April-June 2005

India has emerged as the country withthe second largest road network in theworld. With a total road network of 3.3

million km, India has edged out China fromthe second spot while US tops the list witha road network of 6.39 million km. Chinahas road connectivity of 1.76 million km.

Our National Highways span about 65,557km throughout the country and cater toabout 45 per cent of the total road transportdemand. The first major step to improve are under the jurisdiction of the Borderroad infrastructure in India was taken in the Roads Development Board, a central 1980s with the Central Government government organization established in deciding to build roads to link major 1960 to facilitate economic development highways, widen existing roads from single and defence preparedness, especially in the to double and four lanes, and construct North and Northeast.major bridges.

In 1997, ninety eight per cent of the national Compared to 400,000 km of roads of all highways (a stretch of 54,000 km) was 64 per kinds during 1950, the present network of cent single lane and 34 per cent two lane 3.3 million km is bound to appear roads. In 1998, the government articulated impressive but it is a fact that more than 25 the National Highway Development Plan percent of villages still have no road link, and created the National Highways and about 60 percent have no all-weather Authority of India to implement the plan toroad link. Moreover, the quality of roads, strengthen and widen the existing roadincluding major highways, is poor by network.international standards. Nonetheless, these roads carry about 60 percent of allpassenger traffic.

Essentially the plan was to be implementedThe National Highways Authority of India in two phases - Phase 1, the Golden(NHAI), set up by the Ministry of Road Quadrilateral (GQ), to convert the nationalTransport and Highways(MoRTH) highways, a stretch of 5,846 km connectingadministers the national highway system the four major metros, to four lanes; Phase 2whereas the state highways and other state of the project involves the North-South androads are maintained by Public Works East West corridors (a total of 7,300 km) toDepartments of respective States. Minor link Srinagar with Kanyakumari and Silcharroads are maintained by the district with Porbander. The entire project is administration and local bodies. Still other targeted to be completed by 2009 at an roads, about 22,000 kilometers as of 1991, estimated cost Rs.54,000 cr. (Rs.540 billion).

Golden Quadrilateral

ROADS & BRIDGESGolden Quadrilateral - The Road Ahead

AP-20 bridge across river Vasista in AP

Punjab highway executed by ECC between Sirhind and Rajpura

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Vol. 28, No.1 April-June 2005

CONTENTS

Editor

Editorial Team

Photography

Content Co-ordinators

Cover Design & Layout

Golden Quadrilateral 2

Jaipur-Kishangarh Expressway 7

Chennai-Tada Road 10

Tumkur-Sira Highway 12

Satara-Kolhapur Road 15

Ahmedabad-Mehsana Road 20

Mumbai-Pune Expressway 21

Second Vivekananda Bridge 28

Bridge Over Ganga 30

Bridging the Valley 34

Second Narmada Bridge 36

AJC Bose Road Flyover 38

Sirsi Flyover 40

International Perspectives 45

Kaleidoscope

Annual Results 2004-05 47

Project Kohinoor 2010 48

Fourth RoSPA Award 50

V.S. Ramana

K.Sridharan Alex BenjaminV.D.S. Prasad V. Ramesh KumarAshwin Chand V. Eswar

Subha Anand

V.S. Natanavelu

R. RangarajanR. Ranganathan

Romaa Communications

Focus

ECC is actively involved inthe design and constructionof roads and bridges in Indiaand abroad. It has also executed some of the criticalroad projects including amajor portion of the GoldenQuadrilateral project. Thisissue of ECC Concord provides an insight into various road & bridge projects executed by ECC.

In a liberalized set-up, an efficient transport

network becomes all the more important to

increase productivity and make the Commencing with the Kolkata-Durgapur Expressway, ECC has executed several major country's economy efficient and capable of road projects across the country such as asserting itself in the world market. The Rourkela-Sambalpur, Bangalore-Hosur, transport system also plays an importantSirhind-Rajpura (in Punjab), Raniganj-role in promoting the development ofBarakar (West Bengal), Mumbai-Pune

backward regions and integrating themExpressway and the Coimbatore Bypass, the

with mainstream economy by throwing uplast one a “greenfield” project that was

opportunities for trade and investment. undertaken as a Build-Operate-and-Transfer(BOT) venture.

ECC’s contribution

The project is partly funded through thelevy of cess on petrol and diesel which istransferred to the central road fund forimplementation of the NHDP.

A snapshot view of the project todayindicates that more than 85 per cent of theGQ project has been completed. The GQproject is scheduled for substantial completion by the end of 2006.

The NSEW corridors are expected to becompleted by 2008 against the target of2009. NHAI has also been creative inevolving financial structures that betterbalance the risk and return. The build-operate-transfer concept has been implemented under toll and annuity methods.

While under the toll method the entire risk is shifted to the private enterprise, the annuity method does better risk sharing. The construction and maintenance contracts are combined and bids areinvited for road development with apromised stream of annuity payments byNHAI as per the concession agreement tothe concessionaire.

The Special Purpose Vehicle route envisages an equity investment of about30-40 per cent by the NHAI and 5-10 percent by the construction/maintenance contractor, with the balance coming through market borrowings. This routegives some sense of ownership to thecontractor but places the risk and returnwith the NHAI.

The factors that have contributed to thesuccess story of road development in Indiaare: A well thought out strategic planarticulated by the government, provision offunding with public, private, market-basedand external borrowings, a schedule forimplementation with careful cost estimates, clearing hindrances for privateparticipation, well empowered regulatoryauthority, transparent procedures for awarding contracts and monitoring progress and a variety of financial structures to balance risk and reward with the private sector.

An efficient transport system is a pre-requisite for sustained economic development. It is not only the keyinfrastructural input for the growth processbut also plays a significant role in promoting National Integration which is particularly important in a large countrylike India.

An Asphalt paver in action

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SM3

SK4

JKEP

TS1

RCO2TN01

ORIIORIV

VB

AP19AP20

RJ11

SVBTC

ECC has been aggressively bidding forprojects under GQ/NS-EW corridor and hasbeen successful in securing about 11%market share against stiff competition.Currently ECC is executing three projectsfor a total length of 180 km, valued at aboutRs.820 cr. Two of these contracts areexclusive “Bridge” packages. The tablebelow gives information on some of theimportant projects executed /currently under execution by ECC.

ECC has so far executed 820 km of road projects valued at Rs.27,794 million.

The Surat-Manor road package funded by first time in National Highway projects. The ADB was the earliest to be awarded to ECC soil at site was having a treacherously lowunder the GQ programme. ECC completed CBR Value (4 - 5). The CBR value was the work ahead of schedule through improved to 15 percent by using cement planned and swift mobilization of treated subgrade. ECC fabricated their ownresources. Certain P&M identified for cement spreader specially for this road,transfer from the nearby Mumbai-Pune which proved to be successful. Also a soilExpressway site were moved to the Surat- stabilizer was imported for thorough mixingManor site even before commencement of of soil and cement. An added feature wasthe work. Meticulous planning ensured the introduction of cement treated subbasethat all bridges in the package were where in cement and water were fed incompleted ahead of schedule and appropriate dosage with aggregate materialfacilitated the execution of road works and then spread evenly with a sensor paverunder the package without breaks as work (that had automatic level controlfronts became available and accessible on a mechanism). With advanced and effectivecontinuous basis. project management techniques we were

able to complete this project 54 days aheadAnother interesting feature here was “soil of schedule.stabilization” which was carried out for the

In India, flexible pavements have heldsway in the years following independence,largely due to limited availability of funds.Even today flexible pavements constitute asubstantial portion of roads being laid.However, concrete pavements are becoming popular now, particularly afterthe experience in the Mumbai-Pune Expressway. Concrete pavements offer theadvantage of savings in cost and time andalso need only minimal maintenance, thuseliminating the need for disruption oftraffic in case of repairs. In the OR -IV, V-Bpackages and the new carriageway inKolhapur-Satara stretch covering a total of130 km, ECC is laying concrete roads.ECC believes that to achieve faster laying,road works have to necessarily be equipment-oriented rather than labour-intensive and has, therefore, mechanized a major part of its road-building activities.

Surat-Manor road project in Gujarat

Kancheepuram-Wallajapet road project in Tamil Nadu

Road /Bridge Projects Length (km)

Completed

Surat-Manor - 57.40

Satara-Kolhapur - 29.00

Jaipur-Kishangarh - 40.00

Tumkur Sira - 41.40

Kancheepuram-Walajahpet - 36.20

Chennai-Tada - 41.80

Chandikhol-Bhadrak - 75.50

AP 19 bridge acrossriver Gowthami - 2,341 m

AP 20 bridge across river Vasista - 940 m

In Progress

Baleshwar-Laxmannath projectin Orissa - 53.14

Kahudag BorataniRoad, Jharkhand - 80.00

(near Baran) - 70.00

Second Vivekananda - 800 mBridge across river (6.1 km incl.Hooghly approches)

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· Rajasthan package

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The Bhadrak-Chandikhole stretch in comprising 19 underpasses, 58 culverts March 2005. An innovative materialOrissa, known as Package OR-II, was and 28 minor bridges) had to be executed included the preparation of bituminousfunded by NHAI through its internal all along. Since there was an acute shortage concrete, using the Crummed Rubberresources. The most formidable aspect of of availability of right aggregates, they had modified bitumen supplied from refinery.this project was the stupendous volume of to be procured from leads of upto 25 km earthwork which involved a quantity of project on NH 60away. Granular sub-base material also had Baleshwar-Laxmannath65,00,000 Cum. The existing roads in this in Orissa is a concrete road package andto be fetched from borrow pits at a distance stretch were at high levels due to vast involved 72,25,000 Cum of earthwork.of 28 km. The site team encountered lot of stretch of water logged areas, presence of Since the entire project was located in a difficulties in the last stages of projectBaitharni river and proximity of sites to water logged area, “Sand Coring” method completion when land for junctions andbackwaters. As a result a large number of was adopted for formation of embankments. overpass were not available. Despite allcross drainage (CD) works (105 A core of sand was encased by a layer ofthese hurdles the project was completed in

murrum to contain the sand. The workconsisted of raising the existing road byabout 2m and symmetrical widening of thesame on either side, necessitating frequentand numerous traffic diversions. Borrowareas were scarce and quarries were located32 km away. ECC raced against all theseodds and completed the project. This roadshortens the distance between Kolkata andBalasore by about 30 km.

