The 40-meter-long girder, weighing approximately 970 metric tonne, stands as the heaviest PSC Box Girder in India’s construction history. Cast as a single piece without construction joints, the girder demonstrates a major advancement in India’s rail infrastructure. It required 390 cubic meters of concrete and 42 metric tons of steel, reflecting the engineering precision involved in its production. This achievement is part of efforts to expedite viaduct construction, with substructure and superstructure work being carried out simultaneously to accelerate project progress.

The release stated that substructure work—comprising the construction of piles, pile caps, piers, and pier caps—is underway, while 13 casting yards have been developed along the Maharashtra alignment, extending from Shilphata to the Gujarat-Maharashtra border. Currently, three of these casting yards are operational, equipped to produce both full-span and segmental box girders. The full-span 40-meter girders, which enable construction progress up to ten times faster than segmental girders, will be used extensively.

Advanced machinery such as Straddle Carriers, Bridge Launching Gantries, and Girder Transporters will launch the full-span girders. To ensure seamless construction, the girders will be pre-cast in advance and systematically stored at the casting yards. These facilities are equipped with state-of-the-art technology, including jigs for rebar cage production, hydraulically operated prefabricated moulds, batching plants, and quality control laboratories, to maintain high standards and streamline the process.

The Maharashtra section of the Bullet Train corridor spans 135 kilometers and features critical infrastructure, including four major river bridges (Ulhas, Vaitarna, Jagani, and Kharbao), 11 special bridges over national highways and railway lines, and three stations located in Thane, Virar, and Boisar. Additionally, seven mountain tunnels are planned along the route.

The release further noted that the approach to girder construction and the development of casting yards has already proven successful in the Gujarat section of the corridor. Significant progress has been achieved there since April 2021, with 255 kilometres of viaduct completed, highlighting the effectiveness of this innovative technology.

News source: ET Infra