CASTING YARD

A casting yard is a confined place where all the concrete structures like
segments, parapets, I- girders/beams, boundary wall panels, cable troughs etc. Re-
casted/manufactured, shifted to their stack yard, cured for the specific period/days
and then shifted to the working site/viaduct after they gain their required strength.
Different concrete structures manufactured in this casting yard are
 U - girders
 I - girders
 Pier caps
 Cross-arm
Different steps involved in casting are caging, moulding, stressing, placing of
concrete, curing and dressing. Casting of all girders include all the above steps but
their order depends on type of stressing implemented in the casting yard.

Caging:

The process of preparing the reinforcement cage according to the its structural
reinforcement design is called caging. The cage is prepared separately in a stand. All
the steel bar that are used are bent according to the reinforcement bending schedule
before starting this process. The caging process of all the girders is same but they
vary in their design.

In the caging of i-girders, pier-caps and cross-arms the pipes are used for
stressing are supported by means of extra steel rods. After the cage in made the
reinforcement is checked to ensure that it is according to the reinforcement schedule.
 The cage of i-girder

The cage of u-girder

 Cage of pier-cap

Moulding

The mould is prepared by using the pre-casted steel structures. For the u-
girders the cage is lifted and placed in the mould with the help of a gantry crane. The
iron stand is lifted and placed above the cage so that the cages is fixed in between
them tightly to ensure the proper concreting. Grease is applied to the surface of iron
stands to prevent the bond and chemical reactions between concrete mix and steel.

For the I-girder the mould is attached to the cage by combing and attaching
iron stands. The stand are pre-casted and all the units are combined to form the
complete mould. For the i-girders caging and mould is done in the same place.
Lifting and placing of iron stands to prepare mould of i-girder

Mould preparation of i-girder

 Mould of a cross-arm

For the pier caps and cross arms the cage is prepared with in the mould
according to the reinforcement design. It consists of a converging circular section in
which the upper section of the pier is fixed. This mould is also prepared with same
materials as of I and u girders. For some pier caps the mould is directly prepared
above the piers and are casted there itself.

The cement pieces to which galvanised iron wires are attached to the
reinforcement which are cover blocks to ensure proper support for the reinforcement
on the mould.

Concreting

The reinforcement is checked by officials before concreting. The concrete mix

is prepared in the batching plant in the site. The concrete obtained is transported to
the structure by the ready mix concrete trucks. From these trucks the concrete is
poured in to the concrete pumps. The concrete is pumped in to the mould by the
pipe.
 Concrete pump

Concreting of u-girder

The avoid segregation and bleeding of concrete electric external vibrators are
used the are dipped into the concrete immediately after the concrete is placed. The
levelling of surface is done manually with help of wooden bars. The concreting
process is continuously monitored by officials to ensure that concrete is filled exactly
according to the design.

Concreting of i-girder

STRESSING
Stressing can be defined as subjecting the beam to th tension. It can also be
called as tensioning. There are two types of stressing they are
 Pre-stressing (or) Pre-tensioning
 Post-stressing (or) Post- tensioning

Pre-tensioning
Procedure:
Pre-tensioning is accomplished by stressing wires or strands, called tendons,
to predetermined amount by stretching them between two anchorages prior to
placing concrete as shown in figure. The concrete is then placed and tendons become
bounded to concrete throughout their length. Once concrete has hardened and
reaches the required strength, the stretching forces are released. The tendons are
released by cutting them at the anchorages. The tendons tend to regain their original
length by shortening and in this process transfer through bond a compressive stress
to the concrete. The tendons are usually stressed by the use of hydraulic jacks. The
stress in tendons is maintained during the placing and curing of concrete by
anchoring the ends of the tendons to abutments. The abutments and other formwork
used in this procedure are called pre-stressing bench or bed.
 Applying tensional force to tendons at stressing

Fig(a).
Fig(a) :
it shows the rim to which the tendons are attached inside and to the ouside extending rods
hydraullic jacks are fixed
Achievement of compressive strength by concrete:
The stretching forces are released the concrete reaches the required strength.
As the steel reacts to regain its original length, the tensile stresses are translated into
a compressive stress in the concrete. The amount of bond achievable between the
freshly set concrete and the surface of the tendons is critical to the pre-tensioning
process, as it determines when the tendon anchorages can be safely released. Higher
bond strength in early-age concrete allows more economical fabrication as it speeds
production. To promote this, pre-tensioned tendons are usually composed of
isolated single wires or strands, as this provides a greater surface area for bond
action than bundled strand tendons.