The Chennai-Tada stretch on NH-5 passesthrough several stretches of densely built-uparea. Considerable ribbon developmentalong the route, acquisition of land anddiversion of utilities / services were some ofthe major problems faced in this project. Inthe interest of expediting the work, ECCtook upon themselves the work of diversionof services even though this was not in theoriginal scope. This work also involvedconstruction of two bridges using pre-stressed concrete 'I' Girders and cast in-situslab for decking. Foundations were raisedon wells taken to approx. 14 m depth.

162 km Sambalpur-Rourkela expressway in Orissa

Satara-Kolhapur road project in Maharashtra

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The scope also included the constructionof a flyover near Madhavaram having sixspans of 25 m each, featuring a continuousdeck being built up using void form. Theproject was completed against all odds.Yet another notable feature in this projectis the use of polymer-modified bitumen(imported from Ooms Ooverhorn of Netherlands) for the first time in India.

Package V-B in Jharkhand is a JointVenture between L&T and HindustanConstruction Company Limited for the firsttime (for road projects), with L&T as thelead partner. The work involves dismantling the existing 2-lane road offlexible pavement and widening it to fourlanes with concrete (rigid) pavement. The

even though they may be lowest for more · Meticulous planningdismantled pavement material will be re-than one package. The new carriageway is · Judic ious sourc ing o f mater ia l sused as fill in medians. Here also we aremade up of concrete pavement while the locally availableworking in a very hostile environment asexisting lane is of flexible pavement. Herethe project area is a stronghold of Naxal · Trained manpower to operate the also we have completed the project almostelements. Also, land acquisition for a machineryseven months ahead of schedule.stretch of about 12 km is yet to be · Unimpeded availability of work fronts for

completed. For the first time NHAI have prompt deployment of equipment as perKancheepuram-Wallajapet road packagestipulated the provision of kerb with work schedule(bituminous pavement) on NH-4 is fundedreinforcement for which we have procuredfully by National Highways Authority ofstate-of-the-art It is significant to mention that ECC possesses India (NHAI). Two sets of crushing plants We have mobilised a and deploys critical plant and machinery that and two hot mix plant were mobilized for huge fleet of plant and machinery to are essential for faster execution of road the project. ECC completed this project ensure speedy completion. We expect the projects. Some of these vital P&M include:ahead of schedule. project to be completed in March 2006.

· Large capacity crushers - stationary andTumkur-Sira road is funded by Asian NHAI assigned the Kolhapur-Satara road mobileDevelopment Bank. This package consists project to Maharashtra State Road

· Pneumatic tyre rollersof 42 km of bituminous pavement andDevelopment Corporation (MSRDC) for

· Motor gradersnearly 76 km of service roads / slip roads toexecution. MSRDC in turn split the work

· Vibratory compactorscater to slow moving local traffic.into five packages and invited bids from

· Batching plants - automatedcontractors. To ensure transparency in

· Hot mix plants - automatedExecution of a modern road project award of contracts as also to speed up · Pugmillinvolves the efficient use of resources and work, it was a basic condition that each · Slipform concrete paversProject management capabilities such as :bidder would secure only one package · Sensor controlled pavers

· Kerb casting machine

Facts and figures described above represent just the tip of the iceberg. In fact, the golden quadrilateral is a massive exercise taken up in the country, on a war footing and this has simultaneously resulted in a serious constraint on skilled human resources. This has to be met only by imparting a lot of training and by mobilizing an optimal mix of experienced personnel and those eager to learn mostly on the job. Almost a new breed of contractors are being generated through aprocess of back-to-back contracting but with a lot of support in terms of resources both financial and technical to enable small timecontractors to think big (e.g.) free supply of aggregates. The philosophy is that the major players will be resorting to Project Management and Control.

R.RangarajanContracts Manager (R&R), HQ

slipform kerber from Power Curbers.

Asphalt Rolling using pneumatic tyre roller

A motor grader at a road project

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ational Highway No.8 (NH 8) is National Highways Authorityone of the major arteries of the road of India (NHAI), the nodaln e t w o r k s y s t e m o f I n d i a agency entrusted with theN

connecting the National Capital New Delhi task of modernising thewith the Financial Capital Mumbai and highway network, called forforms part of the Golden Quadrilateral. The tenders to implement theJaipur-Kishangarh section on the Delhi- project through the build-Mumbai corridor connects Pink City Jaipur operate-transfer (BOT) route.to Marble City Kishangarh and extends from L & T I n f r a s t r u c t u r ekm 273.500 to km 363.865. Due to heavy Deve lopmen t P ro j ec t straffic on this two-lane, 90.365 km stretch, Limited (L&T IDPL), intraffic jams and accidents were a regular association with GVK Groupfeature, making the region and the State and B. Seeniah & Companyunattractive for investors. The Government, Private Limited (BSCPL),therefore, made a study of the situation and formed a Special Purposedecided to widen the Jaipur-Kishangarh Vehicle (SPV) called “GVKsection to six lanes. Thanks to successive J a i p u r - K i s h a n g a r hregimes taking to the path of liberalization Expressway Limited” for

Completed in a record time of 24 months,and encouraging public-private partnership implementing this project. L&T IDPL, GVK six months ahead of schedule, this is India'sfor infrastructure development, funds were and BSCPL hold equity in the SPV in the first such six-lane expressway and India'snot a constraint for implementing the ratio of 40:41:19. The project has a largest Build-Operate-and-Transfer (BOT)project. concession period of 20 years including highway project to date.the construction period.

Salient Features:Total Project Length - 90.365 kmProject Length for L&T - 40 kmContract Award Amount for L&T - Rs.295.96 cr.SPV - GVK Jaipur-Kishangarh

Expressway LimitedEPC Design Consultant - L&T-Rambøll Consulting

Engineers Limited EPC Contractor - Larsen & Toubro Limited

ECC DivisionOwner's Engineer/ - Lea Associates South AsiaSupervision Consultants Pvt LimitedIndependent Consultants - BCEOM, France

thCompletion Date - 9 April 2005

ROADSJaipur-Kishangarh Toll Road Project

A view of the Jaipur-Kishangarh toll road project executed by ECC six months ahead of schedule

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L&T and BSCPL were the EPC contractorswith L&T taking up the initial urban stretchof 40 km from km 273.500 to km 313.500

Major Plant & Machineryand BSCPL the balance 50.365 km. L&Thad taken up the responsibility for the state-of-the-art Toll & Highway Traffic Major Equipment deployed for the Management System along the entire execution of works were as follows :corridor including BSCPL's portion. Quantities are given in brackets

BCEOM were appointed as independent 300 TPH Crusher Plant (1), 150 TPH Crusherconsultants for the project. While Lea Plant (1), Hot mix Plant (2), Batching PlantAssociates South Asia Pvt Limited were (2), WMM Plant (1), Paver Finisher (3),chosen by the SPV as Owner's Engineer and Motor Grader (6), Transit Mixers (10), Kerbfor supervision of the work of EPC Casting machine (2), Vibromax Rollers 10tcontractors, the EPC contractors (L&T and (3) , Tandem Rollers -W752 (6) TandemBSCPL) engaged L&T-Rambøll Consulting Rollers-W252 (7), Hess Block Making M/cEngineers Limited as EPC consultants for the (1) Wheel Loaders (6), Bitumen Sprayer (4),preparation of detailed engineering. Emulsion Plant (1).

Following Plant & Machinery were supplied by our sub contractors’.

WMM Plant (2), Paver Finisher (2), MotorGrader (3), Vibromax Rollers -10t (3),Excavators (13), Dumpers (9), Wheel loader(4), GSB Crusher (1).

per standard specifications. See table fordetailed scope of the project.

Scope

L&T's scope was to construct the 40 km six-lane road with 13 km service roads in theurban area commencing from km 273.500to km 313.500 along with all specifiedfacilities in the EPC contract agreement as

Scope of work

Details Quantity /Unit

· Road Way Excavation - 10,04,074 Cum

· Construction ofEmbankment/Subgrade - 14,39,551 Cum

· Granular Sub Base - 2,98,674 Cum

· Wet Mix Macadam - 2,79,880 Cum

· Bituminous Macadam -73,730 Cum

· Dense BituminousMacadam - 1,08,928 Cum

· Bituminous Concrete - 56,808 Cum

· Flyovers - 03 Nos.

· Major Bridges - 02 Nos.

· Minor Bridges - 08 Nos.

· Culverts - 31 Nos.

· Cattle Crossing - 05 Nos.

· Bus Lay Byes - 24 Nos.

· Truck Lay Byes - 10 Nos.

· Toll Plaza - 01 Nos.

· RE Walls - 2,240 RM

· Crash Barrier - 46,944 RM

· Pedestrian Guard Rail - 26,000 RM

· Stone Masonry/ Concrete Drains -26,000 RM

· Kerb -1,11,596 RM

View of the flyover and the highway at Jaipur Inset : View of a junction

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Problems and Solutions

We are giving below some instances of thelocal problems encountered during execution of the job and how they wereresolved.

