LAUNCHING GIRDER

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TYPES OF LAUNCHING
GIRDER
Mainly Two Types:
Over Head Launching Girder
Under Slung Launching Girder
UNDER SLUNG LAUNCHING
GIRDER
It consists of 4 Supports like
Front support
Middle support
Rear support Dummy support
Rear Trolley
Telescopic Leg Middle Support
Rear Support
Rear Trolley Rear Trolley with
Rail arrangement
LAUNCHING GIRDER
Length 31m
Spans 7 namely S1,S2,S3
Length of each span 9.25m
Height of each span 2.8m
All bolts should be checked for
Torque for every 3 months
Components of Launching
Girder
4 supports
Crab Hoists
Sliding Beams
Lifting Beams
Splice
Jack Hammers
Temporary Prestressing Beams
Telescopic Leg
Span Fixed end and Rear end
Segments S1F, S1R, S2F, S2R
SegmentDeck Level and Soffit Level
Segment Dimensions:
Length of S1- 1.95m,S2,S3,S4 3m
Width -8.8m
Expansion Joint Provided between
each span 100mm
There is a Provision for future
Stressing in S3 segment
Anchor Cones are provided at S1
Segment for provision of Grouting and
Water test
Temporary Prestressing is done at
both Soffit level and Deck level
Stressing Arrangement at Deck Level
Anchor Cone
Expansion Joint
Front Support and Sliding Beams
Sliding Beams Holding the Segment
Temporary Stressing using Brackets
TEMPORARY STRESSING
Two types of Bars are used
Macalloy Bar
Divedeck Bar
Segment is checked for sand
ballasting at site
Shear Keys both male and female
joints are checked cause it might
affect during dry matching.
Macalloy Bar Dive Deck Bar
Steps followed during
Launching of segments
Cleaning and checking of segments
Lifting of segments.
Dry matching
Gluing of segments
Cutting of strands and threading
Stressing of segments
Steps followed during
Launching of segments
Span lowering
Grouting of segments
Water test
Auto launching of girder
Alignment of S1 segment
LIFTING OF SEGMENTS
Different lifting beams for S1 &
other segments
While lifting segments are vertically
pre stressed using Jack hammer &
Macalloy bar @ 250 kg/cm2
Once segments are lifted dry
matching is done.
Segment with Lifting Beam
DRY MATCHING
Two segments are brought together
and checked for even surfaces.
Less pressure of 50 kg/cm2 is
allowed to make segments join.
No gap should be found in both deck
level & soffit level.
So once dry matching is done &
found satisfactory permission is given
for gluing.
GLUING
Gluing material mixture of base &
hardener
BASF & FOSROC
It should be mixed for 5 min in
gluing machine & applied to both
segments in 20 min
GLUING
Rpm of gluing mixer should be less
than 600
O-ring is provided on sheathing duct.
After applying glue the segments are
brought together & pressure is
applied @ interval of 50kg/cm2
Segments after Gluing
Base Hardener
Gluing Mixer
Gluing Mixer
CUTTING OF STRANDS
AND THREADING
After gluing strands are cut to
required length & then inserted into
sheathing ducts.
Every segment has got ten sheathing
ducts.
Strands are inserted into it for
stressing.
A base plate is provided along with
wedges to hold the strands.
CUTTING OF STRANDS
AND THREADING
Live wedges are left along with
cables & mater wedges which are
used on seating plate of jack is
removed after stressing
19 strands are inserted in all the 8
ducts and 7 strands are inserted in 2
of the ducts
 PERMANENT STRESSING
Once threading of cable is completed.
They are ready for stressing.
2 cables at a time are stressed, Like
1R&1L.
Pressure is loaded in intervals of
50kg/cm2
For every pressure loaded piston
reading is noted.
PERMANENT STRESSING
Maximum pressure of 357 kg/cm2 is
loaded & elongation is noted. once
pressure is achieved it is locked for a
minute and removed.
Piston reading is again note while
releasing at 50kg/cm2.
For ducts having 7 cables pressure is
loaded at 30 kg/cm2 for maximum of
139 kg/cm2
PERMANENT STRESSING
After stressing strands are checked
for a slip of 200mm in 24 hrs
Once stressing is completed
segments arrested using slings are
removed for auto launching
Strands before Stressing
Strands after Stressing
SPAN LOWERING
Segments are usually placed in upper
gradient for easy placement of
stressing jacks.
Placed height should not be more
than 600 mm
All wooden planks & hydraulic jacks
on which segments were resting are
removed and segments are made to
rest on pedestal.
Wooden Planks and Jack used before
Span Lowering
WATER TEST
It is carried out to find out leakages
in segments
Water is pumped inside through inlet
provided at anchor cones
Test is carried out at a pressure of 0.3
mpa
WATER TEST
Repair works are carried out using
rendroc plug along with cement in
1:3 ratio @0.4 w/c ratio
Before grouting anchor cones are
painted black to prevent corrosion of
plates
Air compressor is used to pump all
water out of segments
 GROUTING
Grout cap is placed before grouting.
Cebex 100 is used as admixture along
with cement at 0.4 w/c ratio (Approx
18 to 22 lts).
One bag of cement one packet(225
gms) of cebex 100 is used.
Water used should be of less than 18 c
GROUTING
Once mixed properly without any
lumps it is pumped into segments
through inlet & made to flow out at
outlet
It is continued until fresh grout is
observed
Pressure of 5 kg/cm2 is maintained
for one minute
GROUTING
Density is checked using hydrometer
which should be 1.925 gm/cc
Grouting is done to prevent corrosion
of strands in sheathing duct.
Density should be checked at both
inlet and outlet.
AUTO LAUNCHING
All sliding beams need to be shifted
near counter weight
Middle support is shifted to s1 of
next span & to the same span.
Front support is then lifted and
moved
Girder is now resting on middle
support and rear support & rear
trolley
AUTO LAUNCHING
While front support is moved using
power jack rail arrangement is made
for movement of rear trolley.
Power jack arranged at middle
support work as both pushing jack
and pulling jack.
Once front support reaches next pier
it is made to rest on pedestal.
AUTO LAUNCHING
Telescopic leg is adjusted as needed.
Then rear support is lifted & placed
on s3 segment of same span.
All the supports are anchored & this
finishes process of auto launching
Power Jack (Pushing and Pulling Jack)
Brake System Knuckle Bearing
ALIGNMENT OF S1
SEGMENT
Most important thing to be done once
segment is lifted. once it is lifted it is
aligned to center of alignment by
taking next pier center as reference.
Center of S1 segment should match
with center of alignment.
ALIGNMENT OF S1
SEGMENT
Before placing of segments
elastomeric bearing is placed over
pedestal by checking levels properly
as pedestal may not have even
surface
Counter Weight
Thank you