Casting Yards

 

June 2021 - A test pre-cast segmented box girder being cast.
Source: LinkedIn

The construction of the Jurong Region Line (JRL) includes the construction of piers and viaducts that will form the trackbed for the line. One of the most common methods for construction of the viaducts is using segmented box girders to form a complete span which is laid between two pier columns. Wires are passed through the interior of the box girders and tensioned, providing the force necessary to keep the span rigid and able to withstand the loads that are placed upon it.

Source: Youtube

In order to construct the box girders, a casting yard is required. This is usually an off-site facility that produces the box girders, similar to how tunnel ring segments are produced and then later brought to the site for installation by the tunnel boring machine.

Most of the casting yards for the JRL contracts are clustered in Tengah estate - in three different areas. For contract J102 (Choa Chu Kang, Choa Chu Kang West & Tengah stations), the casting yard is located in Tengah East, near the junction of Brickland Road and Choa Chu Kang Avenue 3. A roadway has been constructed that leads past the Hai Inn Temple as an access road to the J102 construction site within Tengah, the J102 casting yard & a heavy vehicle park.

An aerial view of the contract J102 casting yard looking southwards.
Source: STEC

02 February 2022 - Contract J102 casting yard at Tengah East.

02 February 2022 - Contract J102 casting yard. Forms for the pre-cast
segment boxes are visible.

02 February 2022 - Contract J102 casting yard. A completed segmented
box is visible.

In Tengah Central, near the location of Tengah station, lies the casting yard for contract J108 (Tengah Plantation, Tengah Park & Bukit Batok West stations). As the site is not accessible, the only shots can be taken of the site from afar. Nonetheless, segment box production is well under way as at February 2022.

Gantry crane installation at contract J108 casting yard in Tengah.
Source: Jenmon

Gantry crane at contract J108 casting yard in Tengah.
Source: Jenmon

02 February 2022 - Contract J108 casting yard as seen from West Ridges@
Bukit Batok HDB precinct.

02 February 2022 - Contract J108 casting yard as seen from West Edge@
Bukit Batok HDB precinct. Precast segment boxes are visible.

02 February 2022 - A close up image. The gantry crane in the foreground
belongs to the casting yard under the Housing & Development Board.

Meanwhile in Tengah West, just east of the construction site for the Tengah JRL depot, is a cluster of casting yards belonging to contracts J103 (Hong Kah & Corporation stations), J105 (Jurong West & Bahar Junction stations), J106 (Boon Lay interchange) & J107 (Gek Poh & Tawas stations). Each casting yard is separated by hoarding and utilizes its own set of gantry cranes for segment box casting.

24 April 2022 - A view of the contract J106 & J107 casting yards in
Tengah West, next to the Tengah depot site.

An aerial view of the casting yard for contract J106.
Source: Jenmon

24 April 2022 - A pre-cast segmented box girder visible in the contract
J106 casting yard.

March 2022 - A view of the rebar support being used for the test segment under contract J106.
Source: LinkedIn

March 2022 - A view of the rebar assembly for the test segment. The pipes will allow the
pre-tensioned cables to be pulled through the segment to form a single viaduct span.
Source: LinkedIn

March 2022 - A view of the formwork assembly for the test segment casting.
Source: LinkedIn

24 April 2022 - Contract J107 casting yard with a pre-cast segment visible.

A view of the contact J107 casting yard shed being set up.
Source: Acre Works

A view of the contact J107 casting yard shed being set up.
Source: Acre Works

A view of the contact J107 casting yard shed being set up.
Source: Acre Works

A view of the gantry crane installation within the contract J107 casting yard shed.
Source: Acre Works

24 April 2022 - Contract J103 casting yard. Casting of segments is underway.

With visible pier construction taking place at Choa Chu Kang and Tengah Plantation station sites, it will not be long before the segmented box girders will be launched into place. The launching of these precast boxes will utilize launch gantries and will likely be one of the most visible aspects of construction along the line.