DELHI METRO RAIL CORPORATION

ELEVATED VIADUCT FROM KM 0.62 TO KM 8.00 ON BARAKHAMBA ROAD CONNAUGHT PLACE DWARKA SECTION (LINE NO.3) 3C21R

METHOD STATEMENT FOR LAUNCHING OF SEGMENTS

Document No Pages Date

: 215/DMRC/3C21R/MS-13/R- 1 : 1 TO 141 : 09.04.2004

CONTRACTORS:

IJM-NBCC- VRM JV

CONSULTANTS: ARCH CONSULTANCY SERVICES (P) LTD.

IN ASSOCIATION WITH

BRIDGECON INDIA

CONTENTS

1.0 Drawings

INTRODUCTION

Configuration requirement for Delhi metro project Steel Fabrication Safety 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3.1 4.3.2 MAIN COMPONENTS OF LAUNCHING GIRDER General Main Box Girder Front Support Middle Support Rear Support Rear Trolley Slider Beam Moving Trolley Counter Weight Fixed Mounted Hoist Platform / Walk way SCHEME FOR AUTOLAUNCHING General List of Drawings for ready reference Steps for Auto Launching STAGES OF ERECTION OF SPAN General List of Drawing Erection Procedure for 31.0m Span Erection Sequence of Precast Segments in Different Span

5.0 5.1 5.2 5.3 6.0

MANUAL FOR ERECTION OF FIRST SPAN General List of Drawings Erection of Launching Girder in First Span. REFERENCES ANNEXURE A PROCEDURE FOR VERTICAL ROTATION

A.1 A.2 A.2.1 A.2.2 A.3 A.4 A.4.1 A.4.2

General Detailed Description of Various Conditions of Launching Girder in Vertical Grade & Corresponding Height Adjustment of its Supports. Down Grade Up Grade Permissible Range of Height to be Ensured at Front Support Calculation of Height at Front Support For a Known Height at Rear Trolley and Middle Support Down Grade Up Grade ANNEXURE B PROCEDURE FOR MOVEMENT OF MIDDLE SUPPORT / REAR SUPPORT USING MOVING TROLLEY ANNEXURE C PROCEDURE FOR RAISING / LOWERING OF TELESCOPIC LEG / BOTTOM BEAM OF FRONT SUPPORT

1.0

INTRODUCTION This document has been specifically written for the Launching Girder to be used in DMRC Project: BARAKHAMBA ROAD CONNAUGHT PLACE DWARKA SECTION (LINE NO.3) This document covers following sections:(a) (b) (c) (d) Description of Launching Girder Scheme for Auto Launching & Erection Description of Operations performed by various parts of Launching Girder. Safety

1.1

CONFIGURATION REQUIREMENT FOR DELHI METRO PROJECT This section includes requirements and information regarding the configuration of the bridge and Launching Girder

S.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Item Maximum span length Minimum span length Maximum longitudinal slope Maximum weight of segment Maximum length of segment Minimum Horizontal radius Total height of intermediate segment Total height of end segment Segments gluded or dry jointed Loading of segments from ground / rear

Criteria 31.0m 16.0m 2.74% 80.0 t 3.0m 302.05m 2.0m 3.0m Epoxy Glue From ground only

1.2

DRAWINGS: The following drawings apply to DMRC project:

S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.

Title General Arrangement of Launching Girder Details of Launching Girder (Sh.1 of 3) Details of Launching Girder (Sh.2 of 3) Details of Launching Girder (Sh.3 of 3) Details of Monorail General Arrangement Erection stage lifting Details of wire rope assembly for intermediate segment Scheme for auto launching (Sh.1 of 3) Scheme for auto launching (Sh.2 of 3) Scheme for auto launching (Sh.3 of 3) Details of Middle Support (Sh.1 of 7) Details of Middle Support (Sh.2 of 7) Details of Middle Support (Sh.3 of 7) Details of Middle Support (Sh.4 of 7) Details of Middle Support (Sh.5 of 7) Details of Middle Support (Sh.6 of 7) Details of Middle Support (Sh.7 of 7) Details of Front Support (Sh.1 of 6) Details of Front Support (Sh.2 of 6) Details of Front Support (Sh.3 of 6) Details of Front Support (Sh.4 of 6) Details of Front Support (Sh.5 of 6) Details of Front Support (Sh.6 of 6) Details of Rear Support (Sh.1 of 3) Details of Rear Support (Sh.2 of 3) Details of Rear Support (Sh.3 of 3) Details of Rear Trolley (Sh.1 of 5) Details of Rear Trolley (Sh.2 of 5) Details of Rear Trolley (Sh.3 of 5) Details of Rear Trolley (Sh.4 of 5) Details of Rear Trolley (Sh.5 of 5) Details of Sliding Beam (Sh.1 of 2) Details of Sliding Beam (Sh.2 of 2) General Arrangement for Temporary Prestressing (25.0m) Details of Lifting & Temporary Prestressing for End Segments Erection Stage (Sh.1 of 4) Details of Lifting & Temporary Prestressing for End Segments Erection Stage (Sh.2 of 4) Details of Lifting & Temporary Prestressing for End Segments Erection Stage (Sh.3 of 4) Details of Lifting & Temporary Prestressing for End Segments Erection Stage (Sh.4 of 4) Details of Lifting & Temporary Prestressing for Intermediate Segments Erection Stage (Sh.1 of 6) Details of Lifting & Temporary Prestressing for Intermediate Segments Erection Stage (Sh.2 of 6)

Drawing No. 215/LG/01 215/LG/02 215/LG/02 215/LG/02 215/LG/03 215/LG/04 215/LG/05 215/LG/06 215/LG/06 215/LG/06 215/LG/07 215/LG/07 215/LG/07 215/LG/07 215/LG/07 215/LG/07 215/LG/07 215/LG/08 215/LG/08 215/LG/08 215/LG/08 215/LG/08 215/LG/08 215/LG/09 215/LG/09 215/LG/09 215/LG/10 215/LG/10 215/LG/10 215/LG/10 215/LG/10 215/LG/11 215/LG/11 215/LG/12 215/LG/13 215/LG/13 215/LG/13 215/LG/13 215/LG/14 215/LG/14

41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51.

