SIMPLEX-SOM DATT BUILDERS JV

DOC. NO.
PROCEDURE FOR LAUNCHING OF SEGMENTS
SDB-SIMPLEX
JV./252/HUDA/WP-10
Project : Construction of Elevated Expressway Corridor
Hyderabad REV. NO: 0
for
HYDERABAD URBAN DEVELOPMENT AUTHORITY

ISSUED TO
NAME:
CONTROLLED COPY NO.: DESIGNATION:
ISSUED BY

SIGNATURE/DATE:

METHOD STATEMENT FOR LAUNCHING OF

SEGMENTS

R-0
APPROVED
DESCRIPTION PREPARED CHECKED REVISED APPROVED
REV DATE BY
OF REVISION BY BY BY BY
(HUDA)

CONSULTANTS:

ARCH-BRIDGECON J0INT VENTURE

202, BALAJI PLAZA, SECTOR – 8
ROHINI, NEW DELHI - 11085
 CONTENTS

1.0 INTRODUCTION
1.1 Configuration Requirement for HUDA Project
1.2 List of Drawings
1.3 Steel Fabrication
1.4 Safety

2.0 MAIN COMPONENTS OF LAUNCHING GIRDER

2.1 General
2.2 Main Box Girder
2.3 Front Support
2.4 Middle Support
2.5 Rear Support
2.6 Rear Trolley
2.7 Slider Beams
2.8 Moving Trolley
2.9 Counter Weight
2.10 Fixed Mounted Hoist
2.11 Platform, ladders and Walk way

3.0 SCHEME FOR AUTOLAUNCHING

3.1 General
3.2 List of Drawings for ready reference
3.3 Steps for Auto Launching

4.0 STAGES OF ERECTION OF SPAN

4.1 General
4.2 List of Drawing
4.3.1 Erection Procedure for 35.0m Span
4.3.2 Erection Sequence of Pre-cast Segments

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5.0 MANUAL FOR ERECTION OF FIRST SPAN
5.1 General
5.2 List of Drawings
5.3 Erection of Launching Girder in First Span.

6.0 REFERENCES

ANNEXURE A
PROCEDURE FOR VERTICAL ROTATION
A.1 General
A.2 Detailed Description of Various Conditions of Launching Girder in Vertical
Grade & Corresponding Height Adjustment of its Supports.
A.2.1 Down Grade
A.2.2 Up Grade
A.3 Permissible Range of Height to be ensured at Front Support
A.4 Calculation of Height at Front Support For a Known Height at Rear Trolley
and Middle Support
A.4.1 Down Grade
A.4.2 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

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1.0 INTRODUCTION

This document has been specifically written for the Launching Girder to be used at
HYDERABAD ELEVATED EXPRESSWAY PROJECT

This document covers following sections:-

(a) Description of Launching Girder

(b) Scheme for Auto Launching & Erection

(c) Description of Operations performed by various parts of Launching Girder.

(d) Safety

1.1 CONFIGURATION REQUIREMENT FOR THE PROJECT

This section includes requirements and information regarding the configuration of

the bridge and Launching Girder

[Link] Item Criteria

.
1. Maximum span length 35.0 m
2. Minimum span length 35.0 m
3. Maximum longitudinal slope 2.00%
4. Maximum weight of segment 75.0 t
5. Maximum length of segment 3.1m
6. Minimum Horizontal radius 200.00 m
7. Total height of intermediate segment 2.0m
8. Total height of end segment 2.300m
9. Segments gluded or dry jointed Epoxy Glue
10. Loading of segments from ground From ground only
1.2 DRAWINGS:

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 The following drawings apply to HUDA project:

