Segmental casting yard at Village-Vaktana, Surat (@ Ch. 254) has been developed to produce 294 spans (35-60m length), involving casting of 5292 segments. These spans will make about 9 km length of viaduct for Mumbai-Ahmedabad HSR corridor (MAHSR).
NHSRCL has adopted Full Span Launching Method (40m length) along with Segmental Method. The Full Span girders (40m length) are preferred over Segmental girders as their erection is seven times faster. However, at locations where Full Span Girder launching is not feasible due to site constraints, Segmental Girders are launched. These site constraints can be in the form of Road Crossings, Canal, Pipelines, Major Rivers and Curvature Radii less than 6000m.
Full Span Girder of 40m is casted in one go while Segmental Girders are casted in small pieces (15-24 nos.) of length varying from 1.75-2.5m each. These small pieces are stitched together at site using pre-stressing cables to make spans of length from 35-60m.
Casting yard @ 254 has been developed in an area of 22 acres near Bhatia Toll Plaza, Village-Vaktana, Surat. All required facilities like Concrete Batching Plant (90 Cu.M./Hour), 4 gantry of 150 MT each, 4 gantry of 10 MT each, material storage, Laboratory for testing of material, site office, labour camp to accommodate 500 personnel, medical facility including ambulance etc. have been developed so as to ensure continuous casting of segments.
For casting of Full Span box girders and Segmental girders, Casting Yards at 25 strategic locations have been developed along the alignment. Out of 25 casting yards, 17 are Full Span casting yards and 8 are Segmental casting yards. Each Casting Yard is spread over an area of 16 to 93 acres as per requirement and are located adjacent to the High-Speed Rail Alignment. The cumulative area of 25 Casting Yards is approx. 1000 acres.
Mumbai – Ahmedabad High Speed Rail (MAHSR) Project is 508 Km long first High- Speed Rail (HSR) network planned to be constructed in India. Out of 508Km, 352Km lies in the State of Gujarat (348Km) and Dadra & Nagar Haveli (4Km) and balance 156Km lies in the State of Maharashtra.
The Construction Work is in progress in both Gujarat and Dadra & Nagar Haveli where 98% and 100% land has been acquired respectively. In Gujarat, High Speed Rail alignment passes through eight districts i.e. Valsad, Navsari, Surat, Bharuch, Vadodara, Anand, Kheda and Ahmedabad and work is in progress in all the eight districts. In Maharashtra land acquisition done so far is 40%.
The project will entail an investment of 72,000 Crs in the state of Gujarat in both Land & construction. So far an expenditure of 14,200 Crs has been done. The project will generate direct & indirect employment of 60,000 in Gujarat state.