Details of Lifting & Temporary Prestressing for Intermediate Segments Erection Stage (Sh.3 of 6) Details of Lifting & Temporary Prestressing for Intermediate Segments Erection Stage (Sh.4 of 6) Details of Lifting & Temporary Prestressing for Intermediate Segments Erection Stage (Sh.5 of 6) Details of Lifting & Temporary Prestressing for Intermediate Segments Erection Stage (Sh.6 of 6) Scheme for Erection of precast segments (Sh.1 of 2) Scheme for Erection of precast segments (Sh.2 of 2) Details of Bracket for fixed-mounting-hoist Details of counter weight Erection sequence of launching girder in first Span (Sh.1 of 3) Erection sequence of launching girder in first Span (Sh.2 of 3) Erection sequence of launching girder in first Span (Sh.3 of 3)

215/LG/14 215/LG/14 215/LG/14 215/LG/14 215/LG/15 215/LG/15 215/LG/16 215/LG/17 215/LG/18 215/LG/18 215/LG/18

Note: A complete set of above drawings should be available at site for ready reference. 1.3 STEEL FABRICATION The Launching Girder including all its accessories will be fabricated with the drawings supplied by Arch Consultancy Pvt. Ltd. unless otherwise communicated through a written document. Items modified or rectified during assembly shall be reported for discussion & final details must be supplied to Arch Consultancy Services Pvt. Ltd. 1.4 SAFETY Safety shall be ensured as per safety manual. This manual should include the following information: Safety Personnel Site Training Personal Protection Equipments i.e. safety boots, safety nets. Lifting of parts and equipments Use of flame cutter and welding sets Storm wind / Emergency conditions

High power cable

2.0 2.1

MAIN COMPONENTS OF LAUNCHING GIRDER General This sections gives a brief description of main parts of Launching Girder. Reference shall be made to the detailed drawings. This section is built up as follows: Main Box Girder..(Refer Drg .No. LG /02 sheet 1 of 3 to 3 of 3) Front Support...(Refer Drg .No. LG /08 sheet 1 of 6 to 6 of 6) Middle Support....(Refer Drg .No. LG /07 sheet 1 of 7 to 7 of 7) Rear Support....(Refer Drg .No. LG /09 sheet 1 of 3 to 3 of 3) Rear Trolley.....(Refer Drg .No. LG /10 sheet 1 of 5 to 5 of 5) Slider Beams....(Refer Drg .No. LG /11 sheet 1 of 2 to 2 of 2) Moving Trolley....(Refer Sketch No. LG/SK-02) Counter Weight....(Refer Drg .No. LG /17) Fixed Mounted Hoist...(Refer Drg .No. LG /16) Platform / Walk ways...

2.2

Main Box Girder

Main Box Girder has been split in seven close plate girder (box type steel structures) of length 9.250m each. These are spliced at their ends with the help of 24 dia. HSFG bolts. The details of splicing & bolting arrangements have been shown in drawing no. (LG/02 Sheet 1 of 3 to Sheet 3 of 3). Bearing stiffeners have been provided at all support locations covering all span ranges. In addition normal stiffeners are also provided at 975 c/c. The Launching Girder main box structure rests on four supports viz. Front Support Middle Support Rear Support Rear Trolley

2.3

Front Support Front Support consists of following parts Top Beam Top vertical leg Telescopic leg Bottom Beam Slide bracing & Tie members

This support has in built ability for adjustment of height depending upon the situation encountered at the site. This flexibility is provided by the telescopic leg which can move into the top vertical leg & can be locked using 100 pin provided in the support. The tie members are fixed to the top vertical leg. The side bracing connects top vertical leg with the bottom beam. The change in length of side bracing during adjustment in height of support can be partially done by changing its points of connection with vertical leg for which four different connection holes have been provided & partially by 300mm long screw jack provided at its bottom.

The entire support rest on concrete pedestals provided in the pier cap as shown in the drawing no. LG/08, The Front Support is secured to the pier cap using 32 anchor bolts. Note: Maximum height of the front support = Minimum height of the front support 5370mm = 3690mm

Measured from top of support to bottom of its bottom beam. The front support is fixed at 2500 mm from the front of the launcher. Two nos. vertical hydraulic jacks (150t capacity) are provided to carry out vertical adjustment of the support. Side shifting of front support with respect to Launching Girder is not possible.

10

11

12

13

2.4 Middle Support The middle support is positioned on the rear pier segment and supports the launching girder together with the front support during the span erection. The level of middle support can be varied using 4 number single acting hydraulic jacks, (200T capacity). Middle Support consist of following main parts (1) (2) (3) 3.1 3.2 3.3 (4) (5) Side beam B2 2nos. Cross beam B1 Launching bearing 2nos. Longitudinal sliding bearing Kunckle bearing Cradle Longitudinal pushing assembly Braking assembly

Side beams (B2) rests over 200t capacity single acting jacks as shown in the drawing no. LG/07 & forms the basic supporting structure of middle support. Side Beams (B2)

14

are connected by cross beam B1 provided at its top. Cross beam provide support and sliding surface (Stain less Steel top) for the Launching Bearing. Launching Bearing consists of three parts a) Longitudinal sliding bearing which consists of a sliding surface over which the launching girder slides during auto launching process. b) Knuckle bearing, it consist of a 165 pin connecting four vertical plates. The launching girder can be vertically rotated over this knuckle pin. c) Cradle consists of a vertical pin embedded into steel stool over which the whole Launching girder can rotate horizontally. It is provided with a PTFF sliding surface at its bottom side, which assists its transverse movement over cross beam B1. The whole assembly of launching-bearing can be pulled when required by the help of macalloy bar connecting the cross B1 & the cradle to ensure proper position of the launching bearing with respect to the cross beam B1. Longitudinal pushing assembly is an independent device attached to the monorail on front side of middle support through longitudinal movement jack connected to a bracket provided at center of plate connecting the two cradles. This assembly is responsible for forward movement of launching girder during auto launching operation. Braking assembly is another independent assembly provided at the rear side of middle support. It is mounted on monorail & can be connected to the middle support through 40 pin as shown in the drawing LG/07. When this assembly is connected to the support it restricts forward movement of launching girder with respect to the support.