S. No. Title Drawing No.

1. General Arrangement of Launching Girder 252/LG/101
2. Details of Launching Girder (Sh.1 of 4) 252/LG/201
3. Details of Launching Girder (Sh.2 of 4) 252/LG/202
4. Details of Launching Girder (Sh.3 of 4) 252/LG/203
5. Details of Launching Girder (Sh.4 of 4) 252/LG/204
6. Details of Monorail 252/LG/205
7. Details of Bracket for fixed-mounting-hoist 252/LG/206
8. General Arrangement Erection stage lifting 252/LG/207
9. Scheme for auto launching (Sh.1 of 6) 252/LG/301
10. Scheme for auto launching (Sh.2 of 6) 252/LG/302
11. Scheme for auto launching (Sh.3 of 6) 252/LG/303
12. Scheme for auto launching (Sh.4 of 6) 252/LG/304
13 Scheme for auto launching (Sh.5 of 6) 252/LG/305
14 Scheme for auto launching (Sh.6 of 6) 252/LG/306
15. Details of Middle Support (Sh.1 of 7) 252/LG/401
16. Details of Middle Support (Sh.2 of 7) 252/LG/402
17. Details of Middle Support (Sh.3 of 7) 252/LG/403
18. Details of Middle Support (Sh.4 of 7) 252/LG/404
19. Details of Middle Support (Sh.5 of 7) 252/LG/405
20. Details of Middle Support (Sh.6 of 7) 252/LG/406
21. Details of Middle Support (Sh.7 of 7) 252/LG/407
22. Details of Front Support (Sh.1 of 6) 252/LG/501
23. Details of Front Support (Sh.2 of 6) 252/LG/502
24. Details of Front Support (Sh.3 of 6) 252/LG/503
25. Details of Front Support (Sh.4 of 6) 252/LG/504
26. Details of Front Support (Sh.5 of 6) 252/LG/505
27. Details of Front Support (Sh.6 of 6) 252/LG/506
28. Details of Rear Support (Sh.1 of 3) 252/LG/601
29. Details of Rear Support (Sh.2 of 3) 252/LG/602

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 30. Details of Rear Support (Sh.3 of 3) 252/LG/603
31. Details of Rear Trolley (Sh.1 of 5) 252/LG/701
32. Details of Rear Trolley (Sh.2 of 5) 252/LG/702
33. Details of Rear Trolley (Sh.3 of 5) 252/LG/703
34. Details of Rear Trolley (Sh.4 of 5) 252/LG/704
35. Details of Rear Trolley (Sh.5 of 5) 252/LG/705
36. Details of counter weight 252/LG/801
37 252/LG/901
38 252/LG/1001
39. Details of Sliding Beam (Sh.1 of 2) 252/LG/1101
40. Details of Sliding Beam (Sh.2 of 2) 252/LG/1102
41. Details of wire rope assembly for intermediate segment 252/LG/1103
42. General Arrangement for Temporary Pre-stressing 252/LG/1201
43. Details of Lifting & Temporary Pre-stressing for End 252/LG/1202
Segments Erection Stage (Sh.1 of 4)
44. Details of Lifting & Temporary Pre-stressing for End 252/LG/1203
Segments Erection Stage (Sh.2 of 4)
45. Details of Lifting & Temporary Pre-stressing for End 252/LG/1204
Segments Erection Stage (Sh.3 of 4)
46. Details of Lifting & Temporary Pre-stressing for End 252/LG/1205
Segments Erection Stage (Sh.4 of 4)
47. Details of Lifting & Temporary Pre-stressing for 252/LG/1206
Intermediate Segments Erection Stage (Sh.1 of 6)
48. Details of Lifting & Temporary Pre-stressing for 252/LG/1207
Intermediate Segments Erection Stage (Sh.2 of 6)
49. Details of Lifting & Temporary Pre-stressing for 252/LG/1208
Intermediate Segments Erection Stage (Sh.3 of 6)
50. Details of Lifting & Temporary Pre-stressing for 252/LG/1209
Intermediate Segments Erection Stage (Sh.4 of 6)
51. Details of Lifting & Temporary Pre-stressing for 252/LG/1210
Intermediate Segments Erection Stage (Sh.5 of 6)
52. Details of Lifting & Temporary Pre-stressing for 252/LG/1211
Intermediate Segments Erection Stage (Sh.6 of 6)

Note: A complete set of above drawings should be available at site for ready reference.

