India’s longest U-Girder cast for Bengaluru Suburban Rail Project

Bengaluru, India (Metro Rail Today): In a significant leap forward for the Bengaluru Suburban Rail project (BSRP), Larsen & Toubro (L&T) has embarked on the monumental task of casting India’s longest U-girder. This engineering marvel is a crucial component of the 149 km BSRP, enhancing connectivity and transforming the urban landscape of Bengaluru.

Pouring Progress: U-Girders Take Shape

Last week witnessed the commencement of concrete pouring as L&T initiated the casting process for the first set of 31-meter-long U-girders. This marks the beginning of the construction of an 8.027 km elevated viaduct, a pivotal segment of the 23.866 km Corridor 2, also known as the ‘Mallige Line,’ stretching between Benniganahalli and Chikkabanavara.

Situated in Devanahalli, L&T’s casting yard is a hub of activity, supporting the realization of this ambitious project. The intricate mould/formwork used in the casting process has been meticulously designed and manufactured by Winsteel Engineering Works, showcasing the fusion of precision and innovation in this colossal undertaking.

Setting Records: India’s Longest U-Girder Unveiled

This endeavor achieves a historic feat, with the U-girder reaching an impressive length of 30 meters – a milestone for rail line viaduct construction in India. Comparatively, U-girders for metro projects in various cities like Delhi, Bangalore, Mumbai, and Kanpur have typically measured a maximum of 27.90 meters. This breakthrough highlights L&T’s commitment to pushing the boundaries of engineering excellence.

Extending Excellence: Beyond Bengaluru

Not confined to Bengaluru, L&T's prowess extends to Chennai, where last week marked the initiation of launching 30-meter-long U-girders for the 116.1 km Chennai Metro Phase 2 project’s Line-3 on Old Mahabalipuram Road (OMR). This showcases the company's versatility and leadership in the realm of urban infrastructure development.

Engineering Marvels in Numbers

Karnataka’s Rail Infrastructure Development Company (K-RIDE) reveals that L&T plans to cast a total of 450 U-girders in Bengaluru for the BSRP. Each of these pre-tensioned U-girders is a structural masterpiece, composed of 69.5 cubic meters of M60 grade concrete and weighing an impressive 178 tonnes. This underscores the magnitude of the engineering precision involved in executing such projects.

Contractual Commitment and Beyond

In 2022, K-RIDE awarded Larsen & Toubro the contract for the BSRP corridor-2 viaduct, amounting to Rs. 849.97 crore. With a deadline of 27 months, L&T is tasked not only with constructing the 8.027 km elevated viaduct but also with the comprehensive development of ramps, embankments, cuttings, bridges, walls, and various other components across the 17.551 km long at-grade section of the project.

L&T's achievement in casting India’s longest U-girder for the Bengaluru Suburban Rail Project stands as a testament to the country's engineering prowess. This milestone not only propels the BSRP into a new era of connectivity but also establishes L&T as a trailblazer in the field. As we witness the transformation of Bengaluru's urban landscape, it is evident that such feats of engineering will leave an indelible mark on India's infrastructure narrative.