15

16

17

2.5

Rear Support:Rear Support is a replica of middle support except that longitudinal pushing assembly is not provided in this support. As rear support shares lesser load compared to load shared by middle support therefore the capacity of supporting jacks have been restricted to 100t as shown in the detail drawing LG/09.

18

19

20

2.6

Rear Trolley The Rear trolley is positioned 4450mm from the rear end of the main box girder and provides support during longitudinal launching. It is A type truss supported on eight wheels which rests on 90R rails laid on the erected superstructure at a spacing of 4.7m c/c. The top beam of the truss is connected through four no knuckle pins so that it can rotate vertically if required & maintain proper contact with the Launching Girder. Launching Girder rest directly on the top beam of this support through SS verses SS interface provided between the two. After launching along a curved span, it is necessary for the main box to be side shifted on the rear trolley. Macalloy bars have been provided to pull the main box over stainless steel plates fixed on top beam of the rear trolley. The Launching Girder can be locked with respect to this support with the help of four set of macalloys bars passing through brackets provided in launching girder & movable bracket consisting of two ISMC 200 & bolted at top & bottom end.

21

22

23

2.7

Slider Beams Slider beams are independent assembly of two built up I sections connected together with the help of stiffeners. Slider beams rests on 40 x 40 plate with 3 thick SS plate fitted on top of launching girder main box as shown in drawing no.LG/02. The slider beams are provided with two suspender bars at each end, which can move 500mm on either side in transverse direction while maintaining a constant distance of 5.8m among themselves. The tension bars are connected to two beams that have been secured to the precast segment. Vertical adjustment is carried out using the vertical tension bars while transverse movement is done using the horizontal jacks positioned on top of the slider beam. The longitudinal position of segment / slider beam is adjusted through a cable running through all the slider beams which is pulled by two monojack fitted at extreme ends of the launching girder main box.

24

25

26

27

2.8

Moving Trolley Moving trolley is an independent device consisting of two stools resting on a platform mounted on four wheels. It is mainly used for forward movement of middle support & rear support. Moving trolley is also useful for temporarily supporting the rear support & middle support for minor repair / maintenance of supporting jacks. Note: Moving trolley is not designed for supporting middle support or rear support during erection & the same shall be avoided.

28

29

2.9

Counter Weight A counterweight is provided in the form of pre-cast concrete segments, which will remain fixed at the rear end of Launching girder during entire launching process unless otherwise specified in some special circumstances. This counter weight balances the launcher during auto launching of the Launching Girder.

2.10

Fixed Mounted Hoist It is a electrically operated device fixed over a bracket provided at 13.4m from the front end of the Launching Girder. It has a lifting capacity of 80 t & is meant for lifting of precast segment during erection stage.

2.11

Platform / Walk way Working platforms have been provided at all the supports for operating mechanisms associated with each support. Details of access plat forms have been provided in the detailed drawings of the supports. The main body of the Launching Girder is a close box type structure with a width of 2.0m so that persons operating the Launching Girder can walk along its entire length when required. However, in general practice, a separate ladder shall be used wherever permanent access is not provided.
30

31

32

3.0 3.1

SCHEME FOR AUTOLAUNCHING OF LAUNCHING GIRDER GENERAL The term auto launching used here stands for forward movement of Launching Girder from already erected span to the span to be erected. This section gives a simplified step-by-step sequence of auto launching of Launching girder in chronological order of auto launching process. Extracts from various drawings have been incorporated for ready reference to site engineers. To simplify and to avoid mishapenings during auto launching several checklists have been presented along with the following detail, which shall be strictly adhered by the construction engineers.

3.2

LIST OF DRAWINGS FOR READY REFERENCE Drawing nos. LG/06 (Sh. 1 of 3 to Sh. 3 of 3) Title Scheme for Auto Launching

33

3.3 STAGE 1 Step 1 Step 2

STEPS FOR AUTO LAUNCHING

The Launching Girder rests on the already erected span as shown. Bring the slider beams backward so that one slider beam rests at 4.45 m from the end of Launching Girder (Near Rear Trolley) & all other slider beams rests in succession at spacing of 0.9m.

Step 3 Affix the 90 R rails on the newly erected span for further movement of Launching Girder.

34

35

STAGE 2 Step 1 Remove the brakes provided at middle support by removing pins connecting monorail & the braking assembly. Step 2 Check the Jacks of Rear Support & ensure that it experiences a minimum reaction of 10tonnes (total reaction on four jacks) on it. Step 3 Position the moving trolley below the middle support exactly at the center of it. Step 4 Close the jack of middle support so that the reaction on the jack of middle support is fully released. As a result of which, the reactions will be transferred on the jacks of rear support & the middle support finally rests on the moving trolley. Note: Allowable reaction to be transferred on intermediate segment through rear support = 120tonnes Step 5 Open the anchors of middle support to allow its forward movement.

Step 6 Move the middle support with the help of moving trolley & position it over the front pier segment of newly erected span so that a distance of 0.9 m is achieved between the expansion joint of the span & centerline of the middle support. (Refer sketch showing position of middle support over pier segment in plan on next page) Note: Refer detailed procedure for movement of middle support /rear support using moving trolley from annexure B. Step 7 Open the jacks of middle support to transfer a minimum reaction of 10tonnes on it ensuring that the moving trolley is released.