· Presence of Temples and Mazars in theproject area: Due to the presence of 55temples along the route and two mazarsat km 276.500 and km 300, we were notable to carry out roadwork at manylocations. Representatives of L&T andSPV spoke to the local people andconvinced them of the need to re-locatethe temples. As for the mazars, the oneat km 276.500 could not be relocatedand hence the width of the service roadwas reduced with the consent of IC,NHAI and others. The road at 300 kmwas realigned and the width of themedian at this location was increasedfrom 5.0 metres to 6.50 metres toaccommodate the mazar within themedian.

.· Crusher and Quarry Area: Due to Benefits from the Project· Catt le Pass at km 280: Land

heavy movement of traffic, locals were acquisition was not done at km complaining about dust generation. We As a result of this project, land prices in the280 and construction of cattle made arrangements for continuous area went up steeply, children were able to pass was very important there. pouring of water to prevent this and commute to bigger and better schools, We impressed on the land-owner upgraded the earthen roads to GSB tourist inflows increased, travel time came to allow us to construct the road roads. down considerably and there was a decline even if he had not received any

in maintenance and running cost of compensation. We awarded him · Construction in Urban Area: Our vehicles. In short, the Jaipur-Kishangarh some of the stone masonry work

section passed through 13 kms of Expressway has become the new highway tofor which we were facing labour densely populated urban area. prosperity for all sections of the people in shortage.Working was most difficult in the urban the area.area whether it is construction of drains, S.H. Vora· Underpass at Bhakrota: Due to utility ducts or other activities. By Sector Projects Managerthe demand f rom some loca l

(Transportation Infrastructure Sector)employing some of the good local people for an underpass at Bhakrota, Ahmedabad Regional Officemates, giving drain and utility work to which was not in our scope, work

local subcontractors, these problems was stopped in one km for more `were brought down to minimum. In than a month. However, using our extreme cases, we had taken help of good relations with the locals, wel o c a l p o l i c e w h o w e r e v e r y were able to pacify them and continuecooperative with us. our work

View of the state-of-the-art toll plaza at Jaipur

Dr. A. Ramakrishna and Mr. K.V. Rangaswami seen with the Prime Minister Dr. Manmohan Singh during the inaugural ceremony of Jaipur-Kishangarh expressway on May 23, 2005.

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he Government of India is contractual completion period of 31 · Minor bridges - 06implementing a very ambitious months. · Slab culvert - 36Thighway development programme · Encumbrance-free site was to be · Pipe culvert - 44

to expand the capacity of national handed over in a phased manner · Box culvert - 02

highways by strengthening the existing during the first eight months of the two-lane carriageway and by adding a two- contract.lane carriageway. This is expected to bring · The contract had a clause providing

· New Jersey type RCCabout substantial improvement in the road for payment of bonus for early crash barrier of median - 14,900 RMinfrastructure and contribute to the socio- completion at 1% of the contract

· Metallic crash barrier economic growth of the country. This value per month for a maximum of (both sides) - 30,500 RMprogramme is called the “Golden six months and for levy of liquidated

· Bus shelter - 43 Nos.Quadrilateral” and will connect the four d a m a g e s , i n c a s e o f n o n - metros of New Delhi, Mumbai, Chennai completion at Rs.3 lakh per day.

Difficulties faced during executionand Kolkata. · Execution was done as per MoRTH(Ministry of Road Transport and

Against the contractual requirement of Under this programme ECC has H i g h a y s ) s p e c i f i c a t i o n s i n handing over of encumbrance free site in 4constructed the TN01 package from km c o n j u n c t i o n w i t h t e c h n i c a l parts in 3 phases, the site was made available11/00 to km 52/80 of NH-5, which is the specifications specifically amended forfor work in more than 600 parts.starting point of the Chennai-Kolkata this project.

corridor.· FIDIC terms & conditions were The preliminary notification to public

applicable to the execution of this towards land acquisition, generally known Salient Features of the Project project. as 3A, was not issued.

· Designed to meet the demand for the Scope of Work As the works commenced it came to light next 20 years for a traffic census of that utility service providers like TNEB, 33196 vehicles. Metrowater, TWAD and local Panchayat

· Designed for upgradation into 6 lane · Unions had not been advised to initiate

carriageway after 15 years. relocat ion act ivi t ies . Under the · To relieve congestion of traffic, a 4 km circumstances the site management had to

long by-pass is provided at Karanodai. interact with the authorities concerned,obtain estimates from them and forward the

Project Information same to the employer for necessary action, as· Grade Separator - 01otherwise it was not possible to take up the· Overpass - 01works even in the available meagre · The order was secured through · Underpass - 04stretches.International Competitive Bidding · Major bridges - 06

(ICB) at Rs.185.02 cr. with a

Road furniture

Road Works

Widening & s t reng then ing o f carriageway and construction of additional carriageway - 42.96 km

Structures

ROADSChennai-Tada RoadGateway to Tamil Nadu & Andhra Pradesh

Four lane Chennai-Tada road project

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Since our resources were idle and substantial completion certificates with underutilized due to pending matters like effect from 18/12/2004, 20/01/2005 and land acquisition we complied with the 12/04/2005.employer's request to carry out the utility relocation works even though they did not By April 6 2005, the contract period had form part of our scope. already been extended by 15 months

beyond the contractual period and due to Due to pending land acquisition works, engineer's decision based on the ground certain stretches and structures could not conditions, our liabilities towards the be commenced/completed by us whereas extension had come down.

Other problems facedthe other completed stretches were already being used. Specialised works executed

Decisions

Since the continuing delay in completing Reinforced Earth Wall Due to non-clearance, availability of land “certain stretches and structures” would in

and existence of utilities, road alignment turn delay the completion of individual Reinforced earth wall technology was a and median width were modified several sections as a whole which also would patented technology newly introduced in times to accommodate the utilities. extend our contractual liabilities likeIndia to replace heavy RCC retaining walls Additional provisions and modificationsinsurance of works, defect liability period,to retain high embankment which would were made in drawings and the engineeretc., the clients were persuaded to agreebe durable, cost effective and enhance the changed category of CD works from slab tothat those “certain stretches and aesthetics of the structure. pipe or vice-versa. At certain locationsstructures” would be completed by us

structures were cast even in parts.during defects liability period though thereVoided Deck Slabwas no such provision available in the

Statues/Religious Structurescontract.Void is maintained by providing void

To facilitate execution of the work, certainAs per the above arrangement sections C, former in deck slab to reduce dead load ofstatues and religious structures were to be re-B and A were substantially completed deck slab in order to minimize the cost.located. Though this did not form part of our(except works under exclusions) and the The voided deck slabs are provided atcontract we interacted with the locals,engineer issued the respective section's grade separator and 53/1 bridge.panchayat union officials and others andcarried out the re-location work in a smoothmanner.

Statutory Compliances

In such highway projects we need to takep r i o r a p p r o v a l s f r o m l o c a l bodies/government agencies for procuringsand from local sources. Pollution controlnorms too have to be met while executingroad projects. We satisfied both therequirements and were able to get the co-operation of the authorities as well as thelocal people.

K.S. ReddyProject Manager

Road related

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Excavator -

· Dozer

· (0.9 -1.2) - 12

· Motor grader - 04

· Vibratory roller-10 t - 06

· Paver (wet mix) - 02

· Paver (bituminous)-600 t - 03

· Tandem roller - 10 t - 06

· Pneumatic tyre roller-18 t - 03

· Wet mix plant (60/100 tph) - 03

· Hot mix plant (100/170tph) - 03

Name/Capacity Qty.of P&M

Name/Capacity Qty.of P&M (Nos.)

Concrete related

· Concrete batchingplant - 30 Cum - 02

· Concrete pump - 02

· Transit mixer - 6 Cum - 08

· Crusher - 100/150 tph - 02

· Wheel loader - 04

· 5/500 kva DG Set - 12

· Trailer - 01

Common service

(Nos.)

Major Plant & Equipment deployed during peak execution

Major Quantities of work

Earthwork - 11,59,515 Cum GSB - 2,52,066 Cum WMM - 2,52,583 CumKerb - 1,10,654 LmBM/DBM - 1,55,555 CumPMA - 33,384 Cum Concrete (insitu) - 10,200 Cum Reinf.steel - 3,800 tPrecast t beam - 107 Nos.Prestressing - 116 tVoid former - 2,242 RMRE wall - 13,950 Sqm

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Above and below : Completed view of the road

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ndia is going through a phase of rapidd e v e l o p m e n t o f i t s h i g h w a y infrastructure, thanks to the ambitious I

National Highway Development Project (NHDP) worth Rs.54,000 cr., launched by the National Highways Authority of India (NHAI). NHDP is aimed at strengthening and widening the Golden Quadrilateral (GQ) and North-South and East-West Corr idors (NS-EW). The Golden Quadrilateral programme involves widening of the existing highway to 4/6lanes, connecting the four metropolitancities - Delhi, Mumbai, Chennai andKolkata -, accounting for a total length of5,846 kms., as also the NS-EW corridorcovering 7,300 km.

The Tumkur-Sira Section of National final value of Rs.186 cr. The project scope underpasses, 6 pedestrian foot over-Highway No.4 in Karnataka starts at 75 bridges.included:kms. from Bangalore, spans a length of 42kms. and forms part of the GQ route of · Construction of reinforced earth wall to· Six-laning for a length of 9 kms. andMumbai - Chennai Corridor. an extent of 5150 Sqm for a length offour-laning for a length of 33 kms.