1.3 STEEL FABRICATION

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 The Launching Girder including all its Accessories will be fabricated with the
drawings supplied by M/s Arch-Bridgecon JV 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 Bridgecon JV.

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 MAIN COMPONENTS OF LAUNCHING GIRDER

2.1 General
This section 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 /201 to 207)

Front Suppor (Refer Drg .No. LG /501 to 506)

Middle Support (Refer Drg .No. LG /401 o 407)

Rear Support (Refer Drg .No. LG /601 to 603)

Rear Trolley (Refer Drg .No. LG /701 to 705)

Slider Beams (Refer Drg .No. LG /1101 to 1103)

Moving Trolley (Refer Drg .No. LG /1001)

Counter Weight (Refer Drg .No. LG /801)

Fixed Mounted Hoist (Refer Drg .No. LG /206)

Platform / Walk ways…….…..

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2.2 Main Box Girder

Main Box Girder will be consisting of eight segments of close Box 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/202 to 204).

Bearing stiffeners have been provided at all support locations. 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

Side bracing & Tie members
This support has in built ability for adjustment of height depending upon the
gradient negotiated at site for various spans and vertical alignment of the corridor
at the site. The telescopic leg, which can slide into the top vertical leg, provides this
flexibility & can be locked using 100Ø 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.

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 The entire support rests on concrete pedestals provided in the pier cap as shown
in the drawings of front leg, The Front Support is secured to the pier cap using 32Φ
anchor bolts.

The front support is fixed at 2500 mm from the front of the launcher. Two nos.
vertical hydraulic jacks (200t capacity) are provided to carry out vertical adjustment
of the support. Side shifting of front support with respect to Launching Girder is not
possible.

2.4 Middle Support

The middle support is positioned on the pier segment of already erected span and
supports the launching girder together with the front support during the span
erection. The level of middle support can be adjusted by using 4 number single
acting hydraulic jacks, (200T capacity). These jacks are provided with locknut.

Middle Support consist of following main parts

(1) Main Beam.

(2) Cross brackets to support the Jacks
(3) Knuckle bearings – These bearings are tailor made and capable of
longitudinal sliding of launching girder during auto launching, vertical and
plan rotation and transverse movement.
(4) Longitudinal pushing assembly
(5) Braking assembly

Cross-brackets rest over 200t capacity single acting jacks as shown in the drawing
of middle support & forms the basic supporting structure of middle support. These
brackets are connected to main beam as its integral part. Main beam of middle
support provide support and sliding surface (Stain less Steel top) for the Knuckle
Bearing.

Knuckle Bearing consists of three parts

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 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 165Ø 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 main
beam.
The whole assembly of knuckle bearings can be pulled for side shifting of
launching girder whenever required by the help of STRESS BARS connecting the
main beam of middle support and cradle to ensure proper position of the launching
bearing with respect to the middle support.
Longitudinal pushing assembly is an independent device attached to the monorail
on front side of middle support through longitudinal movement jack connected to
bracket provided at center of plate connecting the two cradles. This assembly is
specially designed 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 40Ø pin as shown in the drawing LG/403. When this assembly is
connected to the support it restricts forward movement of launching girder with
respect to the support.

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 100 t as shown in the detail drawing LG/601 to 603.

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 of truss supported on eight wheels which rests on 90R rails laid on the
erected superstructure at a spacing of 8.8 m c/c.

9
 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. STRESS 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 STRESS BARSs passing through brackets provided in launching girder
& movable bracket consisting of two ISMC 200 & bolted at top & bottom end.

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 150 x 150 plate with 15
mm thick PTFE sheet fitted on bottom of slider beam and slides on rail consisting
of 75x40 mm bar and 4mm SS plate on top of launching girder main box as shown
in drawing no. LG/201.

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 5.1m among themselves.

The tension bars are connected to two temporary pre-stressing frames, which are
secured to the pre-cast 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 by a HT strand

running through all the slider beams which is pulled by two mono strand jacks fitted
at extreme ends of the launching girder main box.

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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.