36

Step 8 Anchor the middle support (i.e. tie it with the pier segment). Now move the moving trolley from the middle support position & place it below rear support.

37

Step 9

Apply brakes at middle support.

Step 10Remove the brakes provided at rear support by removing pins connecting monorail & the braking assembly. Step 11Close the jacks of rear support so that the reaction on jacks is fully released as a result of which the reaction will be transferred automatically over jacks of middle support & the rear support finally rests on the moving trolley. Step 12Open the anchors of rear support to allow its forward movement.

38

STAGE - 3

39

Step 1 Move the rear support with the help of moving trolley & position it over pier segment as shown so that a distance of 0.9m is achieved between center line expansion joint of the span & the center line of the rear support. (Refer sketch showing position of rear support over pier segment in plan on next page) Note: Refer detailed procedure for movement of middle support /rear support using moving trolley from annexure B. Step 2 Anchor the rear support at this position (i.e. tie it with the pier segment).

Step 3 Open the jacks of rear support so that the jacks experiences a reaction of 10tonnes (total reaction on four jacks) on it. Step 4 Apply brakes at rear support.

Step 5 Move the moving trolley from rear support position & place it below middle support. Step 6 Remove the brakes provided at middle support by removing pins connecting monorail & the braking assembly. Step 7 Close the jacks of middle support so that the reaction on jacks is fully released as a result of which, the reaction will be transferred over jacks of rear support & the middle support rests over moving trolley.

40

41

42

STAGE - 4 Step 1 Move the middle support & position it over front pier segment of the newly erected span so that a distance of 0.9m is achieved between centerline expansion joint of the span & the centerline of middle support as shown. (Refer sketch showing position of middle support over pier segment in plan on next page) Step 2 Open the jacks of middle support to transfer a reaction of 10tonnes (total reaction on four jacks) on it. Step 3 Anchor the middle support (i.e. tie it with the pier segment).

Step 4 Attach longitudinal movement jack with the middle support Step 5 Remove the 100 pin provided in the telescopic leg of the front support using jacks provided over the bottom beam of front support. Step 6 Close the jacks of the front support & remove the jacks along with stools provided, so that the reaction is fully transferred to the middle support. STAGE - 5 Step 1 Close the telescopic leg of front support to its minimum length as shown in the drawing and lock it in this position so that the front support hangs over the launching girder. Note: Refer detailed procedure for lowering / raising of bottom beam/ telescopic leg of front support from annexure C.

43

44

45

46

STAGE 6 Step 1 Rotate the Launching Girder vertically by lowering the jacks of rear support so that the bottom of launching girder rests over the top beam of rear trolley. Procedure for vertical rotation 1. 2. 3. Lock the knuckle pins of rear trolley using 20 bars provided on its both sides. Close the jacks provided in box S-7 of Launching Girder Lower the jacks of rear support until the bottom of launching girder touches the top of rear trolley. Note: In case the minimum height of rear support is achieved before achieving contact between launching girder & rear trolley then the same can be achieved by raising the jacks of middle support. 4. Remove the 20 bars provided on the sides of Knuckle pins of rear trolley to allow free rotation of Knuckle pins in vertical plane. Step 2 Align the Girder horizontally by pulling macalloy bar at rear trolley so that centerline of Launching Girder passes through the center of middle support and rear trolley. For straight span this step is not required. PROCEDURE FOR HORIZONTAL ROTATION 1. Ensure that the Rear Trolley, Rear Support & Middle Support are properly anchored at their respective positions.

2.

Ensure that the Front Support telescopic leg is closed to its minimum so that there is no possibility of clash between brackets / projections in bottom beam of the front

47

support & the pier segment of the already erected span & the shear key provided at the pier cap during rotation. 3. Loosen the Macalloy bars connecting the launching girder with top beam of the rear trolley Note: Do not remove the channels provided below top beam for anchoring unless it is required to cross the knuckle pins. 4. Anchor the middle support cradles using the Macalloy bars provided over the cross beam B1 so that it doesnt get pulled during rotation process. Note: The cradles must be connected to each other by a suitable system so that their c/c distance of 1.8m is maintained during rotation. 5. Clamp the anchor plates of longitudinal sliding bearing of middle support & rear support as shown. (Refer sketch on next page) 6. Loosen the macalloy bar anchor provided at top of cross beam B1X at rear support so that the cradles are free to move in the required direction along with the launching girder while it is pulled at rear trolley for rotation. Note: The cradles must be connected to each other by a suitable system so that their c/c distance of 1.8m is maintained during rotation. 7. 8. Lock the knuckle pins of rear trolley using 20 bars provided on its both sides. Pull the launching girder in the required direction using macalloy bars provided on the side face of top beam of rear trolley so that launching girder slides over top beam to the center of rear trolley.

48

49

50

9.

Put the 100 vertical pin passing through the launching girder bottom flange & the center of the top flange of top beam of rear trolley.
51

Note: In case the holes provided in the launching girder & the top beam flanges does not match after rotation adjust them by pulling launching girder longitudinally using the turn buckles provided at the center of top beam of the rear trolley. 10. After horizontal rotation the centerline of Launching Girder should pass through the center of rear trolley and middle support, the placement of 100 pin will ensure it at rear trolley however at middle support it shall be checked and rectified if wrong by pulling the cradles using macalloy bar provided in transverse direction over top of cross beam B1 of middle support. Note: The cradles must be connected to each other by a suitable system so that their c/c distance of 1.8m is maintained. 11. Anchor the middle support cradles using the Macalloy bars provided over the cross beam B1 so that it doesnt move in transverse direction during launching. Note: Macalloy bar anchor provided at top of cross beam B1X at rear support shall remain loose during auto launching so that the cradles are free to move in the required direction along with the launching girder while it is auto launched along a curved span. auto

52

STAGE - 7

53

Step 1

Remove the anchors of rear trolley to allow its forward movement.

