en.Wedoany.com Reported - Chennai Metro Rail Limited (CMRL), along with general consultant AEON and contractor L&T (Larsen & Toubro), completed the casting of the last 19.5-meter U-shaped girder for Adambakkam Station on Chennai Metro Line 5 at the ECV-02 precast yard. This milestone marks the completion of all 824 U-shaped girders for the line. The project is part of CMRL's Phase 2 construction, involving a 13.1-kilometer elevated corridor and associated stations for Line 5. The 43-acre precast yard has become one of the most productive precast facilities in the country.
The ECV-02 precast yard is divided into six dedicated production zones for manufacturing the extensive precast components required for the elevated corridor. The facility used approximately 120,000 cubic meters of concrete and produced nearly 300,000 tons of structural components during mass production. The entire project involved casting 5,836 precast components, including 302 pier caps, 1,465 pier arms, 824 U-shaped girders, 2,055 I-shaped girders, 194 T-shaped girders, 68 portal U-shaped shells, and 1,079 crash barriers. All components were transported from the precast yard to the project site, approximately 18 kilometers away.
This project introduced automated station U-shaped girder mold operations integrated with hydraulic systems for the first time in India. The technology enables automated U-shaped girder precasting through advanced controllers, helping to improve construction safety and quality standards, shorten production cycles, and reduce reliance on manual labor. This initiative also supports lowering the overall project cost.
The project team completed the casting of U-shaped girders in various sizes, ranging from the smallest 8.9-meter girder to India's longest 33.3-meter U-shaped girder (weighing 225 metric tons), without operational issues. This process reflects the project team's design capabilities, engineering precision, and execution capacity. The completion of the last U-shaped girder casting for Line 5 represents a phased achievement in CMRL's Phase 2 project, demonstrating India's technical capabilities in metro infrastructure construction through large-scale precast production, automation technology application, and record-setting U-shaped girder construction.
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