500 metres.i n c l u d i n g d i s m a n t l i n g a n d NHAI is the Employer for the Project and reconstruction of the entire 42 kmLouis Berger Group, (comprising of stretch. · Providing chain link fencing for a length M/s.Louis Berger Inc., Canada, in of 66 km and masonry walls for 18 kmassociation with Roughton International (on both sides) between the main · Construction of service roads for a Consulting Engineers, UK, Sheladia carriageway and the service road.total length of 76 km.Associates & Consultants (India) Pvt. Ltd. and Consulting Engineers Group Ltd., Providing metal beam crash barriers for a Construction of 24 box culverts, 40 ··

India) the Engineer. The Tumkur-Sira length of 17 km at vulnerable locations.p i p e c u l v e r t s a n d 9 b r i d g e sproject , per formed under F IDIC i n c l u d i n g d i s m a n t l i n g a n d Conditions and with Financial Assistance reconstruction of the existing ones. · Providing raised pavement markers, by Asian Development Bank (ADB), took road signages, etc. for the entire off at an estimated cost of Rs.153.23 cr. and length.· Construction of 7 pedestrian subways, was completed by December 2004 within 3 vehicular overpasses, 7 vehicularthe contractual duration of 34 months at a

Rehabilitation and upgradation of Tumkur-Sira road in Karnataka

A bridge executed for the Tumkur-Sira road project

ROADSTumkur-Sira Highway, Karnataka

12

In providing the above facilities, top Major fleet of equipment deployed topriority was given to safety engineeringmeasures. NHAI had to acquire land from

about 1000 individuals - 900 titleholders·

The main carriageway was designed for a and 100 non-titleholders - spread over 25speed of 120 km. per hour and the service villages along the project length of 42 kms.·

roads were intended to segregate the local This was a stiff task and could only be traffic. As pedestrians are not expected to accomplished in close co-operation with

·

venture into the highway, the entire NHAI and by nominating an exclusive staff ·

highway has been secured by means of to co-ordinate with NHAI, the villagers andchain link fence and masonry walls. authorities concerned. Furthermore, all the

·

Suitable provisions have been made for the trees within the ROW (right of way) were pedestrians at appropriate locations to required to be cut but there was stiff cross over to the other side. resistance from 'tree lovers', following

·

which the Forest Department hesitated to·

Following are the major items of work permit the felling of trees.·carried out for the execution of the project:

· Tree cutting/stump·removal - 10,439

· Excavation in·soil/rock - 6.72 lakh Cum ·

· Embankment/Sub·grade filling - 19.40 lakh Cum·

· Granular sub base - 3.39 lakh Cum

· Wet mixmacadam - 3.02 lakh Cum

·· Bituminous Works - 2.12 lakh Cum

· Concrete - 1.07 lakh Cum

· Reinforcement steel - 5,100 t

· Aggregateproduction - 24.50 lakh t

At many places the work had to be executedachieve the above completion: as and when workfronts (land) became

available.

Stone crushers - 3 Nos. of 150/250 tph capacity

Hot mix plant - 2 Nos. of 160/120 tph. capacity

Sensor pavers - 4 Nos.

Concrete - 2 Nos. of 30 Cum batching plant capacity

Wet mix - 2 Nos. of Macadam plant 150 /100 tph.

capacity

Excavators - 15 Nos.

Motor graders - 7 Nos.

TandemVibratory/vibratory rollers - 10 Nos.

Pneumatic tyredNos.Rollers - 2 Nos.

Kerb caster - 2 Nos.

Transit mixers - 8 Nos.

Wheel loaders - 5 Nos.

DieselGenerators - 10 Nos.(varying capacities)

Dumpers - 50 Nos.

The project duration of 34 months tocomplete the above scope required veryc o m p r e h e n s i v e p l a n n i n g a n d corresponding deployment of resources.

View of four lane road passing through a cut section. Inset: Completed view of a bridge

13

However, due to the concerted actiontaken by L&T and NHAI, the issue wasresolved amicably and we were able toproceed with the work.

During project execution, we had to facenumerous hurdles from the villagers inoperating our quarries and crushers. Tomeet our requirements of blue metal, ablast on every second day was mandatoryto produce about 5,000 t. of boulders. Forthis blasting operation we had to use 1,600kgs. of booster and ammonium nitrate.This again was objected to by the villagersliving about 300 metres from the quarry.Here too the site team was successful inconvincing the villagers about the measures taken to ensure their safety and going ahead with the work.

We attribute the successful and timely completion of the project to the teamwork of the representatives of the Employer, Engineer and our staff, all of whom had one · PAPs were paid compensation for market comprising of 33 stalls wasslogan to guide them: their land at the prevailing market constructed by us.

rates, in addition to payment of an“Your problem is my problem and my add i t i ona l sum towa rds t he i r · A sum of Rs.6 cr. was paid to the PAPs

problem is your problem and let us join rehabilitation and resettlement. under this policy for this project and hands and solve them jointly without Rs.1.5 cr. was paid to us for construction pointing fingers at any one and wasting · All community structures that were of structures.precious time.” dismantled have been reassembled/re-

constructed at new locations. As part NHAI had appointed an NGO toAs a special feature under this loan of this exercise, we constructed 3 implement this policy and a Monitoring and agreement, NHAI had introduced a Policy schools, 1 hospital, 1 police station a n d Evaluation Consultant monitored theof Rehabilitation and Resettlement of 11 temples. NGO's work.Project Affected Persons (PAPs) and relocation of public utility structures under Bellan Sreedharan· Public awareness programme was ADB norms. Under this policy: Construction Managerconducted.

· The main objective was to ensure that· Income-generating schemes for the

the social status of the PAPs was not PAPs were introduced and a vendoraffected.

Above and below: Completed view of the four lane highway with median and road markings

14

he National Highways Authority of L&T secured Package IV (Km. 668/000 to India (NHAI) had taken up four- 697/000) at a contract price of Rs.118 cr. Tlaning of NH-4 from Mumbai to v i d e M S R D C ' s l e t t e r N o .

MSRDC.LTD./462 (Letter of Acceptance)Chennai forming part of the GoldenQuadrilateral. NHAI assigned the section dated January 24, 2002. The Notice Tofrom Satara to Kolhapur on NH-4 for four- Proceed with the works was issued videlaning to Maharashtra State Road letter No.MSRDC Ltd./2158 dated May 3,Development Corporation 2002 after obtaining environmental (MSRDC) for

clearance for the project.implementation from preliminary design tofinal completion.

The project consisted of widening theexisting road from two lanes to four lanesMSRDC divided this section running fromand construction of two additional laneskm. 592/240 to km. 725/000 into fivewith rigid pavement including newindividual packages as shown below andembankment, major and minor bridges,invited bids for all the packages with theflyovers, subways, CD works, drainagecondition that a bidder would be awardedsystem, strengthening of existing pavementonly one package.with flexible pavement, overlay and appurtenances, etc, as well as repair and1.Package I - km. 592/240

m. modification to the existing structures.to k 616.000Service roads have been provided all along2.Package II - km. 616/000the main highway for the local traffic andto km. 639/000necessary junction improvements and 3.Package III - km. 639/000construction of subways carried out. Other to km. 668/000amenities like bus-bays, etc. have also been 4.Package IV - km. 668/000provided.to km. 697/000

5.Package V - km. 697/000 To km. 725/000

Four Laning of Satara-Kolhapur road for MSRDC

ROADSSatara-Kolhapur Road, Maharashtra

Project Highlights

· Name of the - Four-laning of Project Satara-Kolhapur

Road

· Employer - MSRDC

· Project - Span ConsultantsManagement Pvt.Ltd.,Consultant NewDelhi

· Length of projectunder package IV - 29 km

· Original contractvalue - Rs.118 cr.

· Revised contractvalue - Rs.185 cr.

· Date ofcommencement - 3rd May, 2002

· Original durationof project - 27 Months

· Original date ofcompletion - 2nd Aug, 2004

· Extended durationof project - 42 Months

· Extended date ofcompletion - 31st Oct, 2005

· Actual date ofcompletion - 17th Mar, 2005

· Actual durationof the project - 35½ Months

15

The project road length in Package IVpasses through Satara District in theDeccan Plateau which experiences average rainfall of about 2800 mm and

0temperature ranging between 40 C and

012 C. Along the entire road stretch there is lot of agricultural activity with some industrial estates near Karad and some commercial activities around Rethre, Wathar and Vahagaon.

The new alignment, consisting of 2additional lanes in eccentric widening,had a composition of rigid pavement. Thisconsists of 320 mm thick M40 GradePavement Quality Concrete (PQC). Belowthis, 150 mm thick Dry Lean Concrete(DLC) was provided. Out of the totallength of 29 Km, rigid pavement isprovided for a length of 22.040 Km. Thebalance length of 6.960 Km is flexiblepavement consisting of widening of theexisting road and overlaying with bituminous surface.

On the existing carriageway bituminousoverlay was provided which consists ofDense Bituminous Macadam (DBM) overlaid with a layer of Bituminous Concrete (BC) wearing course with crumb rubber modified bitumen of Grade 50. Service roads have been provided on either side of the main road for a total length of 51 Km. The construction involves embankment/sub-grade filling,GSB, WMM and wearing surface withbituminous macadam and seal coat.

Major Items of Road Work

Cross Drainage Works and Drainage System

Lot of cross drainage works across the maincarriageway as well as the service roads,major and minor bridges, subways andflyovers have been carried out for properchannelling of water and providing uninterrupted movement of traffic. This is supplemented with a proper drainage system to drain the water. The details ofthese works are as under.

Proper drainage arrangements have beenmade by providing drains (lined and unlined) across the length of the road, crosspipes across the embankment of the road, retaining wall for toe protection, drains in median at super-elevation portion, etc.