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 girder during auto launching of the Launching Girder.

2.10 Fixed Mounted Hoist

It is an 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 and is supposed
to lift the pre-cast segments during erection stage.

2.11 Platform ladders and Walk ways:

Working platforms and ladders are 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

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 length when required. However, in general practice, a separate ladder shall be
used wherever permanent access is not provided.

3.0 SCHEME FOR AUTOLAUNCHING OF LAUNCHING GIRDER

3.1 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 any miss happening 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. Title

LG/301 to 306) Scheme for Auto Launching

3.3 STEPS FOR AUTO LAUNCHING

STAGE – 1

Step 1 The Launching Girder rests on the already erected span as shown.

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Step 2 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 Lay and fix the 90 R rails on the newly erected span for further movement of
Launching Girder.
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 10 t (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 four jacks 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 = 130 t

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 recently erected span so that a distance of 1150 mm is
achieved between the centerline of expansion joint of the span & centerline
of the middle support.
(Refer sketch for position of middle support on pier segment in plan)

Note: Refer detailed procedure for movement of middle support /rear support
using moving trolley from annexure B.

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Step 7 Open the jacks of middle support to transfer a minimum reaction of 10 t on it
ensuring that the moving trolley is released.
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.
Step 9 Apply brakes at middle support.
Step 10 Remove the brakes provided at rear support by removing pins connecting
monorail & the braking assembly.
Step 11 Close 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 12 Open the anchors of rear support to allow its forward movement.

STAGE - 3

Step 1 Move the rear support with the help of moving trolley & position it over pier
segment as shown so that a distance of 1150 mm is achieved between
centerline of expansions joint of the span & the centerline 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
10 t (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.

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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.
STAGE - 4

Step 1 Move the middle support & position it over front pier segment of the newly
erected span so that a distance of 1150 mm is achieved between centerline
of expansion joint of the span & the centerline of middle support as shown.
(Refer sketch-showing position of middle support over pier segment in plan)
Step 2 Open the jacks of middle support to transfer a reaction of 10 t (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 100Ø 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 / rising of bottom beam / telescopic
leg of front support from annexure C.

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.

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 Procedure for vertical rotation

1. Lock the knuckle pins of rear trolley using 20φ bars provided on its both
sides.
2. Close the jacks provided in box S-8 of Launching Girder
3. 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 20φ 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 STRESS BARS 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 support & the pier segment of the already erected span
during rotation.
3. Loosen the STRESS 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 STRESS BARS provided over
the main beam so that it doesn’t 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.

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5. Clamp the anchor plates of knuckle / sliding bearing of middle support &
rear support as shown.
6. Loosen the STRESS BARS anchor provided at top of main beam 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. Lock the knuckle pins of rear trolley using 20φ bars provided on its both
sides.
8. Pull the launching girder in the required direction using STRESS 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.
9. Put the 100Ø vertical pin passing through the launching girder bottom flange
& the center of the top flange of top beam of rear trolley.
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 100Ø
pin will ensure it at rear trolley however at middle support it shall be checked
and rectified if wrong by pulling the cradles using STRESS BARS provided
in transverse direction over top of main beam 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 STRESS BARS provided over
the main beam so that it doesn’t move in transverse direction during
auto launching.
Note: STRESS BARS anchor provided at top of main beam 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.

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STAGE - 7

Step 1 Remove the anchors of rear trolley to allow its forward movement.

Step 2 Remove the 20φ 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 rollers guide the Launching girder
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
STAGE – 8

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 segments as shown.

Note: Do not open the jacks of rear support so that it remains inactive during
further auto launching.

Step 3 Anchor the rear support at this location.

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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.

STAGE – 10

For straight span this stage is not required.

Step 1 For curved span remove the 100φ vertical pin passing through center of top
beam of rear trolley and launching girder & rotate the launching girder about
middle support by pulling STRESS BARS 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.

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5. Loosen the vertical STRESS 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.

6. Anchor the middle support cradles using the STRESS BARS provided over
the main beam of middle support so that it doesn’t 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 Knuckle sliding bearing of middle support as

shown.

