CMRL Erects India’s First 33.33-Metre U-Girder in a Metro Rail Project

As part of Phase 2, Corridor 5 (ECV-02), Chennai Metro Rail Limited (CMRL) has accomplished a historic engineering achievement by successfully constructing the nation’s first-ever 33.33-meter-long U-Girder at Ramapuram. In the history of Indian metro rail projects, this is the first accomplishment of its kind. The project was completed in cooperation with Larsen & Toubro (L&T), the contractor, and General Consultant AEON.
This ground-breaking girder, which weighs 225 metric tons, is an important engineering milestone that demonstrates the project team’s technical expertise, inventiveness, and execution skills. Six U-Girders, each measuring 33.33 meters, were erected across three spans, with two girders on each span, demonstrating remarkable agility and superior design.

Specialized 6+6 axle multi-axle trailers driven by a Volvo FH 520 HP puller were used to move the girder. Pre-tensioning, complex reinforcing, and adherence to the strictest quality control guidelines were all part of the casting process. It required careful logistical preparation and smooth coordination to move the enormous girder from the casting yard to the erection site.

Senior representatives from CMRL and L&T attended the event, along with Thiru T. Archunan, Director (Projects), CMRL; AGM-EC Thiru C. Murali Manoharan; DGM-Civil Thiru A. Ramakrishnan; Tmt K. Bhavani, EVP & IC Head/Heavy Civil Infra; and Thiru K. Krishna Prabhakar, Project In-Charge/L&T.

Technical Highlights of the Project

• Length of U-Girder: 33.33 metres
• Weight: Approximately 160 tonnes
• Corridor: Phase II, Corridor 4 (Lighthouse to Poonamallee Bypass)
• Total Corridor 4 Length: 26.1 km (including future extensions)
• Total Girders in Project: Over 2,000, with increasing adoption of longer formats
• Time to Erect Girder: Less than 6 hours using hydraulic jacks and cranes

CMRL officials noted that such large U-Girders help reduce the number of piers required, thereby saving time, material, and urban space. This also contributes to reducing environmental impact during construction.

Engineering Innovation and Indigenous Manufacturing

The 33.33-metre U-Girder was manufactured indigenously in Chennai, showcasing the growing capabilities of Indian infrastructure firms and supporting the ‘Make in India’ initiative. The increased length also means fewer joints and smoother alignment of tracks, resulting in a more stable ride for metro passengers.

CMRL engineers collaborated with structural experts and consultants to ensure the design met all safety norms and seismic resilience parameters, especially since parts of Chennai lie in seismic zone III.

A Boost for the Chennai Metro Phase II Project

The erection of this U-Girder comes as part of the much-anticipated Chennai Metro Phase II, a ₹61,843-crore project covering 118.9 kilometers across three corridors. Corridor 4 alone will host 27 stations and significantly ease traffic congestion along the city’s western corridor.

CMRL has consistently emphasized speed and innovation in Phase II, aiming to complete several stretches by 2026. The use of longer U-Girders is expected to accelerate the pace of construction and reduce the overall project timeline.

National Impact and Future Implications

This achievement sets a new benchmark for metro rail construction across India. Other metro projects in Delhi, Bengaluru, and Mumbai are expected to study CMRL’s execution model for possible replication.

Additionally, by proving the structural viability of a 33.33-metre U-Girder, CMRL has opened the door for longer spans and more flexible metro design approaches. This will be particularly helpful in urban settings where land acquisition is a challenge, and reducing the number of pillars can ease both bureaucratic and physical hurdles.

Quotes from Officials

CMRL Managing Director Dr. M.A. Siddique stated:
“This 33.33-metre U-Girder is not just a construction component but a symbol of how Chennai Metro is pushing the limits of urban transportation innovation. It’s a proud moment for Tamil Nadu and a strong message to the rest of the country.”

A senior project engineer added:
“Reducing piers means reducing impact on roads, shops, trees, and homes. It’s about smart growth, not just fast growth.”

Challenges Overcome

Erecting a structure of this size in a crowded city like Chennai involved several hurdles:

• Traffic management: Coordinated nighttime installation to minimize commuter disruption
• Precision engineering: Ensuring perfect alignment using GPS and laser-guided measurements
• Safety protocols: Adhering to strict safety norms for workers and public spaces

Despite these, the team managed to stay on schedule, earning praise from urban development observers.

Public and Environmental Benefits

• Faster project execution leads to early public use
• Fewer disruptions to existing city roads
• Reduced emissions from machinery due to decreased construction duration
• Enhanced rider experience with smoother track alignment

Environmentalists have also commended the initiative for its minimal footprint design, which reduces the need for extensive excavation and raw material usage.

Urban Infrastructure Game-Changer

The deployment of the 33.33-metre U-Girder is not merely an engineering marvel—it represents a strategic shift in urban infrastructure planning. With Indian metros growing at an unprecedented rate, innovations that minimize disruption and maximize efficiency are no longer optional—they’re essential. CMRL’s move will likely prompt other metro authorities to rethink their strategies for elevated corridors, especially in densely packed cities where space is a major constraint.

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Comparison With Other Metro Systems

While cities like Delhi, Mumbai, and Bengaluru have relied on U-Girders in their metro systems, none have matched the length and scale of the one used by CMRL. Typically, U-Girders in those cities fall in the 25–28 metre range. By achieving a 33.33-metre span, CMRL has surpassed national norms, joining global metro systems in cities like Singapore and Dubai that adopt longer spans for faster execution and better aesthetics.

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Speeding Up the Metro Rollout

Another significant benefit of this engineering feat is the acceleration in project timelines. Longer U-Girders mean fewer supports or piers are needed across a given distance, allowing for quicker deck laying and track installation. For commuters, this means that services can begin sooner than originally scheduled. In a city like Chennai, where road congestion is a growing issue, earlier access to metro routes is a major public benefit.