Step 2 Remove the 20 bars provided on the sides of Knuckle pins of rear trolley to allow free rotation of Knuckle pins in vertical plane. Step 3 Unclamp the anchor plates of longitudinal sliding bearing of middle support & rear support as shown so that the Launching girder is guided by the rollers during further auto launching. (Refer sketch on next page) Step 4 Remove brakes provided in the middle support & rear support.

Step 5 Start pushing the launching girder using longitudinal movement jack provided in front of middle support, so that the launching girder slides over the middle support & rear support & the rear trolley moves along with the launching girder on rails provided along the erected span. Step 6 Continue pushing of Launching Girder until the rear trolley reaches close to the rear support so that the further movement is not possible. Note: A minimum clear distance of 300mm between rear trolley and rear support must be ensured

54

55

56

STAGE 8

57

Step 1

Remove anchors of rear support.

Step 2 Lower the jacks of rear support and move rear support using moving trolley and position it over S-9 segment as shown. Note: Do not open the jacks of rear support so that it remains inactive during further auto launching. Step 3 STAGE 9 Step 1 Start pushing launching girder again using longitudinal movement jack provided in front of middle support so that the front support reaches the next pier location as shown in the drawing. Note: Brakes shall be applied at middle support in all conditions where launching girder is at rest or auto launching has stopped / completed. Anchor the rear support at this location.

58

59

60

STAGE 10

For straight span this stage is not required. Step 1 For curved span remove the 100 vertical pin passing through center of top beam of rear trolley and launching girder & rotate the launching girder about middle support by pulling macalloy bar provided along the top beam of the rear trolley so that the launching girder is now aligned along the chord of next span to be erected. PROCEDURE FOR HORIZONTAL ROTATION 1. Ensure cantilever of length equal to (Span to be erected + 4.250) in meters measured from centerline of middle support to front end of launching girder. 2. Apply brakes at middle support. {Incase the holes provided in monorail and braking system does not match the launching girder shall be auto launched forward by few millimeters (Less than 100mm)} 3. Ensure that the Rear Trolley, Rear Support & Middle Support are properly anchored at their respective positions. 4. Ensure that the Front Support telescopic leg is closed to its minimum so that there is no possibility of clash between brackets / projections in bottom beam of the front support & the pier segment of the already erected span & the shear key provided at the pier cap during rotation. 5. Loosen the vertical Macalloy bars connecting the launching girder with top beam of the rear trolley Note: Do not remove the channels provided below top beam for anchoring unless it is required to cross the knuckle pins.

61

6.

Anchor the middle support cradles using the Macalloy bars provided over the cross beam B1 so that it doesnt get pulled during rotation process.

Note: The cradles must be connected to each other by a suitable system so that their c/c distance of 1.8m is maintained during rotation. 7. Clamp the anchor plates of longitudinal sliding bearing of middle support as shown. (Refer sketch shown in stage 6 of auto launching) 8. Loosen the macalloy bar anchor provided at top of cross beam B1X at rear support so that the cradles are free to move in the required direction along with the launching girder while it is pulled at rear trolley for rotation. Note: The cradles must be connected to each other by a suitable system so that their c/c distance of 1.8m is maintained during rotation. 9. Remove the 100 vertical pin passing through the launching girder bottom flange & the center of the top flange of top beam of rear trolley. 10. 11. Lock the knuckle pins of rear trolley using 20 bars provided on its both sides. Pull the launching girder in the require direction using macalloy bars provided on the side face of top beam of rear trolley so that launching girder slides over top beam to attain the required position. 12. Unclamp the anchor plates of longitudinal sliding bearing of middle support as shown so that the Launching girder is guided by the rollers during further launching. (Refer sketch shown in stage 7 of auto launching) Note: No auto launching shall be done after side shifting of the Launching Girder at rear trolley auto

62

Step 2 Rotate the Launching girder vertically to ensure that acceptable heights at all supports is achieved before anchoring the front support Note: Refer detailed procedure for vertical rotation from annexure A.

63

64

STAGE - 11 Step 1 Open the telescopic leg of the front support so that the bottom beam of front support rests over the concrete pedestal as shown in the drawing. Step 2 Anchor the front support over pier cap by tightening anchor bolts in the sleeves provided in the pier cap. Note: Refer detailed procedure for lowering / raising of bottom beam/ telescopic leg of front support from annexure C. STAGE 12 Step 1 Open the jacks of rear support & ensure that it experiences a minimum reaction of 10tonnes (total reaction on four jacks) on it. Step 2 Apply brakes at rear support using braking assembly provided at rear side of the rear support. Step 3 Tighten the vertical macalloy bars provided at top beam of rear trolley to ensure that there is no possibility of relative movement between top beam of rear trolley & launching girder during erection of next span. Step 4 Move slider beams forward for the erection of next span as shown in the drawing.

65

66

67

4.0 4.1

STAGES OF ERECTION OF SPAN General This section gives a general guideline for erection of precast segments in various spans. This section is divided in two parts. 4.3.1 4.3.2 This part gives a detailed description for erection of 31.0m span and This part gives the sequence of erection of segments in all spans

assuming that the general procedure for lifting of individual segment shall remain same as that detailed out for 31.0m span. 4.2 List of Drawings Drawing no. LG/15 (Sheet 1 of 2 & Sheet 2 of 2) Title Scheme for Erection of Precast Segments

68

4.3.1 STAGE 1

ERECTION PROCEDURE FOR 31.0M SPAN

Step 1 Move all the slider beams towards the span to be erected as shown. Note: Only number of slider beams required for the erection of the span shall be moved CHECK LIST BEFORE ERECTION 1. 2. All Supports are properly anchored with the span erected/pier cap. Supporting jacks of middle & rear support are locked using lock nut provided in the jacks. 3. Brakes are applied at middle support using braking assembly provided at their rear side. 4. The Launching Girder is anchored to the top beam of rear trolley using four no. macalloy bars provided. 5. Middle support cradles are anchored using the Macalloy bars provided over the cross beam B1 so that it doesnt move in transverse direction during erection of precast segments.