The hydraulic jacks are released once the concrete hardens

Advantages:
The main advantage of this pre-stressing process is that These anchorages form the
ends of a "casting bed" which may be many times the length of the concrete element
being fabricated. This allows multiple elements to be constructed end-on-end in the
one pre-tensioning operation, allowing significant productivity benefits and
economies of scale to be realised for this method of construction.
Pre-stressing record sheet
 Anchoring end in u-girders

Applications in field
Here in the field pre-stressing is adopted only for u-girders because more number
of u-girders can be pre-tensioned in a single span. Post-tensioning can also be
adopted for u-girders but only one u-girder can be pre-stressed once. So it takes very
long time for post-tensioning all the girders. This is also one of the reasons for
adopting pre-stressing for u-girders.

Post-tensioning
In the post-tensioning method, the tendons are stressed and each end is
anchored to the concrete section after the concrete has been cast and has attained
sufficient strength to safely withstand the pre-stressing force. In post-tensioning
method, tendons are coated with grease or a bituminous material to prevent them
from becoming bonded to concrete. Another method used in preventing the tendons
from bonding to the concrete during placing and curing of concrete is to encase the
tendon in a flexible metal hose before placing it in the forms. Here in this project
second method is adopted that is the tendons are encased with plastic pipes. In post-
tensioning it is necessary to use some types of device to attach or anchor the ends of
the tendons to the concrete section. These devices are usually referred to as end
anchorages. The metal hose is referred to as sheath or duct and remains in the
structure.
After the tendon has been stressed, the void between the tendon and the sheath is
filled with grout. Thus the tendons become bonded to concrete and corrosion of steel
is prevented. Post-tensioning can be done at site.

Applications in field:

This post-tensioning method is employed for pre-casted structures like I girders, pier
caps and cross-arms. As i-girders are lesser in magnitude of cross-section it is easier
to carry out post-tensioning method. As the span length and cross-sectional area of
I-girders vary, it depends on the span between the two piers and mode of their
application. same reason can be applied in case of the cross-arms and pier caps.

post-tensioning in i-girder

Advantages:
This procedure may become necessary or desirable in certain cases. For heavy loads
and large spans in buildings or bridges, it may be very difficult to transport a member
from pre-casting plant to a job site.

Curing:

The curing method followed is membrane curing the surface of all these
structures are covered by gunny bag membranes. The concrete mix is designed in
such a way that it gains its strength and hardens in 3 days.

Curing of u-girders

launching:

These structures are placed on the lanes in between piers by using heavy
cranes. U-girders are used for continuous route and short span length between piers.
In between two piers only two u-girders can be placed. A pier cap can accommodate
two u-girders exactly.
 Cross arm is used because of a turn in the lane

Portal beam on which six i-girders are placed

I -girders are used for long span and also multiple tracks can be laid on the
deck slab on i-girders. Cross arm also accommodates two u girders but it gives a
large space between them so they are used in case of turns in the lane. I girders are
also used while the lane approaches the station because the tracks need to be divided
before the station. In case of more number of platforms more number of tracks are
required so more number of I girders should be used. At this points portal beams
are used they can accommodate up to seven I girders.

Pier-cap carrying i-girders on both sides

Pier cap carrying both I and u girders on either sides

Deck slab:
 The slab laid on the I girders is called as deck slab. Deck sheets are placed on
the gaps between I girders. These deck sheets are made up of galvanised iron.