Completed view of four lane Satara-Kolhapur road

·

·

·

·

·

·

·

·

· Dry lean concrete· Pavement Quality

·

·

·

·

·

·

·

·

·

·

Earthworkexcavation in soil - 6,96,893 CumEarthworkexcavation in rock - 26,084 CumEarthwork filling with excavated earth - 58,360 CumEarthwork fillingwith borrow earth - 18,72,827 Cum(Incl. RE wall filling)Rock-filling forembankment andbehind structures - 67,453 CumGranular Sub-base - 1,89,262 CumWet mix macadam - 1,28,637 CumKerb laying - 6,294 Cum

- 28,762 Cum

concrete - 57,580 CumPrime Coat - 5,80,608 SqmTack Coat - 5,59,060 SqmBituminousMacadam - 15,278 CumSeal coat - 2,68,037 SqmDense BituminousMacadam - 45,416 Cum Bituminous Concrete - 16,782 CumMetal Crash Barrier - 4,919 RMThermoplastic lanemarking - 22,098 SqmPainting of Kerb - 34,879 SqmStone pitching of Slopes - 91,628 Sqm

Major quantities of work

Types of Nos.Structure ConstructedMain CarriagewayHume pipe culvert 50Box Culvert 29Minor Bridge 5Major Bridge 1Subway 21Floyover 3Foot overbridge 1

Total 110

Service Road Hume pipe culvert 97Causeway 28

Total 125

16

Major Bridge Across Koyna River

Koyna River crosses the alignment at Km.682/700 of NH-4. This is a perennial riverwith its discharge regulated from the KoynaDam upstream. The water from this river isthe main source for meeting the needs ofKarad Town.

A new bridge has been constructed for theadditional two-lane width and the existingbridge has been rehabilitated. The structural details of the new construction are as under:

Flyovers

In order to provide through passage for the traffic on NH4, three flyovers have been constructed in the urban areas near Karad Town - at Dhebewadi, Karad and Chiplun. The details of the flyovers are as under:

No. of spans -7Length -30.4 m eachWidth -14.00 m (3 lane +Footpath)Foundation type -Open foundation - 3 Nos.

Well Foundation - 4 Nos. (Diameter of well - 8 m external and 5.6 m internal)Pile foundation-1No(12 piles of 1 m diameter with liner)

Sub-structure - Abutments - counterfort retaining wallpiers- circular tapering diameter for bottom 3 m height and 2.4 m diameter at top with pier cap (2.7 m width x10.8 m length)

Super-structure -Pre-cast and post-tensioned RCC girders with concrete deck slab 250 mm thick.

Wearing course - Mastic asphalt (12 mm thick) overlaid with Bituminous concrete.

No.of girders - 28 nos. (2.15 m height with each girder weighing 85 t )

Technique used - Erection using launching girder

Type of bearing - POT & POT cum PTFE bearings (56 Nos.)

Type of - Single strip seal jointExpansion joint with movement upto

80 mm.

Foot Overbridge

The foot overbridge at Karad at Km. 681/788 across NH 4 has been constructed to provide crossing for the local residents. Apart from the deck slab and main tie beam, the entire structure was precast and erected at site.

Details

Location on NH4 km. 680/700 km. 682/000 km. 683/800

No. of Carriageways 2 1 2

No. of Spans Module 1 1 No. 18 Nos. 2 Nos.Module 2 2 Nos.

Length of each Span 20 m 20 m 20 m

Length of structure 20 m + 40 m 360 m 40 m

Width of structure 2 x 12 m 1 x 12 m 2 x 12 m

Type of Foundation Pile foundation Pile foundation Pile foundation

No. of piles 60 Nos. 90 Nos. 36 Nos.

Sub-structure Circular piers of Circular piers of Circular piers of 2 m dia 2 m dia 2 m dia

Super-structure Pre-cast, post- Pre-cast, post- Pre-cast, post-tensioned RC tensioned RC tensioned RC Girders with Girders with Girders with Concrete deck Concrete deck Concrete deckslab 240 mm thick slab 240 mm thick slab 240 mm thick

Wearing Course Mastic Asphalt Mastic Asphalt Mastic Asphalt(12 mm thick) (12 mm thick) (12 mm thick)overlaid with BC overlaid with BC overlaid with BC

No. of Girders 24 Nos. 72 Nos. 16 Nos.

Erection Tandem lifting Tandem lifting Tandem lifting Technique with crane with crane with crane

Type of Bearing POT PTFE POT PTFE POT PTFE (48Nos.) (144 Nos.) (32 Nos.)

Type of Single strip seal Single strip seal Single strip sealExpansion Joint with movement with movement with movement

upto 80 mm upto 80 mm upto 80 mm

Type of Reinforced Earth Reinforced Earth Reinforced Earth Approach Wall Wall Wall

Length of Kolhapur End-440m Kolhapur End-187m KolhapurApproach Module 1&2-120m Satara End -111m End-298m

Satara End-316m Satara End-384m

Dhebewadi Flyover Karad Flyover Chiplun Flyover

Bridge across Koyna river

17

Equipment Deployed

The major equipment deployed for theexecution of the works at peak were asfollows. Quantities are given in brackets.

Finisher 5.5 m wide (1), Mechanical PaverFinisher (1), Hydraulic Motor Grader (5),Vibratory Earth Compactor ( 7), TandemVibratory Roller (2) Tandem Vibratory Roller2 T (3), Mobile Cranes 16-20 T capacity (3),Concrete Cutting Machine (3), Kerb CastingMachine (1), Wheel Loader (2), ExcavatorCrushing Plant 150 tph (1), Crushing Plant(8), Rock breaker (2), Heavy Duty Dumpers2 x 50 tph (1), Concrete Batching Plant 100(16), Tippers 10 T (90), Trucks (3), Watercu.m./hr (1), Concrete Batching Plant 30Tankers (10), Gantry Crane (3), Transit Mixercu.m./hr (1), Hot mix Plant 160 tph (1), Hot(7), Weigh Bridge (3), Pneumatic TyredMix Plant 90 tph (1), Wet Mix Plant 60 tphRoller (1), Bitumen Sprayer (1), Lighting(1), Slipform Concrete Paver (1), PaverMast (7), Bull dozer (1).Finisher for Asphalt 9 m wide (1), Paver

This enabled the completion of the FOBwithin a time span of two months. Architectural elements have been used inthe construction of the foot overbridge togive an aesthetic appearance.

Subway

At all major junctions and crossings, theroad has been elevated and crossing acrossNH4 has been provided by construction ofRCC box opening. These subway openingsfacilitate crossing for the vehicles, cattle,etc. and thus prevent mingling of localtraffic with the NH4 through traffic.

The quantities of major items of workinvolved in construction of cross drainageworks and other structures are as follows.

Item of Work Quantity

· Earthworkexcavation insoil forfoundations -1,54,475 Cum

· Earthworkexcavation inrock forfoundations - 11,548 Cum

· Pile foundation - 1,160 RM· Well sinking - 31 RM· Random rubble

Masonry - 8,060 Cum · Structural

concrete forfoundation andsub-structure/drains - 70,788 Cum

· Structuralconcrete forsuperstructure - 16,986 Cum

· HYSD Steelreinforcement - 7,315 t

· HT strands - 101 t· Reinforced

earth wall forapproaches offlyover - 3,829 RM

· Concrete crashbarrier - 5,428 RM

· POT PTFEbearings - 286 Nos.

· Strip seal joints - 514 RM· Pipe laying NP4

class for maincarriageway - 3,145 RM

· Pipe laying Np2class for serviceroad - 7,014 RM

Approach road to the toll plaza

Completed view of the Koyna bridge

18

Handling of Local Issues

Problems Encountered

Successful Completion

The area in the vicinity of the projectlength, especially Karad town, is highlypolitically sensitive. There is a high degreeof political awareness among the localpeople. Some prominent politicians, bothNational and State level, hail from thisregion.

The main occupation of the local people isagriculture and the level of employment isnot very high. The project was considered apotential source of employment.

The locals were engaged strictly on meritand on the basis of their capabilities andexpertise. This approach proved to beadvantageous as due to their local influence many critical works such as The final handing over of the land by the piecemeal basis with the final handing overarranging and bringing borrow earth was Employer in the busy urban area oftaking place in the month of January 2005, done without much difficulty. This aspect Malkapur, Karad was effected in Januarytwo months prior to the actual completion also helped in developing in them a sense 2005. The works were taken up in full swing of work.of ownership towards the project and in simultaneously with all the finishing works ensuring smooth sailing for the project. over the entire Package IV length. The delay in land acquisition was mainly on

account of long-drawn litigation following The site team established a healthy and We completed the entire work in all respects disputes over valuation of the land beingcordial relationship with the local and handed over the project to the Employeracquired, discrepancies in the books ofdignitaries like MP/MLAs, Revenue on March 17, 2005, 7-½ months ahead ofRevenue Department with regard to landauthorities, Police officials and others, due the revised date of completion and earnedownership, etc. We were compensated forto which their cooperation was always bonus for early completion.the delays that had taken place on accountforthcoming. of late handing over of site by grant of

extension of time by 15 months. R.K. BansalConstruction Manager

Land acquisition was the only majorproblem encountered which caused Following the grant of extension of time,substantial delay in our getting possession the date for completion of works wasof site. The major part of the road length revised to October 31, 2005.was handed over for execution on a

View of the completed reinforced earth wall and underpass

View of the Karad flyover

19

hmedabad-Mehsana Toll Road Company Limited (AMTRL) is an SPV promoted by Government of A

Gujarat. L&T is an EPC contractor, O&M operator as well as a shareholder in this project. The other shareholders include Gujarat Toll Road Investment Company Limited, formed by Government of Gujarat and Infrastructure Leasing & Financial Services (IL&FS), L&T Holdings Limited and other Institutional Investors.

This SPV implemented the Rs.323 crore 51.6 km long four-lane toll road (including two service lanes on either side) from Ahmedabad to Mehsana and the Kadi Kalol spur road (11km) on Build-Operate and Transfer (BOT) basis.

