Chennai Metro Rail Limited (CMRL) has completed the casting of all precast concrete elements for Phase-2 Corridor-5, covering the stretch between Ullagaram and Sholinganallur. The achievement, reported on October 14, 2026, includes the production of 3,126 precast elements, with the package recording the highest number of U-girders produced among the Phase-2 project packages.
The completion of precast casting marks a major step in the construction work for the corridor. The elements will support the development of the elevated metro infrastructure required for the project.
Corridor-5 Records Highest U-Girder Production
The Corridor-5 package produced 892 U-girders, the highest production figure for this component among the Chennai Metro Phase-2 packages. U-girders are commonly used in elevated metro construction to support the track structure while accommodating the alignment and design requirements of the viaduct.
The package’s precast production included five categories of structural elements: 1,041 I-girders, 892 U-girders, 871 pier arm segments, 303 pier caps and 19 portal shells. Together, these components account for a total of 3,126 precast elements.
Precasting involves manufacturing concrete components at designated casting facilities before transporting them to the construction site for installation. This method allows structural elements to be produced under controlled conditions while reducing the amount of concrete casting required at elevated construction locations.
For metro viaducts, precast components are used across different structural sections. Girders form the supporting spans, while pier arms and pier caps help transfer loads between the superstructure and supporting piers. Portal shells are used in specific structural arrangements according to the project’s design.
Concrete and Steel Consumption
The precast works for Corridor-5 involved substantial quantities of concrete, reinforcement steel and high-tensile strands. According to the reported figures, the package used 98,052 cubic metres of concrete, 18,550 tonnes of reinforcement steel and 3,010 tonnes of high-tensile strands.
These materials form the main components of the precast concrete elements used in elevated metro infrastructure. Concrete provides compressive strength, reinforcement steel helps resist tensile stresses, and high-tensile strands are used in prestressed concrete components to improve their structural performance.
The production of thousands of precast elements requires coordination between casting facilities, material supply, quality control and construction planning. Each component must meet the specified dimensions and structural requirements before it can be transported and installed.
The scale of production for Corridor-5 reflects the volume of precast manufacturing undertaken for this section of Chennai Metro Phase-2.
Coordination Among Project Stakeholders
CMRL completed the precast casting work through coordinated efforts involving the project authority, its general consultant and the construction contractor. AEON Consortium serves as the general consultant, while HCC-KEC Consortium is the contractor for the package.
The completion of casting does not, by itself, indicate that all construction and installation activities on the corridor have been completed. However, it establishes that the package’s reported precast element production has reached completion.
The next stages of construction and infrastructure development will depend on the progress of the remaining site activities, including the installation of structural components wherever required and subsequent works associated with the elevated corridor.
With 3,126 precast elements cast, Corridor-5 has recorded a significant production achievement within Chennai Metro Phase-2. The package’s 892 U-girders also place it at the top among Phase-2 packages for this component, highlighting the scale of precast manufacturing undertaken for the Ullagaram–Sholinganallur stretch.