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A Model for Sustainable Growth

Longer girders also reduce the use of intermediate piers, which minimizes land usage, excavation, and overall material consumption. This aligns with sustainable development goals and ensures a reduced carbon footprint during construction. With increasing climate sensitivity and urban heat challenges, these eco-friendly engineering practices will shape how Indian cities grow in the coming decades.

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Future-Ready Infrastructure

CMRL’s use of advanced materials, digital monitoring systems, and modular components makes the infrastructure more resilient to seismic activity, weather fluctuations, and long-term operational stress. The design team reportedly factored in Chennai’s seismic Zone III risk, ensuring that the girder can withstand earthquakes and monsoons alike, thereby increasing the life span of the structure.

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Public Reception and Civic Pride

The announcement of this record-breaking girder erection was met with widespread appreciation on social media and in local news outlets. Citizens have praised CMRL’s pace of construction and its focus on world-class standards. Local civic groups and transportation think tanks have also acknowledged the symbolic importance of indigenous innovation, calling it a moment of pride for Tamil Nadu and India.

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Training and Knowledge Transfer

CMRL has also announced that it will document and share the processes and technical strategies used for this milestone. Engineering colleges, urban planning institutes, and municipal corporations are expected to benefit from the knowledge transfer, which could pave the way for broader adoption of similar innovations across the country.

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Looking Ahead

With this breakthrough, CMRL is expected to continue pushing the envelope with new construction technologies, including segmental box girders, precast stations, and AI-driven construction monitoring. Phase II of the Chennai Metro is set to become one of the most technologically advanced public

The Chennai Metro Rail Limited (CMRL) has set a new benchmark in metro construction by successfully erecting India’s first 33.33-metre-long U-Girder. This structural achievement marks a significant milestone not just for Tamil Nadu but for India’s rapidly evolving urban infrastructure. As part of the ambitious Chennai Metro Phase II, this U-Girder was installed in Corridor 4, connecting Lighthouse to Poonamallee Bypass—one of the most vital transit routes under development in the city.

U-Girders, commonly used in elevated metro projects, are pre-cast, pre-stressed concrete components shaped like the letter “U”, designed for rapid installation and alignment of metro tracks. Until now, the standard length of such girders in Indian projects ranged between 25 to 28 metres. CMRL’s successful launch of a 33.33-metre U-Girder not only exceeds the national benchmark but also demonstrates engineering capabilities on par with international standards seen in metro systems in cities like Singapore and Dubai.

The girder was erected between the Poonamallee and Power House metro stations—key locations along the Corridor 4 alignment. Weighing approximately 160 tonnes, the massive U-Girder was manufactured locally, aligning with the ‘Make in India’ vision. The erection process, which involved synchronized heavy-duty cranes and advanced hydraulic equipment, was completed in under six hours with minimal traffic disruption. This careful execution in a densely populated urban area highlights CMRL’s planning efficiency and technical acumen.

The longer span of the U-Girder translates to fewer piers or support columns along the route, which offers multiple benefits. It not only reduces the cost and time involved in building additional support structures but also helps minimize the urban footprint of the project. This has a positive impact on land acquisition, pedestrian and vehicle movement, and environmental conservation by reducing excavation and concrete usage. For commuters and residents, fewer piers mean more open roads, better visibility, and lower noise levels during construction.

From a design and durability perspective, the 33.33-metre U-Girder provides a more stable and seamless base for laying metro tracks. It improves alignment accuracy, reduces the number of joints, and enhances overall ride quality. CMRL engineers have also ensured that the girder meets all necessary safety norms, including resilience against seismic activity, which is crucial since Chennai lies in seismic Zone III.

The move is expected to have ripple effects throughout the metro rail ecosystem in India. Other metro systems, including those in Delhi, Mumbai, Hyderabad, and Bengaluru, may soon consider adopting similar long-span girders to fast-track construction and improve efficiency. The success of CMRL’s initiative provides a model that could revolutionize elevated metro construction practices nationwide.

In terms of timeline acceleration, the use of longer girders means faster construction as fewer components are needed per kilometer. This reduces installation time significantly and keeps the project on or ahead of schedule. CMRL has consistently focused on rapid, high-quality delivery for Chennai Metro Phase II, which spans 118.9 km across three corridors and aims for completion of major segments by 2026.

Public reception to this achievement has been overwhelmingly positive. Residents and metro users have lauded CMRL for its forward-thinking approach and for pushing the boundaries of civil engineering in India. Media outlets and social media users alike have expressed pride in the fact that such a significant innovation has emerged from a city-based project.

Environmentalists and urban planners have also applauded this development, noting that fewer piers mean less disruption to natural habitats, lower emissions during construction, and reduced urban clutter. With the metro system increasingly becoming the backbone of sustainable urban mobility in Chennai, such smart engineering choices will pave the way for greener growth.

Looking ahead, this milestone is likely to influence future metro and flyover projects across India. By showcasing the feasibility and effectiveness of longer U-Girders, CMRL has demonstrated how infrastructure can be both innovative and context-sensitive. This is especially relevant in land-starved, congested cities, where elevated infrastructure must work in harmony with limited space and dense populations.

As the Phase II construction progresses, CMRL plans to adopt more such engineering solutions to ensure faster execution and better commuter experience. Training programs, documentation, and design models from this girder launch are expected to be shared with engineering institutions and metro authorities across the country, encouraging the spread of knowledge and replication of success.

CMRL’s 33.33-metre U-Girder isn’t just a structural component—it’s a symbol of India’s growing self-reliance in metro rail technology and its readiness to innovate on a global scale. It embodies the convergence of smart engineering, local manufacturing, sustainability, and visionary urban planning.

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