Placing of deck sheets on i- girders

Deck slab
 The decks sheets act as form work for the slab. The quantity of deck sheets
required depends on the length of the i- girders used. They are 1m in length exactly
and approximately 1.3m in width. Crossings of tracks can be made on deck slab near
stations.

Pedastal:

A concrete pedestal is a compression element provided to carry the loads fromm

supported elements like pier-cap, cross-arm and portal beam. The width of the
pedestal is greater than the height. The main functions of a pedestal are

 To avoid the contact between concrete and the elements of metal and wood in
the formwork.

 To offer support elements at some elevation.

Pedestal below the u-girder

Seismic stoppers:

Seismic stopper are mainly based upon the concept of vibration control devices with
capability of giving a stable stage to a structure. It mainly absorb the vibrations and
prevent the collapse of structures. They restrain the transverse and longitudinal
seismic movements of the deck.

Here two types of seismic stoppers are used

 Transverse seismic stoppers

 Longitudinal seismic stoppers

Transvers seismic stoppers are used to restrain the transverse seismic

movements and longitudinal seismic stoppers are used to restrain longitudinal
seismic movements.

The concrete block in middle shows transverse seismic stopper

 The drawing of stoppers alignment on pier cap

Diaphragm:

The major functions of a diaphragm are

 Diaphragms provide transverse shear capacity. They help in load sharing

between different girders so that the shear and transverse loads are reduced on
girders vertical and horizontal loads.

 Diaphragms provide transverse flexural capacity. They provide local

stiffening for the deck slab resulting in better load distribution and and there
by decreasing transverse reinforcement in the deck slab.
 Middle diaphragm

End diaphragm

Drawings of diaphragms

 Diaphragms provide torsional restraint for longitudinal girders. Girders are

not torsionally fit. In case of longer spans even simple loads like wind in the
deck slab can cause twisting in the girders.
 Abstract

The main aim of this project report is to study about the casting yard, details
about various structures manufactured in the casting yard and the deck slab and its
components in the construction of Noida – Greater Noida Metro Project (NC03). It
is a CEC and SAM India joint venture project (JV) to establish link between the twin
cities of Noida and Greater Noida.

Table of contents:

 Casting yard

 Caging

 Moulding

 Stressing

 Concreting

 curing

 launching

 Deck slab

 Seismic stoppers

 diaphragm
 Acknowledgement
It is a genius pleasure to express my sense of gratitude to Mr. P V SURYA
PRAKASH RAO, Deputy General Manager (HR and Admin), CEC group for giving
us an opportunity to explore the knowledge in this project and his guidance.
We also profeously thank Mr. Mangal Singh, Sr. Engineer of casting yard for all his
support for us and help.
We also thank MR. Vishal, engineer in deck slab and launching for helping us in
knowledge of components of deck slab and portal beams

Introduction
CEC international corporation (india) private limited is a wholly owned
subsidiary of Continental Engineering Corporation (CEC) established in 2005 is a
civil engineering and construction company in Delhi.
CEC India office has received the letter of acceptance dated on may 15, 2015
for three contracts on the Noida-Greater Noida Metro Project in India. The Project
scope includes design and construction of approximately 30,000m elevated viaducts
and 21 elevated stations.
The project was awarded to CEC-SAM India Joint Venture. The total contract
value is INR 15.076 billion for the three contracts: NC-01, NC-02 and NC-03. The
metro construction project is a part of the latest Delhi Metro development and will
connect the twin cities of Noida and Greater Noida. Upon completion it shortens
the travel time between two cities, which are presently connected by road
transportation system. The project construction is 24 months.
 Project Repot

Noida-Greater Noida Metro

Project
CEC-SAM India JV
Under the guidance of industrial experts

MR. P V Surya Prakash Rao

Deputy General Manager ( HR and Admin)
CEC India pvt ltd.

Mr. Mangal Singh

Manager (Civil)

Mr. Vishal (Engineer deck slab)

Students
K. Rakesh Naidu (15341A0124)
K. Khaleel (15341A0129)
P. Anand Swaroop Varma (15341A0142)