8. Loosen the STRESS BARS anchor provided at top of main beam 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 100Ø vertical pin passing through the launching girder bottom
flange & the center of the top flange of top beam of rear trolley.

10. Lock the knuckle pins of rear trolley using 20φ bars provided on its both
sides.

11. Pull the launching girder in the required direction using STRESS 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.

20
12. Unclamp the anchor plates of longitudinal sliding bearing of middle support
as shown so that the rollers guide the Launching girder during further
auto 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
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.

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 / rising 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 10 t (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 STRESS 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.

21
Step 4 Move slider beams forward for the erection of next span as shown in the
drawing.

4.0 STAGES OF ERECTION OF SPAN

4.1 General

This section gives a general guideline for erection of pre-cast segments in

all the spans. This part gives a detailed description for erection of 35.0m
span This part also gives the sequence of erection of segments in all spans
assuming that the general procedure for lifting of individual segment shall
remain same as detailed.

4.3.1 ERECTION PROCEDURE FOR 35.0M SPAN

STAGE – 1

Step 1 Move all the slider beams towards the span to be erected as shown.

CHECK LIST BEFORE ERECTION

1. All Supports are properly anchored with the span erected or pier cap.

2. 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. STRESS BARS provided.

5. Middle support cradles are anchored using the STRESS BARS provided
over the main beam of the support so that it doesn’t move in transverse
direction during erection of pre-cast segments.

22
STAGE – 2

Step 1 Position the trailer having pre-cast 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 Pre-stressing frames attached to the segment at deck level.

Note: Temporary Pre-stressing frames will be vertically stressed at casting yard

itself 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 3.3m
between sofit of launching girder & the top of crown of the segment.

STAGE – 3

Step 1 Attach the suspenders through wire rope assembly of first slider beam to the
temporary pre-stressing frames at deck level of the segment.

Step 2 Slightly lift the suspender by Hollow jacks on the top of slider beam.

Procedure For Transferring The Weight of Segment From Hoist To Suspender Bars

1. Lift the suspenders by hollow jacks and transfer a force of not more than 0.5
t 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

23
 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
Pre-stressing frames.

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 span being
erected.

Step 6 Lock the slider beam in this position using removable brackets provided for
locking.

Step 7 Secure the position of the segment by placing wooden packing

STAGE – 4 TO STAGE – 6

Step 1 Repeat steps of stage 2 & stage 3 with segments, 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.

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.

24
STAGE – 7

Step 1 Move remaining slider beams towards segment S-6 as shown.

STAGE – 8

Step 1 Lift the pier segment S-12 exactly in the same manner as the earlier
segments & position it with the respective slider beam as near to the
expansion joint center as possible, as shown.

Note: Do not pack the segment S-12

STAGE – 9

Step 1 Lift the segment S-11 exactly in the same manner as the earlier segments &
park it over S-12 segment as shown.

Note: Maintain a min. vertical gap of 100 mm between segment S-12 and S-11

STAGE – 10 TO STAGE – 11

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

Step 2 Dry match segment S-6, S-7, S-8, S-9 & S-10.

Step 3 Lower the segment S-11 and dry match with the segment S-10

Step 4 Dry match segment S-12 with S-11

Step 5 Check the levels and alignment of span

Step 6 After ensuring correct alignment shift the segment S-12 and S-11 by 100mm
and 50mm respectively towards erected span

25
Step 7 Lift segment S-11 ensuring a vertical gap of 100mm (minimum) between
segment S-11 and S-12

Step 8 Shift segment S-2 to S-10 by 300mm toward S-12 so that a gap is created
between Segment S-1 and S-2 for gluing.

STAGE – 12

Step 1 Apply epoxy glue between segment S1 To S2

Step 2 Do Temporary Pre-stressing of the segments S-1 & S-2 by STRESS BARS

Note: After temporary pre-stressing 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-10

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-10, S-11
and S-12 simultaneously.

Step 2 Lower the segment S-11 by vertical suspender of sliding beam and position
it close to segment S-10.