The road work commencing at chainage 19 km on the State Highway No.41 passes Northwards through the towns of Sertha,

lanes and construction of service May 2000 and was to be completed in 39 Kalol, Chhatral and Nandesan terminating road on either side of the pavement months. However, the entire constructionsouth of Mehsana at Chainage 70.6, a total

was completed in 31 months by December · Strengthening of Kadi-Kalol spur of 51.6 km long. The Kadi-Kalol spur road 2002.road, which commences at Kalolcommences at Chhatral and runs North-

West, to a distance of 11.5 km in length. · Operation and maintenance of the A. Soundararajanentire project facilities throughout the

DGM-Developmental Projects-HQThe scope of works included: concession period.· Strengthening of existing two lane

Construction work began on the project inroad, construction of two additional

ROADSAhmedabad-Mehsana Road, Gujarat

Completed view of the Ahmedabad-Mehsana road project

Strengthening and four laning of Ahmedabad-Mehsana road in Gujarat

20

ECC has successfully executed these The first international class modern contracts. Section 'C' was opened to traffic expressway in India

thon 27 July 2000, while Khandala Lonavala Bypass was thrown open to The Mumbai Pune Expressway is one of

sttraffic on 1 May'2001.the prestigious projects of the Government

of Maharashtra. This project aims at providing a safe and fast access between Mumbai and Pune, the commercial capital of India and the cultural capital of Maharashtra respectively.

Mumbai - Pune Expressway is India's first six-lane modern expressway having concrete pavement. It is designed and built to international standards and is provided with state- of-the-art facilities, road furniture, beautiful landscaping and eco-friendly construction, all along its stretch. Planned for a traffic of 1.0 lakh passenger car units travelling at a speed of 120 km/hr, the expressway will reduce travel time between the two cities by one and half hour.

The total length of the expressway from Toubro Limited, was entrusted with three Kalamboli Junction to Dehu Road, contracts under this prestigious project:including Panvel bypass, is 95 km. The

Government entrusted the construction of· 23.059 km Section 'C” between this expressway to MSRDC (Maharashtra

Kusgaon on the Mumbai end and State Road Development Corporation) onOzarde on the Pune endBuild, Operate and Transfer (BOT) basis.

For ease of execution, the entire project · 8.4 km section of the Khandala was split by MSRDC into eight sections. Lonavala Bypass

· Kamshet 1 B twin tube tunnels falling ECC, the Construction Division of Larsen & within Section C

ROADS & BRIDGESMumbai-Pune ExpresswayA Concrete way to a Concrete future

21

Ghat section at Mumbai-Pune expressway

View of the rigid pavement on Mumbai-Pune expressway

Section 'C' Kusgaon to Ozarde

Client : MSRDCLength : 23.059 kmDesign speed : 120 km / hourLanes : Dual three lane

Carriagewaywith PavementQuality Concrete

Width : 12.45min each direction

Contractth

commencement : 26 January 1998th

Date of completion : 27 July 2000

Structures:Major bridges : TwoMinor bridges/Slabculverts : Thirty fourRailway overbridge : OneUnderpasses : EightOverpasses : TwoHume pipeculverts : Thirty three

Project Highlights

37

Profile of an elevated structure on Khandala-Lonavala bypass.Inset: Top surface of the elevated structure

22

Khandala - Lonavala BypassMajor quantities of work : (lakh Cum)

Mumbai - Pune ExpresswayDesign of Elevated : L&T RambollScope : Improvement to Structures Consultingexisting road on Excavation : 15.27

Engineers Limited, NH-4 between (Hard rock/soil)Chennai.Long Tunnel & Embankment : 30.16

Length of ElevatedKhandala and Granular sub base : 1.32Structure : 2250 mconstruction of Wet mix macadam : 0.74No. of ElevatedKhandala Dry lean concrete : 1.03Structures : FourLonavala Bypass Pavement qualitySuperstructure : Precast, Pre-including Kusgaon concrete : 1.91

tensioned I girdersInterchange. Structural Concrete : 1.05spanning 12-18 mLength : 8.4 km (Includes Asphalt : 0.10

Road stretch : 6,150 m1.3 km of Reinforcement : 2,874 tUnderpasses : FourimprovementOverpasses :works on existing

Khandala - Lonavala BypassCross Drainage NH-4 in the ghatStructures : Fifteenportion of khandala

Excavation in soil : 1.85 Date of valley)Excavation in commencement : September 1998Design speed : 120 km per hourhard rock : 6.73Date of No. of lanes : Six (three on each Embankmentcompletion : May 2001side with pavement filling : 7.51

QualityGranular Sub-base : 0.33

Concrete,BlackWet mix macadam : 0.22

top and Earthen Dry lean concrete : 0.26

shoulders)Pavement qualityconcrete : 0.50Asphalt : 0.08Concrete for superstructure : 1.40Reinforcement : 16,000 tPrecast Girders : 2,202 Nos.

Seven

Logistic Highlights

The expressway has been designed as perinternational standards. In order to complete the work on time and with world class quality, it was important to provide matching resources at all levels from crushing to laying of concrete. To manage a logistic supply chain for providing 25 lakh t of aggregate and 3 lakh t of cement in about 3 years time can itself be a huge challenge, which L&T was able to meet with professional acumen.

Modern crushing plants of combined capacity of 800 tph were mobilised to meet the requirement of aggregates. Similarly, cement silos with a combined storage capacity of 2000 t were erected at various locations. Cement Division of L & T p r o v i d e d t h e n e c e s s a r y infrastructure and faci l i t ies for transporting the required cement in bulk

pavement quality concrete. It was average, 1000-2000 cum of concrete per from Kovayya in Gujrat to Mumbai byimperative to feed the pavers with day was laid with ease, which enabled ship and further on by road to the projectconcrete, matching its speed, since any completion of 23 km of paving of Section C site matching the speed of concretestoppage while paving would have in just 18 months.paving.affected the riding quality. To meet this

R.K.Bansalsingle most important requirement, highConcrete Paving EquipmentConstruction Managercapacity automatic batching plants were

imported and transportation was organisedL&T provided for two concrete pavingthrough heavy duty Tatra dumpers. At anteams for laying dry lean concrete and

Slipform concrete paver at work

Panoramic view of Mumbai-Pune expressway

23

ndore City, the commercial capital of Project Team Design ParametersMadhya Pradesh, has a population ofaround 23 lakhs. The city has a radiusI With a view to gaining the confidence of The road cross-section applicable to Urban

of about 8 kms and has a good road the investors and giving a new dimension Roads was based on IRC 69-1977.network, although very congested, mainly to the corporation's working style, RDDC Accordingly, storm water drains, footpath,on account of concentration of business and the Municipal Administration decided carriageway of two lanes on side, cycle and commercial activities and very old to entrust the project management as well track, central median and unpaved medianstructures along the main roads. as the project execution to nationally were provided. The design of pavement

reputed agencies. Accordingly, was done by the popular engineering To ease the congestion and improve the prequalification bids were invited from institution of Indore, SGSITS, aftercondition of roads, the Municipal project management consultants in line conducting extensive field tests. TheAdministration of Indore City came up with the procedure adopted by NHAI and specifications for roads and drainage werewith a novel idea of floating bonds to fund the successful bidders were Shrikhande based on MoRTH (Ministry of Roadthe project. To assess the quantum of Consultants, Mumbai. Transport and Highways) and CPWD work involved and draw up a plan for the guidelines.project, a Road Design and Development For project execution too, prequalificationCell (RDDC) was formed in the year bids were invited, on the World Bank Initial Difficulties1998. The Cell conducted a survey and pattern, in which 67 companies of nationalidentified the roads to be resurfaced under and international repute participated. There were lot of hurdles in the initial stages the project, mainly those that link the From among them five firms were short- of the project, the major ones being central business hub with the suburban listed and invited to submit price bids. L&T relocat ion of e lectr ic poles and areas. Based on the findings with regard to emerged the winner in the process and transformers, removal of encroachments the prevailing was awarded the Rs.43.10 cr. contract of and illegal structures along the ROW (right and the life cycle cost, the Cell split up the revamping Indore's road network. of way), as also relocation of temples and work into two packages - Bitumen Package cutting of trees. These, coupled with (18 km) and Concrete Package (9 km). financial constraints, delayed the project by

18 months.

status of pavement quality

ROADSAn Urban Road Project for Indore

Completed view of the urban road in Indore

24

How we overcame the Initial Setback

Initially, we waited for full clearance of theroad width to commence construction.However, in order not to lose time and alsoconsidering the problems involved inremoval of encroachments, which hadpolitical and social angles too, we decidedto make a beginning and took up work inthe available widths. This forced the handof the administration to take stern actionagainst the encroachers and paved the wayfor us to carry out work on more fronts.

Once we completed the first major phaseof concreting work on Annapurna Roadand the intersection at Mhow Naka, thecitizens in the area appreciated the seachange brought about by the road improvement project so much so that theydemanded concrete roads everywhere inthe city.

By this time, we had completed a fewstretches of bituminous overlay but theresult was not comparable to concretepavements. In view of this the high-powerTechnical Committee recommended construction of concrete pavements in

massive encroachments, clients excluded Advantages of Concrete Roads over place of bituminous overlays and we also the difficult stretches from our scope and Bitumen Roadsagreed to this proposal. Following this the included other important but less

scope of work for bitumen roads was encroached roads.

· Increased life of the roadreduced from Rs.24 cr. to Rs.10 cr. while - Provides good riding surface for longer for concrete roads it went up from Rs.19 cr.

As the authorities found that the funds periods.to Rs.39 cr. generated through bonds alone were not

· Can withstand heavy traffic density.sufficient to finance the project they

Looking at the speed and the quality of our · Negligible maintenance cost.approached HUDCO for a loan, which was

work and realising the difficulty in clearing · Good performance under following approved In December 2003.conditions:- Low bearing capacity of soil (i.e. black cotton Soil)

- High water table (i.e. marshy soil) and poor drainage of soil sub base.

· Less air pollution in production of concrete.

Considering that this was the first time amajor urban road project was successfullyexecuted with financing through bonds andnotwithstanding the problems faced duringits implementation, the Indore experimentcould be a good example for other Indiancities to emulate. We developed very goodrapport with the administration and the localbodies through our determination and sincere efforts to make the project a success.

