Chennai Metro Rail Limited (CMRL), in partnership with engineering consultant AEON and construction major Larsen & Toubro, has successfully cast the final U-Girder for Corridor 5 (ECV-02) of the Chennai Metro Phase 2 project. The milestone marks the completion of an extensive production program involving 824 U-Girders, one of the largest such undertakings in the history of Chennai Metro construction.
The final precast element, a 19.5-meter-long U-Girder designated for Adambakkam Station, was produced at the Corridor 5 ECV-02 Casting Yard. The achievement underscores the scale, engineering sophistication, and operational efficiency that have characterized the ongoing metro expansion project.
Spread across more than 43 acres, the ECV-02 Casting Yard has emerged as one of the most productive precast manufacturing facilities under Chennai Metro Phase 2. The facility was specifically developed to support the construction of the 13.1-kilometre elevated viaduct and associated stations along Corridor 5. To maximize productivity, the yard was divided into six dedicated production bays, each responsible for manufacturing various structural components required for the project.
Overall, the project involves the production of 5,836 precast elements using approximately 120,000 cubic metres of concrete and nearly 300,000 metric tonnes of material. These components include 302 pier caps, 1,465 pier arms, 824 U-Girders, 2,055 post-tensioned and pre-tensioned I-Girders, 194 T-Girders, 68 portal U-shells, and 1,079 parapets.
One of the most remarkable aspects of the project is the complexity of logistics involved. Every precast component manufactured at the casting yard is transported approximately 18 kilometres to the construction alignment for installation. Managing the movement of such large and heavy structural elements has required meticulous planning and coordination between project teams.
The project has also introduced a significant technological innovation in Indian metro construction. For the first time in the country, automated station U-Girder mould operations integrated with hydraulic systems were implemented in U-Girder precasting. The system uses automated controllers to streamline production processes, improve operational safety, enhance quality consistency, reduce construction cycle times, and lower dependence on manual labour. This innovation has helped optimize productivity while maintaining stringent engineering standards.
Another notable accomplishment was the successful casting of U-Girders of varying sizes, ranging from the smallest at 8.9 metres to India’s longest U-Girder measuring 33.3 metres and weighing approximately 225 metric tonnes. The ability to manufacture and handle such diverse and technically demanding components reflects the project’s advanced engineering capabilities and execution expertise.
The successful completion of the U-Girder casting program without major operational challenges sets a new benchmark for large-scale metro rail infrastructure development in India. As Chennai Metro Phase 2 progresses, milestones such as these continue to strengthen the city’s vision of building a modern, efficient, and sustainable urban transit network capable of serving millions of commuters in the years ahead.
Senior officials from CMRL, AEON, and L&T, including project leadership and engineering teams, were present during the occasion to commemorate the achievement and acknowledge the efforts of all stakeholders involved in delivering this important milestone.
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