Step 3 Shift the segment S-12 close to segment S-11.

STAGE – 14

26
Step 1 Do Temporary Pre-stressing of segments S-10 To S-12 by STRESS BARS
one by one.

Note: The entire procedure of lowering of segment S-11 and subsequent shifting
of S-11 and S-12 for closing the gaps and the Temporary Pre-stressing shall
be done with in the open time of the Epoxy adhesive to be used as per the
supplier’s manual for application of Epoxy adhesive.
STAGE – 15

Step 1 Insert Pre-stressing tendons and install their anchors.

Step 2 Do Longitudinal Pre-stressing of entire span.

STAGE – 16

Step 1 After Pre-stressing load is transferred on temporary bearings provided at

jacking locations.

Step 2 Release the suspenders & remove the Temporary Pre-stressing frames
beams.

Step 3 Move the sliding beams towards the counter weight side.

Step 4 Launching Girder is ready for Auto Launching.

Erection Sequence of Pre-cast Segments For 35m Span

Total number of Segments = 12 (S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11 AND
S12)
STAGES

1. Move 12 Sliding beams towards the Front support & Erect Segment S1
2. Erect Segment S2
3. Erect Segment S3

27
4. Erect Segment S4
5. Erect Segment S5
6. Erect Segment S6
7. Move remaining 5 Sliding beams towards the Segment S6 then Erect Segment
S11 & position it near shear key as possible
8. Erect Segment S10 & park Segment S10 over the Segment S11
9. Erect Segment S9
10. Erect Segment S8
11. Erect Segment S7

5.0 MANUAL FOR ERECTION OF FIRST SPAN

5.1 GENERAL

The erection of pre-cast 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.

5.3 ERECTION OF LAUNCHING GIRDER IN FIRST SPAN

This section gives a series of sketches showing various stages have

Launching Girder and corresponding condition of erection of span.

28
 The complete erection of Launching Girder includes erection of Launching
Girder and subsequent erection of 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 in section 3
and section 4 of this manual.

The scheme has been covered in 22 Stages covering all possible conditions
encountered in the process.

Note: It is important to note that the scheme for Erection of Launching Girder first
time between two Piers is specifically made and the same can not be
applied as it is for initial erection between any other two piers combination
for which detailed drawings will be developed separately as and when
required.

6.0 REFRENCES

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

29
 Annexure A

PROCEDURE

FOR

VERTICAL ROTATION

30
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 3.3 m each measured from top of
crown of the segment to the bottom of Launching Girder.

For change in gradient following procedure shall be followed.

A.2 Detailed description of various conditions of launching Girder in vertical

grade & corresponding height adjustment of its supports

Direction of Launching

Front Middle Rear Rear

Support Support Support Support
α
Grade g1% 5.6m Grade g2% Grade g3%

Span to be Erected 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 be kept at middle support shall be 3.3m however in
odd conditions it can be reduced to 3.2m.

2. If the required height is not achieved raise the height of rear trolley.

31
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 3.3m deliberately which
happens to be its minimum possible height therefore this operation in not
required.

2. Raise the height of middle support to achieve the required height at front
support.
A.3 Permissible range of height to be ensured at front support
Minimum height* - 3.15m (measured from top of crown of the segment to the bottom of
Launching Girder)
Maximum height** - 3.5m (measured from top of crown of the segment 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

32
A.4 Calculation Of Height At Front Support For A Known Height At Rear
Trolley And Middle Support

A.4.1 Down Grade

Assuming following data for sample calculation
Span to be erected = S1 = 35m
Span already erected = S2 = 35m (over which Launching Girder is resting at Present)
Grade g1 = + 1.3% (The height of structure is increasing in the direction of launching)
Grade g2 = + 2.4% (The height of structure is increasing in the direction of launching)
Grade g3 = + 2.5% (The height of structure is increasing in the direction of launching)
Grade g1% < Grade g2% therefore the launcher is moving on down grade

Height at rear trolley = 3.3m (assumed)

