NHSRCL casts 40m full span box girder for Bullet Train project in Maharashtra

The National High-Speed Rail Corporation Limited (NHSRCL) has successfully cast its first Full Span Pre-Stressed Concrete (PSC) Box Girder of 40 meters for the Maharashtra section. Weighing 970 MT, this engineering feat enhances the pace of viaduct construction for the Mumbai-Ahmedabad Bullet Train Project, marking significant progress in India’s infrastructure development.


Details of the Girder:

  • The 40m span PSC Box Girder weighs around 970 MT, making it the heaviest of its kind in India’s construction industry.
  • It is cast as a single piece without construction joints, involving 390 cubic meters of concrete and 42 MT of steel.

Construction Strategy:

To expedite viaduct construction, the substructure (pile, pile cap, pier, and pier cap) and superstructure (girders) are being constructed in parallel. Full Span Girders are preferred due to their faster launching process, up to ten times quicker than Segmental Girders.

Casting Yards and Facilities:

  • 13 casting yards are planned along the Maharashtra alignment, with three already operational.
  • Advanced facilities, including hydraulically operated moulds, batching plants, quality laboratories, and workmen camps, ensure the quality and efficiency of girder production.

Launch and Machinery:

The Full Span Box Girders will be launched using heavy machinery, including Straddle Carriers, Bridge Launching Gantries, Girder Transporters, and Launching Gantries. To ensure uninterrupted progress, girders are pre-cast and systematically stacked in advance.

Comparison with Gujarat Section:

Since April 2021, similar technology has been employed in Gujarat, where 255 km of viaduct construction has been completed. In Maharashtra, the alignment includes a 135 km elevated section with four major river bridges, 11 special crossings, three stations (Thane, Virar, Boisar), and seven mountain tunnels.

Conclusion:

The casting of the first 40m Full Span Box Girder marks a major leap in the Maharashtra section of the Mumbai-Ahmedabad Bullet Train Project. With advanced technology and streamlined processes, the NHSRCL is setting new benchmarks for infrastructure development, aiming to accelerate progress and achieve timely completion of this transformative project.


Source: NHSRCL – Press Release | Images Credit: NHSRCL

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