R. PrakashConstruction Manager

25

Above and below: Completed view of the Indore city road

L&T Transportation Infrastructure Limited new bridge is located across river Noyyal at is a Special Purpose Vehicle (SPV) owning Athupalam, adjacent to the old bridge onthe property and tolling rights of the 28 km NH-47, in Coimbatore.Coimbatore bypass road and a two lanebridge across river Noyyal (Athupalam) on L&T completed the construction of thisNH-47. To overcome the problems of landmark project, using mechanised andtraffic-congestion in Coimbatore City, the innovative construction methods to meetManchester of Southern India, L&T international quality/safety standards.Transportation Infrastructure Limited (LTTIL) constructed a two-lane 28-km long

Project Highlightsbypass road, on Build-Operate-Transfer(BOT) basis. This is the first road

The scope of work includes construction,privatisation project executed in Tamiloperation and maintenance of:Nadu. This company was formed by L&T

with equity participation from Larsen & Toubro Limited (26.24%) LTM Limited · A two lane carriageway of 7m width(24.75%) and L&T Holdings Limited with 1.5m wide paved shoulders and (49%). 1.0m wide earthen shoulders on either

sideThis project is the outcome of an · A road overbridge across broad gaugeagreement between the Union Ministry of railway line near IrugurSurface Transport (since renamed as

· A road overbridge across meter gaugeMinistry of Road Transport and Highways) railway line near Chettipalayamthe Government of Tamil Nadu and Larsen

· A major bridge across river Noyyal,& Toubro Limited (L&T). The bypass road e l e v e n m i n o r b r i d g e s , takes off at Km 141 on the Salem side of the over/underpasses, cross drainage National Highway 47 (NH-47) at Nilambur works as per stringent specifications.and rejoins the highway at Km 171/200 on the Palghat side near Madukkarai.

To make the cost recovery viable for the developer, construction of a major bridge was integrated with this road project. This

Junction at Coimbatore bypass road

ROADSCoimbatore Bypass Road First Road Privatisation Project In Tamil Nadu

26

ConcessionAgreementSigned on - October 03, 1997Signatories - Government of

India, Ministry ofSurface Transport,and Government ofTamil Nadu,Department ofHighways, andLarsen & ToubroLimited, ECCDivision

ContractCommencement - December 3, 1997Construction - Bypass Road -2 yearsPeriod Athupalam Bridge -

1 yearProject - Athupalam Bridgecommissioned on December 12, 1998

Bypass Road-January19, 2000.

Fee Collection - Bypass Road -32 yearsPeriod (upto December 3,

2029)(Including period ofconstruction)Athupalam Bridge -21 years (uptoDecember 3, 2018)

EPC Contractor - ECC Division of L&T

Salient Features

· Two major junctions at Trichy - Pollachi road crossing, Nilambur and Madukkarai ends and 11 other road c r o s s i n g s i n c l u d i n g j u n c t i o n improvement works

· R e t r o - r e f l e c t i v e r o a d s i g n s , thermoplastic road markings, crash barriers and other appropriate road furniture.

·

· Fee collection from users of the projectfacilities as per agreed terms and handing over the facility to the Government in proper condition at theend of concession period.

Quality & Safety· Reduction in congestion in the cityAdvantages· Quality road built to international

This project has been completed to standards - better service to users· Four-lane bridge with junction international standards with stringent improvement at Athupalam · Maintenance by entrepreneur - specifications and standards under strictsavings to Govt./benefit to public· Development of wider roads near thesupervision by Ministry of Surface Athupalam junction · Part of revenue generation put back to Transport, National Highways Dept., Govt. project maintenance / development· Less congestion due to freeing of of Tamil Nadu and Southern Railways. In encroached areas · Lesser vehicle operating costs / fuel addit ion, L&T-Ramboll Consult ing savings to users· Area/junction lighting at major road Engineers was employed for quality control crossings · Reduction in distance and travel timesupervision and review of the critical

· Free and smooth flow of traffic - · Users pay for the facility, two / three pavement design. This association brought

through signalling and overbridges wheelers not tolledin International expertise for enhancing the

· Aesthetic bowstring arch bridge at · Better wayside facilities and amenities quality of the highway project.

Irugur, a new landmark to this city · Land value appreciation due to overall· Well designed drainage/sewer lines area development along the road A. Soundararajan

DGM-Developmental Projects - HQ

Passenger oriented wayside amenities like toilets, parking facilities, service station, drinking water, telephone, first aid facilities, snack bars, and kiosks... at suitable locations.

Toll plaza at Athupalam Bridge

27

28 km long Coimbatore bypass road in Tamil Nadu

he Second Vivekananda Bridge willbe another feather in the cap ofTIndia's capabilities in bridge

engineering. This landmark project, builtadjacent to the existing Bally Bridge nearDakshineswar in Kolkata, will provide ahigh speed link between NH 2/NH 6 onthe Howrah side and NH 34 on theKolkata side by the proposed BelghoriaExpressway. The bridge, being constructed using state-of-the-art techniques, will be completed in 36 months and will be commissioned by 2007.

The bridge will also realize the dream of the Government of West Bengal and the

was reorganized into EPC Design & well and further sinking of the same various people of Kolkata by setting up another Supervision wing and EPC Construction modern techniques are proposed to be used intercity corridor in the face of fast growth wing. The Design & Supervision like :-in traffic volume. This Rs.640 cr. megaresponsibilities were entrusted to a jointproject is being implemented on Buildventure of Consultant Engineering Services Water jetting - This process reducesOperate and Transfer (BOT) basis by ThePvt Ltd (CES), New Delhi and Parsons the cutting shoe resistance upto Second Vivekananda Bridge Tollway Brinckerhoff (PB), USA through an 60%.Company Limited (SVBTC), a special Agreement between L&T and CES-PB. Air jetting - This process reduces the purpose vehicle (SPV) formed by the Further, the CES-PB JV requisitioned the frictional resistance in between outer PASGIC Group (consisting of Pacific serv ices o f In ternat ional Br idge periphery of well and surrounding earth Alliance, USA, and Stradec Group of the Technologies, USA, to bring in extradosed by upto 50%. Philippines) and Larsen & Toubro Limited. cable-stayed bridge technology and make If required, in addition to the above While L&T holds 33% equity in SVBTC, the Second Vivekananda Bridge a World methods, kentiledge will be used for PASGIC holds the balance 67%. The SPV Class project. The construction of the Main well-sinking.has been given a 30-year concession Bridge and its approaches rests with ECC. Precast segmental construction with internal period inclusive of the construction period

post-tensioning is adopted for construction of 3 years to finance, design, build, operate Principal features of the Project of the bridge superstructure. Precast match and maintain the bridge and the

cast segments will be erected by balancedapproaches.cantilever technique and glued to each otherMain bridge-Extra Dosed Cable Stayedusing epoxy.StructureECC is executing the project as an EPC

Turnkey Contractor for SVBTC. ECC'sscope includes: detailed engineering The main river crossing bridge, 880m- Viaduct - Howrah Approachdesign, engineering survey, s i te long, will be parallel to and 50m investigations for the main bridge, downstream of the existing bridge. The The bridge will have a 360m viaduct withviaducts, ramps and approach roads on deck is a box structure with 7 extradosed dual three carriageway forming a part of theboth Howrah and Kolkata sides; at-grade cable stay spans of 110m each and 2 end approach on the Howrah side. This viaduct

spans each of 55m. The design is two spani m p r o v e m e n t s f o r e s t a b l i s h i n g is supported on pile foundation and elegantcontinuous structure having expansioncommercial areas; construction of piers. 10 metre tall piers are cast in a singlejoints every 210 meters. The width of thef o u n d a t i o n , s u b s t r u c t u r e a n d pour to enhance their appearance. Thedeck is 28.6 meters catering to 6 lanesuperstructure of main bridge and viaducts superstructure is built with precast boxcarriageway for traffic. The segments areas well as the at-grade approach roads, segments with external post-tensioning andthe largest to be constructed in India,cross drainage (CD) works, rail overbridges erected with dry joints between segments.maximum segment weighing 140 MT.(ROBs), rail underbridges (RUBs) on both

Howrah and Kolkata sides; slope The superstructure of the main bridgeprotection and drainage, traffic signagesconsists of a single box girder with inclinedand pavement markings, crash barriers,webs and internal stiffening struts. A singleconstruction of a 16-lane toll plaza withplane of cables passing over 14m highbase camp structures including lightingpylons provides the additional support andand other infrastructure development likeenhances the aesthetics of the bridge, apartlandscaping and environment protectionfrom giving it a ribbon-like appearance.to international standards.The bridge pylons are founded on deepwell foundation, the cap of which isTo facilitate Design and Construction withlocated on the riverbed. For construction ofstate-of-the-art technology the EPC Team

·

·

·

Besides a viaduct, the project involvesconstruction of a 3.5 km of approach on highembankment with ground improvement byinstalling prefabricated vertical drains (PVD), one rail overbridge across theHowrah-Burdwan railway line and RailUnderbridges to be constructed across therailway embankment of Sealdah-Dankuniline. The precast RCC boxes will be pushedthrough the embankment using jack pushingtechnique.

Perspective view of Second Vivekananda Bridge, Kolkata

BRIDGESSecond Vivekananda BridgeThe Fourth Crossing Across River Hooghly

28

The toll plaza will be located on the Howrah In addition, to cross the Sealdah-Dankuniside, almost at the Western end of the Rai lway embankment aga in nearpackage, and will have Electronic Traffic & Dakshineswar, one Rail Underbridge will beTransport Management (ETTM) facilities. constructed using the same techinque of

jack pushing.