Height at middle support = 3.2m (assumed)
Distance between middle support & rear trolley
= 64.75 - *4.45 - **2.5 - ***(25 + 1.8)
= 31.0m

33
*Cantilever Distance beyond center line of rear trolley
**Cantilever Distance ahead center line of front support
***Distance between center line front support & middle support

34
Grade of Launching Girder
Top of Crown of Segment

Grade g3%

Rear
Trolley
CL Pier

a
Newly Erected
Span
c
Grade g2%

Middle
Support 0.9m
CL Pier
b

Bottom of
Launching Girder

Grade g1%

d
Direction Span to be
Of Erected
Launching

Front CL Pier
0.9m
Support

35
a = [ 31 - ( 25 - 0.9 ) ] x 2.5 = 0.1725m
100

b = ( 25 - 0.9 ) ] x 2.4 = 0.5784m

100

c = Height of Middle Support – (Height of Rrear Trolley – a - b)

= 3.4 – (3.5 – ( 0.1725 ) – ( 0.5784 ))
= 0.6509 m

Grade of Launching Girder = 0.6509 X 100 = 2.09968%

31

Height of Front Support

X = Height of Middle Support – D + ( Span + 1.8 ) x Grade of Launching Girder

100

d = 0.9 x Grade g2 + ( Span ) x Grade g1

100 100
= 0.9 x ( 2.4 ) + ( 25 ) x ( 1.3 )
100 100
= +ve 0.3466m

x = 3.4 – ( 0.3466 ) + ( 25 + 1.8 ) x ( 2.09968 )

100
= 3.616m > 3.35m & < 3.7m ok

Height of Front Support = 3.616m

For Height at Middle Support = 3.400m
And Height at Rear Trolley = 3.500m

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

36
A.4.2 Up Grade

Assuming following data for sample calculation

Span to be erected = S1 = 25m

Span already erected = S2 = 25m (over which Launching Girder is resting at
Present)

Grade g1 = - 1.3% (The height of structure is decreasing in the direction of launching)

Grade g2 = - 2.4% (The height of structure is decreasing in the direction of launching)
Grade g3 = - 2.5% (The height of structure is decreasing in the direction of launching)

Grade g1% > Grade g2% therefore the launcher is moving on up grade

Height at rear trolley = 3.5m

Height at middle support = 3.6m (assumed)

Distance between middle support & rear trolley

= 64.75 - *4.45 - **2.5 - ***(25 + 1.8)
= 31.0m

*Cantilever Distance beyond center line of rear trolley

**Cantilever Distance ahead center line of front support
***Distance between center line front support & middle support

37
Grade of Launching Girder

Top of Crown of Segment

Grade g3%

Rear
Trolley CL Pier

Grade g2%

c Newly Erected
Span

Middle
0.9m
Support CL Pier
b

Span to be
Bottom of Erected
Launching Girder
Grade g1%

d
Direction
Of
Launching

Front CL Pier
0.9m
Support

X 38
a = [ 31 - ( 25 - 0.9 ) ] x ( -2.5 ) = -0.1725m
100

b = ( 25 - 0.9 ) ] x ( -2.4 ) = -0.5784m

100

c = Height of Middle Support – (Height of Rrear Trolley – a - b)

= 3.6 – (3.5 – ( -0.1725 ) – ( -0.5784 ))
= -0.6509 m

Grade of Launching Girder = -0.6509 X 100 = -2.09968%

31

Height of Front Support

X = Height of Middle Support – D + ( Span + 1.8 ) x Grade of Launching Girder

100

d = 0.9 x Grade g2 + ( Span ) x Grade g1

100 100
= 0.9 x ( -2.4 ) + ( 25 ) x ( -1.3 )
100 100
= -ve 0.3466m

x = 3.6 – ( -0.3466 ) + ( 25 + 1.8 ) x ( -2.09968 )

100
= 3.384m > 3.35m & < 3.7m ok

Height of Front Support = 3.384m

For Height at Middle Support = 3.600m
And Height at Rear Trolley = 3.500m

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

39