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IBEC — Innovative Construction Solutions
Maharashtra · 2023

Expressway viaduct, cast in-situ MSS

An underslung movable scaffolding system casting 7.2 km of continuous deck where no casting yard could be established.

Deck cast
7.2 km
Typical span
42 m
Deck width
24.5 m
Cycle achieved
9 days
SPAN 31 00018 500P1P2P3LAUNCH →1Main truss girder2Winch trolley3Segment being placed4Main support leg on pier5Launching nose1 MAIN TRUSS GIRDER2 WINCH TROLLEY3 SEGMENT BEING PLACED4 SUPPORT LEG5 LAUNCHING NOSE
FIG. 01Overhead launching gantry — span-by-span erection, mid-cycleELEVATION · NTS

Scope of supply

  • Underslung MSS, 44 m casting length
  • Hydraulic launching and formwork adjustment
  • Pier bracket system for 34 piers
  • Commissioning and first-five-span supervision

Divisions involved

01

The problem

Land acquisition left no site for a precasting yard anywhere along a 7.2 km alignment through cultivated land. Casting in place was the only option, but the alignment crossed a canal and two village roads that had to stay open throughout.

02

What we did

An underslung MSS was chosen so that nothing obstructed the ground under the deck between piers. The machine carried its own launching nose and self-launched across the canal without temporary support. Formwork adjustment for the superelevation transition was hydraulic rather than shimmed, which removed roughly a day from each transition span.

03

What happened

A nine-day cycle was held across 172 spans, ending at eight days once the crew settled. Concrete surface was accepted as fair-faced with no remedial treatment on 96 % of the deck soffit.

Measured outcome

7.2 km
Deck cast
42 m
Typical span
24.5 m
Deck width
9 days
Cycle achieved
08Next step

Send us a span table.

Give us the general arrangement and the programme. You will get two or three viable erection methods back, each with a cycle time we are prepared to stand behind — before anyone talks about price.

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