Chennai Metro achieves historic feat; India’s first and longest U-Girder erected in Phase 2

Chennai, India (Metro Rail Today): In a major milestone for Indian metro rail construction, Chennai Metro Rail Limited (CMRL) has successfully erected the country’s first and longest 33.33-meter U-Girder at Ramapuram as part of Phase 2, Corridor 5 (ECV-02). This groundbreaking achievement marks the first use of a U-Girder of this length in any metro project across India.

The engineering feat, executed in collaboration with General Consultant AEON and contractor Larsen & Toubro (L&T), sets a new national benchmark in infrastructure design, execution, and innovation.

Key Project Highlights:

• Girder Length: 33.33 meters – India’s longest metro U-Girder

• Weight: 225 metric tonnes

• Location: Ramapuram, near L&T headquarters

• Corridor: Chennai Metro Phase 2, Corridor 5

• Total Erected: 6 U-Girders across 3 spans (2 girders per span)

Traditionally, longer spans in metro corridors—especially at major junctions or U-turns—rely on steel girders due to anticipated traffic loads. CMRL's bold decision to use long-span U-Girders not only delivered structural integrity but also improved visual aesthetics, offering a sustainable alternative to steel.

Casting a U-Girder of this scale demanded customized molds, precise reinforcement, and advanced pre-tensioning methods. Meticulous attention to quality control ensured successful casting and structural performance.

Transporting the massive girders involved specialized logistics using 6+6 axle multi-axle trailers, powered by a Volvo FH 520 HP puller, highlighting the planning precision and coordination involved in the project.

Mrs. Mamta Shah, MD & CEO of Urban Infra Group, commended the achievement, stating:

“The successful erection of India’s longest U-Girder by CMRL is a momentous leap in indigenous engineering capability. It reflects how Indian metro projects are now embracing bold, innovative solutions that rival global benchmarks. This project is not just about infrastructure — it's about vision, technical excellence, and the future of urban mobility in India.”

This pioneering effort reinforces CMRL’s leadership in metro infrastructure development, pushing the envelope for what's possible in urban transport. With a focus on design efficiency, aesthetics, and advanced construction methods, this project sets the stage for the next generation of metro rail engineering in India.