Bullet Train Project in Maharashtra Hits Milestone with First PSC Box Completion
The Mumbai-Ahmedabad Bullet Train project has reached a significant milestone, as the casting of the first Full Span Pre-Stressed Concrete (PSC) Box Girder for the Maharashtra section has been successfully completed. This 40-meter-long girder, the heaviest of its kind in India’s construction industry, weighs around 970 metric tonnes and has been cast as a single unit using 390 cubic meters of concrete and 42 metric tonnes of steel.
An official from the National High-Speed Rail Corporation Limited (NHSRCL) highlighted the importance of this achievement, stating, “This PSC box girder is integral to the construction of the viaducts for the Maharashtra section. It has been designed similarly to the ones used in the Ahmedabad section of the project, marking a significant step forward in the construction of the high-speed rail infrastructure.” The casting of this first girder marks the commencement of work on the elevated viaducts that will form the backbone of the Mumbai-Ahmedabad corridor. NHSRCL has been working on both substructure and superstructure simultaneously to accelerate the progress. While substructure work, which includes piles, pile caps, piers, and pier caps, is underway, superstructure work is being carried out in dedicated casting yards located along the alignment.
The use of Full Span Girders in the construction process is expected to accelerate progress significantly. Full Span Girders, which are quicker to install than Segmental Girders, allow construction to progress up to ten times faster. However, in areas with space constraints, Segmental Girders will still be used. Currently, 13 casting yards are being established along the alignment between Shilphata and the Gujarat-Maharashtra border, with three yards already operational. These facilities are equipped with advanced technologies to ensure efficient production and quality control of the girders. To transport and place these massive girders, heavy machinery such as Straddle Carriers, Bridge Launching Gantries, Girder Transporters, and Launching Gantries will be deployed. The pre-casting of these girders in advance will ensure a steady supply, allowing for smooth and uninterrupted construction.
The successful use of this technology has already proven effective in the Gujarat section of the project, where 255 kilometers of viaduct have been completed since April 2021. The Maharashtra section includes 135 kilometers of elevated viaduct, four major river bridges, 11 special crossings over national highways and railway lines, and three stations at Thane, Virar, and Boisar, in addition to seven mountain tunnels. This development marks a critical phase in the Mumbai-Ahmedabad Bullet Train project, which is expected to revolutionise rail travel in India, reducing travel time and providing a faster, more efficient mode of transport for passengers.
