The viaduct span is being made up with a minimum of 8 pre-cast viaduct deck segments, which are manufactured and transported from Jebel Ali casting yard. Different spans together when assembled will form the bridge deck upon which the trains will travel. There will be 11,400 pre-cast concrete viaduct deck segments to be used for the Red Line. Each viaduct weighs about 50 tonnes.
The typical formwork for each segment is 6.7 metres wide, 4.0 metres in length and 2.0 meters depth, is being assembled with other similar sized segments individually to form a complete viaduct span bridging across two supporting piers. There are 10 Intermediate segments plus 2 Pier segments in the 25 meter span.The components included 4 side forms, 2 sets of Inner forms, 5 sets of Bulk heads of 5 types. There were over 2000 components to be manufactured totaling about 125 T (approx), including machining items.
The segments are match-casted and glued together. Post-tensioning then takes place using high strength cables threaded through the segments.