CASTING OPERATIONS

VIADUCT SEGMENTS
CONTENTS

i. Preamble
1. Definition
2. Responsibilities and Authorities
3. Casting Yard
4. List of Moulds and Equipments in Casting Yard
5. Moulds
6. Sequence of Casting
7. Time Cycle for Casting
8. Rebar Jig
9. Rebar Cage
10. Cover Block
11. Concreting
12. Debonding Agent
13. Embedded Items
14. Geometry Control
15. Marking of Segments
16. Curing of Segments
17. Strength Requirements
18. De-shuttering
19. Lifting of Segments
20. Pedestals for General Inspection
21. Sand Blasting
22. Handling And Stacking Of Units
23. Casting of Curved Span
24. Safety, Health and Environment
25. Precast yard organisation
PREAMBLE
Construction package CC 26 R for DMRC is consisting of construction of elevated viaduct
for Phase-third of Delhi MRTS Project- Part design and construction of elevated viaduct
including entry net line,Ramp to depot and 8 elevated stations viz Mayur vihar-1,Mayur
vihar PKT-1,Trilokpuri,Vinod Nagar East,Vinod Nager,IP Extension,Anand Vihar and
Karkardurna stations including Architectural finishing,Water supply,Sanitary installation
and drainage works of stations from chainage 37179.000to46214.787 of Line 7
Mukundpur-yamuna vihar corridor of Phase-three Delhi MRTS It is proposed to precast the
segments on long line&short line beds. Segments for. Detailed Method Statement is
presented herein for casting of these segments.
1. DEFINITIONS
a. Jig: Refers to the steel cage fabrication frame that is required for the fabrication of
geometrically and dimensionally accurate steel cages. The jig will conform to all applicable
safety regulations and be easily adjustable to suit all segment dimensional changes.
b. Diaphragm Segment: Two pier segments for both ends of a given span of segments. This
segment is cast as the Wet Cast Segment against the bulkhead on both sides.
c. Wet Cast Segment (W/C): The segment being cast within the casting machine. One face
is formed using a bulkhead; the other face is formed using either bulkhead or the match
cast face.
A. Match Cast Segment (M/C): Used to form one bulkhead face (match cast face) of the
Wet Cast Segment. The match cast face (face against the W/C segment) must be coated
with a suitable bond breaker so that the joint at the interface between the M/C and W/C
segments separates cleanly at slipping with no spoiling of either face.
e. Anchor Head: Hardware which holds the wedges of a multi-strand tendon and transfers
tendon force to the bearing plate, f. Bearing Plate: hardware that transfers the tendon
force into the structure g. Wedge: A conically shaped device that anchors the strand in the
anchor head. h. Duct: Material forming a conduit to accommodate post tensioning tendon
installation. It may be made of high-density polyethylene.
2. RESPONSIBILITIES AND AUTHORITIES
a. The Construction Manager is responsible for coordinating construction operations
related to the Viaduct including the start-up and production of the Casting Yard,
Substructure, Erection and Post-Tensioning areas. He is the final responsible individual for
safety, quality and production of the project within the scope of work of ITD-ITDCEM JV.
b. The Precast Yard Manager is responsible for the day to day management of all work
performed at the CC-26 0 casfing facility including subcontracted work relating to the start-
up and construction of the casting facility.
c. The Precast Yard Superintendent is responsible for the coordination of all subcontracted
work performed at the Sushant Lok casting facility as it concerns the