CHAPTER 6.

SEGMENT CASTING

6. SEGMENT CASTING

The construction of track-supporting viaduct in this project by segmental

approach involves a lot of precast construction. Various segments of the viaduct
are casted on Casting Yard. The incorporation of precast system of construction
helps in achieving uniformity and quality in construction as well as making the
construction process fast.
This chapter includes a detailed discussion on the casting of segments and
exemplary details of segments.

6.1 PROCEDURE FOR CASTING OF SEGMENTS

The casting of segments for a viaduct span involves the following major
activities:

6.1.1 Fabrication of Reinforcement Cage

The fabrication of the reinforcement cage for a segment is done on the casting
yard using a standard jig for that particular segment as shown in Figure 6.2. The
cutting and bending of bars is done according to the approved Bar Bending
Schedule presented in Table 6.1, at the bar bending workshop.
The fabrication of blister reinforcement (spiral ring) is done by winding the
reinforcement around a steel pole by a team of around 10 labors as shown in
Figure 6.1.

FIGURE 6.1 PREPARATION OF BLISTER REINFORCEMENT

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All the prepared bars, stirrups and rings are stitched to form a single
reinforcement cage and cover blocks are tied to it.
Once the cage is prepared, it is tagged and detached from the jig after approval
of DMRC Engineer and then lifted by a crane stacked for use at time of casting of
segment.
Figure 6.3 shows prepared reinforcement cage for pier segment.

FIGURE 6.3 REINFORCEMENT CAGE FOR PIER SEGMENT

6.1.2 Bed Arrangement

The casting of segments for a viaduct span is done on a steel bed. The bed
comprises of various bottom shutters for different segments of the span.
According to the actual alignment of the span, the bed is also arranged in the
same alignment along a gantry bay. For this purpose, temporary bench marks
and control points are established on casting yard and with the help of Total
Station the bed is aligned.

6.1.3 Formwork
The formwork for the casting of segments includes:

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6.1.3.1 Bottom Shutter

The bottom shutter is formed by the bed itself and is laid at the time of bed
arrangement as shown in Figure 6.4 (a).

6.1.3.2 Side shutters

The side shutters (2 in nos.) act as the outer shutters and are fixed along the
sides of the bottom shutter by moving with the help of roller legs arrangement as
shown in Figure 6.4 (b).
The outer shutters are placed before the placement of reinforcement cage.

6.1.3.3 Inner Trolley

Inner trolley acts as the inner shutter and is fixed on rails installed over the bulk
head as shown in Figure 6.4 (c).
For the casting of pier segments, inner trolley is not used. The bulk head itself
forms the inner shutter.
Inner trolley is installed after the placement of reinforcement cage and
installation of bulk head.

6.1.3.4 Bulk Head

The bulk head acts as the shutter to the side of the segment which is in
transverse direction to the span. The bulk head has the arrangement for shear
keys and holes for prestressing ducts as shown in Figure 6.4 (d).

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(a) (b)

(c) (d)

FIGURE 6.4 SHUTTERING FOR SEGMENT CASTING

For the casting of end segments/ pier segments two bulk heads are required
while for other segments one bulk head is required as the side of casted segment
acts as the shutter to the segment to be casted.
For match-cast segment i.e. the segment casted in between two casted segment,
no bulk head is required.
For using sides of casted segments as shutter to the sides of segments to be
casted, a de-bonding agent is applied on the side surface of casted segments.
Bulk head is installed after the placement of reinforcement cage over the bed.
After installation of all the shutters, shutter release oil is applied to all form
surfaces and the formwork is ready for concreting.

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6.1.4 Placement of Reinforcement Cage

The prepared reinforcement cage for the segment to be casted is lifted from the
stacking area by a crane and placed on the bed. The cage is properly aligned and
checked for cover blocks.

6.1.5 Concreting
The method of placing concrete is either through boom placer or by using
concrete bucket and gantry arrangement.
Concrete conforming to the following specifications is used for the construction of
pile:
 Grade of Concrete : M45 (Normal Segments)
: M50 (Pier Segment)
 Slump of concrete : 120 to 150 mm

The concrete pour sequence is as follows:

 Concreting of soffit
 Concreting of web area
 Concreting of deck slab

For proper compaction of concrete two types of vibrators are used:

 Form Vibrator: Attached to outer shutters for compaction of concrete in
web area.
 Immersion Vibrator: For compaction of concrete in soffit and deck slab
area.

6.1.6 De-shuttering
The outer shutters and bulk head are removed after 24 hours of casting and the
segment can be lifted from the bed after 21 days of casting.

6.1.7 Stacking of Segments

After lifting the segments from the casting bed, they are stacked in the stacking
area on wooden beams as shown in Figure 6.5. The stacking is done in such a
manner that easy identification of segments is possible.

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FIGURE 6.5 STACKING OF SEGMENTS

6.2 SEGMENT DETAILS

Details for some typical segments are presented in Figure 6.6 to 6.17

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