELEVATED VIADUCT (APPROXIMATE LENGTH

TENDER No. C3/ECV-01/RT01

RAIL VIKAS NIGAM LIMITED

2 CHENNAI METRO RAIL LIMITED C3/ECV-01/RT01

3. REFERENCE DOCUMENTS ........................................................................................................................ 4

8. MACHINE, EQUIPMENT, TOOLS & TACKLES: .......................................................................................... 10

9. SEQUENCE OF WORKS: .......................................................................................................................... 10

10. WORK PROCEDURE: .......................................................................................................................... 11

10.1 GENERAL ARRANGEMENT OF CASTING YARD....................................................................................................... 11

12. TRAINING & EDUCATION: .................................................................................................................. 33

3 CHENNAI METRO RAIL LIMITED C3/ECV-01/RT01

• CMRL : Chennai Metro Rail Corporation

4 CHENNAI METRO RAIL LIMITED C3/ECV-01/RT01

Project Manager - Shall be responsible for the overall execution of Precast

Dy. Project Manager - Reporting to the Project Manager.

- Documentation /protection of benchmark and survey points.

- Interacting with Engineer’s survey department representatives.

5 CHENNAI METRO RAIL LIMITED C3/ECV-01/RT01

- Quality at all the stages shall be ensured.

Quality Incharge - Reporting to the Project Manager.

Fabrication Incharge - Interacting with Engineer’s representatives and internal departments.

- Ensure operation of P&M as per company norms

Chief SHE Manager - Shall report to Project Manager.

7 CHENNAI METRO RAIL LIMITED C3/ECV-01/RT01

- Responsible for provision of risk assessment.

Construction Prestressing Sr. SAFETY

Sl.No. Name Brand / Source Conforms Remarks

8 CHENNAI METRO RAIL LIMITED C3/ECV-01/RT01

Sl.No. Name Brand / Source Conforms Remarks

11 Hessian cloth Locally available ------

9 CHENNAI METRO RAIL LIMITED C3/ECV-01/RT01

8. MACHINE, EQUIPMENT, TOOLS & TACKLES:

1 100 MT Capacity Gantry 02 Nos.

5 Concrete Cube mould 150*150*150 mm Size 150 Nos.

6 Total Station With Accessories 1Sec Accuracy 02 Nos.

7 Auto Level 02 Nos.

8 Welding Machine 03 Nos.

9 Hydraulic jack With Power Pack 400T capacity 06 Nos.

10 Immersion Vibrator 6 Nos.

11 Mould Vibrator 20 Nos.

12 Casting Moulds – Straight bed 26 Nos.

10. WORK PROCEDURE:

1) Light masts shall be provided for illuminating the casting area.

5) Reinforcement cutting and bending shall be done at Casting Yard.

11 CHENNAI METRO RAIL LIMITED C3/ECV-01/RT01

10.2 Precast Yard Mould

I. Inner form assembly

10.3 Soffit Assembly

10.4 Outer Shutter Assembly

5 Concrete Cube mould 150150150 mm Size 150 Nos.