69

STAGE 2
70

Step 1 Position the trailer having precast segment S-1 between the spans to be erected in such a manner that the center of segment to be erected lies as close as possible to the fixed mounted hoist while looking at it from top of launching girder. Step 2 Attach the lifting beam hanging from the fixed mounted hoist to the Temporary Prestressing beams attached to the segment at sofit level. Note: Temporary Prestressing beams will be vertically stressed at casting yard before its delivery at site for erection. Step 3 Lift the segment slightly & rotate it to the required direction for erection.

Step 4 Lift the segment up to the required height i.e. maintaining a distance of 3.5m between sofit of launching girder & the top of crown of the segment.

71

STAGE 3

72

Step 1 Attach the suspenders through wire rope assembly of first slider beam to the temporary prestressing beams at sofit level of the segment. Step 2 Slightly lift the suspender by monojacks.

Procedure For Transferring The Weight of Segment From Hoist To Suspender Bars 1. Lift the suspenders by monojacks and transfer a force of not more than 0.5tonne per suspender in order to remove initial slackness in the suspender bars. 2. Release the weight of segment from the fixed mounted hoist so that the weight is transferred automatically on the suspenders of the slider beam. Note: It shall be monitored that the slider beam remain in contact with both the flats provided on top of the Launching Girder i.e. there is no uplift (uplift is an indication of load getting transferred on one suspender slightly more than the load getting transferred on the other). In case of uplift, raise the hoist and release the suspenders and check the slider beam and suspenders carefully for the possible reasons and rectify them and then repeat the procedure 1 and 2. 3. After transferring complete load from the fixed mounted hoist to the suspenders remove the pins connecting the lifting beam and the Temporary Prestressing beams. Step 3 Raise the lifting device (Lifting Beam) so that it does not obstruct the movement of slider beam while the segment is shifted to its required position. Step 4 Move the first slider beam along with the suspended segment to the position as indicated. Step 5 Line and level S-1 as per latest G.A.D. of Alignment for the concerned span. Step 6 Lock the slider beam in this position using removable brackets provided for locking (refer details from Drg. No. LG/04 and Sketch No. LG/SK-1).
73

Step 7 Secure the position of the segment by placing wooden packing in the gap between segment and shear key.

74

STAGE 4 TO STAGE 6 Step 1 Repeat steps of stage 2 & stage 3 with segments S-1, S-2, S-3, S-4, S-5, & S-6, one by one, so that the segments from S-1 to S-6 are erected as shown.
75

Note: The correct position / alignment of segments S-2 to S-6 shall be ensured by dry matching S-2 with S-1, S-3 with S-2 and so on in the sequence of their erection. STAGE 7 Step 1 STAGE 8 Step 1 Lift the pier segment S-11 exactly in the same manner as the earlier segments & position it with the respective slider beam as near to the shear key as possible, as shown. Note: Do not pack the segment S-11 with the shear key STAGE 9 Step 1 Lift the segment S-10 exactly in the same manner as the earlier segments & park it over S-11 segment as shown. Note: Maintain a minimum vertical gap of 100 mm between segment S-11 and S-10 Move remaining slider beams towards segment S-6 as shown.

76

77

78

79

80

81

STAGE 10 TO STAGE 11 Step 1 Lift the segments S-9 & S-8 & S-7 in the similar manner as done in earlier cases & positions them as shown.

82

Step 2 Dry match segment S-6, S-7, S-8 & S-9. Step 3 Lower the segment S-10 and dry match with the segment S-9 Step 4 Dry match segment S-11 with S-10 Step 5 Check the levels and alignment of span Step 6 After ensuring correct alignment shift the segment S-11 and S-10 by 100mm and 50mm respectively toward shear key Step 7 Lift segment S-10 ensuring a vertical gap of 100mm (minimum) between segment S-10 and S-11 Step 8 Shift segment S-2 to S-9 by 300mm toward S-11 so that a gap is created between Segment S-1 and S-2 for gluing.

83

84

STAGE 12 Step 1 Step 2 Apply epoxy glue between segment S1 To S2 Do Temporary Prestressing of the segments S-1 & S-2 by Macalloy Bars.
85

Note: After temporary prestressing a gap of 300mm will be automatically created between segment S-2 and S-3. Step 3 Repeat the step 1 & step 2 up to segment S-9

Note: Epoxy shall be applied on both surfaces to be bonded as per the instructions of the supplier. STAGE 13 Step 1 Apply Epoxy glue on remaining segments i.e. surfaces between S-9, S-10 and S-11 simultaneously. Step 2 Lower the segment S-10 by vertical suspender of sliding beam and position it close to segment S-9. Step 3 Shift the segment S-11 close to segment S-10.

86

87

STAGE 14 Step 1 Do Temporary Prestressing of segments S-9 To S-11 by macalloy bars one by one.

88

Note: The entire procedure of lowering of segment S-10 and subsequent shifting of S-10 and S-11 for closing the gaps and the Temporary Prestressing shall be done with in the open time of the Epoxy adhesive to be used as per the suppliers manual for application of Epoxy adhesive. STAGE 15 Step 1 Step 2 STAGE 16 Step 1 Step 2 Step 3 Step 4 After Prestressing load is transferred on temporary bearings. Release the suspenders & remove the Temporary Prestressing beams. Move the sliding beams towards the counter weight side. Launching Girder is ready for Auto Launching. Insert Prestressing tendons and install their anchors. Do Longitudinal Prestressing of entire span.

89

90

91

4.3.2

ERECTION SEQUENCE OF PRECAST SEGMENTS IN DIFFIRENT SPANS

General procedure for lifting of segments remains same for all the spans. However in span of smaller length, only number of segments and their sequence for erection changes.

92

Erection Sequence of Precast Segments For 31m Span Total number of Segments = 11 (S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11) STAGES 1. 2. 3. 4. 5. 6. 7. Move 11 Sliding beams towards the Front support & Erect Segment S1 Erect Segment S2 Erect Segment S3 Erect Segment S4 Erect Segment S5 Erect Segment S6 Move remaining 5 Sliding beams towards the Segment S6 then Erect Segment S11 & position it near shear key as possible 8. 9. 10. 11. Erect Segment S10 & park Segment S10 over the Segment S11 Erect Segment S9 Erect Segment S8 Erect Segment S7

Erection Sequence of Precast Segments For 28m Span Total number of Segments = 10 (S1, S2, S3, S4, S5, S7, S8, S9, S10, S11)

93

STAGES 1. 2. 3. 4. 5. 6. Move 10 Sliding beams towards the Front support & Erect Segment S1 Erect Segment S2 Erect Segment S3 Erect Segment S4 Erect Segment S5 Move remaining 5 Sliding beams towards the segment S5 then Erect Segment S11 & position it near shear key as possible 7. 8. 9. 10. Erect Segment S10 & park Segment S10 over the Segment S11 Erect Segment S9 Erect Segment S8 Erect Segment S7

Erection Sequence of Precast Segments For 25m Span Total number of Segments = 9 (S1, S2, S3, S4, S6, S8, S9, S10, S11)

94

STAGES 1. 2. 3. 4. 5. Move 9 Sliding beams towards the Front support & Erect Segment S1 Erect Segment S2 Erect Segment S3 Erect Segment S4 Move remaining 5 Sliding beams towards the segment S4 then Erect Segment S11 & position it near shear key as possible 6. 7. 8. 9. Erect Segment S10 & park Segment S10 over the Segment S11 Erect Segment S9 Erect Segment S8 Erect Segment S6

Erection Sequence of Precast Segments For 22m Span Total number of Segments = 8 (S1, S2, S3, S4, S8, S9, S10, S11)

95

STAGES 1. 2. 3. 4. Move 8 Sliding beams towards the Front support & Erect Segment S1 Erect Segment S2 Erect Segment S3 Move remaining 5 Sliding beams towards the segment S3 then Erect Segment S11 & position it near shear key as possible 5. 6. 7. 8. Erect Segment S10 & park Segment S10 over the Segment S11 Erect Segment S9 Erect Segment S8 Erect Segment S4

Erection Sequence of Precast Segments For 20.5m Span Total number of Segments = 7 (S1, S2, S3, S6, S9, S10, S11)

96

STAGES 1. 2. 3. 4. Move 7 Sliding beams towards the Front support & Erect Segment S1 Erect Segment S2 Erect Segment S3 Move remaining 4 Sliding beams towards the segment S3 then Erect Segment S11 & position it near shear key as possible 5. 6. 7. Erect Segment S10 & park Segment S10 over the Segment S11 Erect Segment S9 Erect Segment S6

5.0 5.1

MANUAL FOR ERECTION OF FIRST SPAN GENERAL

97

The erection of precast segments for the construction of superstructure requires segments to be lifted by the Launching Girder, however while erection of first span there is no permanent platform available for the Launching Girder to stand, therefore a temporary structure is required initially to support the Launching Girder for the erection of first span. This section is an attempt to enumerate step-by-step procedure of erection of Launching Girder for first and second span and the superstructure required for the movement of Launching Girder. To simplify the process detailed drawing sketches showing position of launching girder and its accessories have been shown along with the detailed step by step procedure. 5.2 LIST OF DRAWINGS Drawing no. 215/LG/22 Title ERECTION SEQUENCE OF LAUNCHING

(SH. 1 OF 3 TO SH. 3 OF 3) GIRDER BETWEEN PIERS 122 TO 123

5.3

ERECTION OF LAUNCHING GIRDER IN FIRST SPAN

98

This section gives a series of sketches showing various stages of Launching Girder and corresponding condition of erection of span. The complete erection of Launching Girder includes erection of Launching Girder and Three spans. It shall be understood that once the Launching Girder is fully erected then it is capable of auto launching and erecting the spans in continuation as explained is section 3 and section 4 of this manual. The scheme has been covered in 23 Stages covering all possible conditions encountered in the process. Note: It is important to note that the scheme for Erection of Launching Girder Between Piers 122 To 123 is specifically meant for erection of Launching Girder between piers 122 to 123 and the same can not be applied as it is for initial erection between any other pier combination for which detailed drawings will be developed separately as and when required.

99

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

6.0

REFRENCES Detailed manual of supplier for different items shall be referred for their operation

123

Annexure A

PROCEDURE FOR VERTICAL ROTATION

124

A.1

GENERAL For spans with no change in gradient the vertical rotation is not required so that the height of various support shall be 3.5m each measured from top of crown of the segment to the bottom of Launching Girder.

Note: Height front support will be 5.2m from top of pier cap to bottom of Launching Girder. For change in gradient following procedure shall be followed.

125

A.2

Detailed description of various conditions of launching Girder in vertical grade & corresponding height adjustment of its supports

Direction of Launching

Front Support

Middle Support Grade g1% Span to be Erected 5.6m

Rear Support Grade g2%

Rear Support Grade g3%

Newly Erected Span

A.2.1

Down Grade

The Launching Girder is said to be moving on down grade if > 0 or grade g 1% < g 2% (with +ve / -ve signs considered)

Procedure 1. Reduce the height of middle support & try to achieve the required height at Front Support. Note: The minimum height to kept at middle support shall be 3.4m however in odd conditions it can be reduced to 3.35m. 2. If the required height is not achieved raise the height of rear trolley.

126

A.2.2

Up Grade

The Launching Girder is said to be moving on upgrade if < 0 or grade g 1% > grade 2% (with +ve / -ve signs considered)

Procedure 1. It is required to reduce the height of rear trolley however during auto launching the Height of rear trolley has to be kept 3.5m deliberately which happens to be its minimum possible height therefore this operation in not required. 2. A.3 Raise the height of middle support to achieve the required height at front support. Permissible range of height to be ensured at front support 3.35m (measured from top of crown of the segment to the bottom of Launching Girder) Or 5.05m (measured from top of pier cap to the bottom of Launching Girder) Maximum height** - 3.7m (measured from top of crown of the segment to the bottom of Launching Girder) Or 5.4m (measured from top of pier cap to the bottom of Launching Girder) *Minimum height for inserting middle support during further auto launching **Maximum length of suspenders available for erection of segments

Minimum height* -

A.4

Calculation Of Height At Front Support For A Known Height At Rear Trolley And Middle Support

127

A.4.1

Down Grade

Assuming following data for sample calculation Span to be erected = S1 = 25m (over which Launching Girder is resting at Present) Grade g3%

Span already erected = S2 = 25m Grade g1 = + 1.3% Grade g2 = + 2.4% Grade g3 = + 2.5%

(The height of structure is increasing in the direction of launching) (The height of structure is increasing in the direction of launching) (The height of structure is increasing in the direction of launching)

Rear Trolley Grade g1% < Grade g2% therefore the launcher is moving on down grade
CL Pier

Height at rear trolley Height at middle support

= =

3.5m (assumed) 3.4m (assumed) a

Distance between middle support & rear trolley = = 64.75 - *4.45 - **2.5 - ***(25 + 1.8) c 31.0m Grade g2%

*Cantilever Distance beyond center line of rear trolley Middle **Cantilever Distance ahead center line of front support Support 0.9m ***Distance between center line front support & middle support b

CL Pier

Grade g1% d Top of Crown of Segment

Grade of Launching Girder

Front Support X

0.9m
128

CL Pier

Newly Erected Span

Bottom of Launching Girder

Direction Of Launching

Span to be Erected

= [ 31 - ( 25 - 0.9 ) ] x 2.5 100

0.1725m

129

( 25 - 0.9 ) ] x 2.4 100

0.5784m

= = =

Height of Middle Support (Height of Rrear Trolley a - b) 3.4 (3.5 ( 0.1725 ) ( 0.5784 )) 0.6509 m = 0.6509 X 100 31 = 2.09968%

Grade of Launching Girder

Height of Front Support X = Height of Middle Support D + ( Span + 1.8 ) x Grade of Launching Girder 100 d = = = x = = 0.9 x Grade g2 + ( Span ) x Grade g1 100 100 100 100 0.9 x ( 2.4 ) + ( 25 ) x ( 1.3 ) +ve 0.3466m 3.4 ( 0.3466 ) + ( 25 + 1.8 ) x ( 2.09968 ) 100 3.616m > 3.35m & < 3.7m ok = = = 3.616m 3.400m 3.500m

Height of Front Support For Height at Middle Support And Height at Rear Trolley

On the same lines the heights at front support, middle support & rear trolley can be calculated for any span.

A.4.2

Up Grade

130

Assuming following data for sample calculation Span to be erected = S1 = 25m (over which Launching Girder is resting at Present)

Span already erected = S2 = 25m Grade g1 = - 1.3% Grade g2 = - 2.4% Grade g3 = - 2.5%

(The height of structure is decreasing in the direction of launching) (The height of structure is decreasing in the direction of launching) (The height of structure is decreasing in the direction of launching)

Grade g3% Grade g1% > Grade g2% therefore the launcher is moving on up grade Height at rear trolley Height at middle support Rear Trolley Distance between middle support & rear trolley = = 64.75 - *4.45 - **2.5 - ***(25 + 1.8) 31.0m = = 3.5m 3.6m (assumed) CL Pier

*Cantilever Distance beyond center line of rear trolley Grade g2% **Cantilever Distance ahead center line of front support ***Distance between center line front support & middle support

Middle Support

CL Pier

Grade g1%

Grade of Launching Girder Front Support 0.9m

131

CL Pier

Top of Crown of Segment

Newly Erected Span

Span to be Bottom of Launching Girder Erected

Direction Of Launching

= [ 31 - ( 25 - 0.9 ) ] x ( -2.5 ) 100

-0.1725m

132

( 25 - 0.9 ) ] x ( -2.4 ) 100

-0.5784m

= = =

Height of Middle Support (Height of Rrear Trolley a - b) 3.6 (3.5 ( -0.1725 ) ( -0.5784 )) -0.6509 m = -0.6509 X 100= 31 -2.09968%

Grade of Launching Girder

Height of Front Support X = Height of Middle Support D + ( Span + 1.8 ) x Grade of Launching Girder 100 d = = = x = = 0.9 x Grade g2 + ( Span ) x Grade g1 100 100 100 100 0.9 x ( -2.4 ) + ( 25 ) x ( -1.3 ) -ve 0.3466m 3.6 ( -0.3466 ) + ( 25 + 1.8 ) x ( -2.09968 ) 100 3.384m > 3.35m & < 3.7m ok = = = 3.384m 3.600m 3.500m

Height of Front Support For Height at Middle Support And Height at Rear Trolley

On the same lines the heights at front support, middle support & rear trolley can be calculated for any span.

133

Annexure B

PROCEDURE FOR MOVEMENT OF MIDDLE SUPPORT / REAR SUPPORT USING MOVING TROLLEY

134

135

136

137

Annexure C

PROCEDURE FOR RAISING / LOWERING OF TELESCOPIC LEG / BOTTOM BEAM OF FRONT SUPPORT

138

139

140

141

REFER AUTOCAD FILE

FOR SKETCHES

ON BLANK PAGES OF THE BOOKLET

142