Viaduct - Kolkata ApproachWhen completed, the Second VivekanandaBridge will relieve the people of Kolkata andThe approach viaduct on the Kolkata side isits suburbs of endless traffic jams and willsimilar to the Howrah viaduct except for twousher in an era of growth and prosperity.up and two down ramps bifurcating fromWith faster transportation of goods andthe main approach with 2 lanes perservices, trade and commerce will also get acarriageway in each direction, to allow forboost.the interchange between Belghoria

expressway and the PWD road and C. Sankaralingam T.S. Anathakumarproviding access to the local traffic throughHead-Bridges Project Managertwo circular ramps.

29

View of the P3 Viaduct segment erection in progress

View of 28.6 m wide casted segment

Name of the - National Highwaysclient Authority of India,

New DelhiConcessionnaire - The Second

Vivekananda Bridge TollwayCompany Limited,New Delhi

EPC Contractor - Larsen & Toubro Limited,ECC Division

Design/Supervision - ConsultingConsultant Engineering

Services (India)Pvt. Ltd.representingCES International,USA; and ParsonsBrinckerhoffrepresentingPBIDC, USA

Independent - Schlaich,Consultant Bergermann und

Partners, Stuttgart,Germany

Duration of - 36 months from contract commencementTotal length - 6.1 km (main

bridge includingapproaches)

Type of - Precast segmental construction sections with cable

stayed extra dosedspans of 110m

Length of the main - 880m (7x110m bridge plus 2x55m span)

Length of the viaduct and approach

Kolkata side : 1.56 kmHowrah side : 3.67 km

Project Highlights

rom the times of Harshvardhana to cr. against stiff competition from The sub-structure has in-situ piers and pier-being the capital of United Provinces Iternational contractors like Daelim, caps.Funder British rule and to the present Ssangyong, and others. This bypass, once

day, Allahabad (original name Prayag) has completed, will make traffic snarls a thing Super-structurebeen one of the holiest of holy places for of the past for the citizens of Allahabad andHindus all over the world. Down the ages will also help reduce the level of pollution The super-structure comprises of pre-castspirituality has developed and flourished caused by emission of smoke from vehicles post-tensioned segments glued togetherhere. The holy city of Prayag is the point of . with cantilever construction. The segmentsconfluence of three holy rivers - Ganga, The proposed bridges, running parallel to are of varying heights (2.5 m to 5.5 m) andYamuna and the mythical, subterranean each other, have two independent lengths (2.5 m to 4.0 m) weighing Saraswati -known as Triveni Sangam. The carriageways, each accommodating a 7.5 approximately between 50 t and 91 t. Thevery mention of Allahabad conjures up m wide two-lane carriageway and 1.5 m segments are being cast about 1.2 km fromimages of vast congregations of devotees pedestrian footpath. The bridges are the bridge location on a long-line bed ofthronging the shores of the Sangam. located at a clear distance of 12 m to 115 m length. The pre-cast yard is

facilitate independent well sinking. Each equipped with one 120 t gantry and two 10These days Allahabad is experiencing bridge has two 6-span continuous units t gantries to handle segments, shutters,development of a different kind and with span lengths of 62+4 x 95+62 m. rebar cage and other associated items. The“Bypass” has become the buzzword. total length of the casting yard inclusive of

Foundation And Substructure stacking area is 300 m. About 200 segments The Allahabad Bypass Project, forming can be stacked in two layers. part of the NH-2 GQ corridor from Delhi to The foundations consist of large diameter Kolkata and being executed by ECC, well foundations of depth of 38.8 m and comprises of two road packages and two 43.8 m below low water level, to be sunk bridges covering nearly 85 km ECC with jack-down technology aided by other secured the contract, valued at Rs.108.23 techniques such as air and water jetting.

120 t gantry shifting the segment in the casting yard

BRIDGESBridge Over Ganga for Allahabad Bypass

30

Assembly of launching girder behind the abutment

Erection of Super-structure

Erection of segments has been plannedwith 195 m long under-slug launchinggirders, weighing about 500 MT, supported on piers and intermediate supports in between the piers.

Each carriageway shall be provided with separate launching tackle with a gantry to handle 120 MT. The launching shall be uni-directional.

The bridge has been designed to be provided with 16 shock transmission units

nd(STU), only 2 time in India after the Second Bassein Creek Bridge on NH-8) to form a rigid link under rapidly applied loads such as braking and seismic, etc., but to move freely under slowly applied loads such as temperature, creep and shrinkage.

The unit is to be connected between the super-structure and the sub-structure nearthe bearing location. It shall share beneficially amongst the sub-structure and the super-structure the short duration loads applied to any one of the sub-structure elements.

With respect to capacity of STU, at 6500 kN, it is one of biggest in the world.

Shock transmission units work on the principle that rapid passage of viscous fluid through a narrow orifice, which generates considerable resistance while slow passage generates only minor resistance.

ECC's team at the Allahabad Bypass Project site is highly motivated and fully equipped to create another engineering marvel, which will add a new dimension to theCompany's construction capabilities and re-affirm L&T's leadership position in theconstruction industry in terms of technologyand construction methods.

G.VinodProject Manager

Shock Transmission Units (STU’s)

Schematic diagram of STU

31

-

he existing Marthandavarma bridgeacross River Periar with a 5.5 mTwide carriageway, considered a

landmark of Aluva (Kochi), was constructed during the pre-independenceperiod of 1940-42 by His ExcellencyMarthandavarma Ilayaraja of Travancore.Owing to manifold increase in density oftraffic over the years the bridge hadbecome a bottleneck and had beenwitnessing frequent traffic snarls. Thepresent intensity of the traffic is 26,189PCU's (Passenger Car Units) per day and isexpected to go up by 156% every year. Insuch a scenario there have been persistentdemands from the public for a new bridge.Paying heed to this as well as representations from local leaders theMinistry of Road Transport and Highways(MoRTH) approved the proposal for construction of a new bridge, parallel to the existing one.

L&T submitted a design-and-construct bid for the New Marthandavarma Bridge in

It was specified by the Government that the arch are of Mac Alloy bars in place of May 2000 to the State Government of the features of the new bridge should the concrete suspenders of the old bridge.Kerala. A Tender Committee appointed generally follow those of the existing by the Government to study and evaluate bridge. To meet this requirement L&T An amount of Rs.7.52 cr. was sanctioned the bid suggested a few modifications to proposed a bow string type girder bridge by MoRTH for this project on the basis of the design, which were accepted and with the same span, but having a 7.50 m the lumpsum price quoted by L&T. Theincorporated by L&T who ultimately carriageway and 1.50 m footpath on work was scheduled to be completed in secured the contract for the new bridge.either side. The bridge rests on bored cast- one year. The agreement for the projectin-situ pile foundation. The suspenders for was signed at the office of the

Superintending Engineer, NH (Central) th

Circle, Thrissur on 30 March, 2001. Due to the change in construction methodology for the superstructure from precast to in-situ and also due to the heavy rains and floods of 2001, the period of completion got extended by one month. The earthwork for the approaches of the bridge

thwas completed by 30 Apr'02 and handedover to NHAI to construct the pavementaccording to their specification and also tomerge with the four lane widening work inNH-47.

Scope of Work

Design and construction of NewMarthandavarma Bridge at Aluva onNH47 in Kerala consisting of thefollowing:

· Three spans of Bow string GirderBridge with two-lane carriagewayand footpath on either side.

BRIDGESNew Marthandavarma Bridge, Kerala

32

Completed view of the new Marthandavarma Bridge

View of the central span of the bridge from the river

· In the existing bridge, the verticalsuspenders for the arches were madeof concrete whereas in the newbridge the arch suspenders are of 72mm dia steel bars imported fromMac Alloy, UK.

· In the new bridge the reinforcedearth wall is provided to retain theapproach road earth vertically onboth the sides (max. height 5.80 m).The cons t ruc t ion o f ve r t i ca l reinforced wall towards the Aluvanarrow to carry the present day two

· Approach embankment on northern side approach avoided costly land lane traffic smoothly. But the new side of proposed new bridge starting at acquisition and the balance land bridge has a 7.5 m wide clear chainage 330/135 and ending at can be used as a service lane for carriageway and has eased the abutment A1. light vehicles. The geogrids were situation.imported from the Netherlands as · Approach embankment on southern reinforcing material for earth fill.side of proposed new bridge starting at

· In the existing bridge, the wind abutment A2 and ending at chainage bracings for the arches were

T. Murugan330/550. constructed with a clearance of 4.80Construction Manager

m from road top level whereas in theGeneral Improvements made during new bridge the wind bracings haveConstruction of New Bridge been constructed with a clearance of

5.80 m from road top level. Therebythe heavy vehicles will have more· T h e e x i s t i n g b r i d g e h a s a headroom.Carriageway of 5.50 m which is too

33

Front view of the completed bridge

Details of Various Components of theBridge

Foundations : Pile foundationof 1.200 m diaand depth 26 mto 32 m.

Sub structure : Solid plate pierwith roundededge upto piercap level

Reinforced earth : Consists ofwall geo-grids as

reinforcementsand RCC faciablocks.

Superstructure : SimplysupportedBow string girder.

Wearing coat : 56 mm thick asphaltic concrete wearing coat for the bridge.

Clients : Government ofKerala,Public worksDepartment(National Highways).

Proof : Span ConsultantsConsultants Pvt.Ltd., New Delhi.Design & : Larsen & Toubro Construction Limited, ECC Division,

Chennai.

Salient Features of the Bridge

Length of the bridge - 159 mLength of the Approach Road Thrissur side - 139.425 mErnakulam side - 135.575 mEffective span length - 45 mNo. of spans - 3Width of the bridge - 12.56 mWidth of carriageway- 7.5 m Footpath width - 1.5 m on either

side

Project Highlights

View showing new bridge on the right and existing bridge on the left

orthern Railway is currently Udhampur section and also one of the executing the ambitious Jammu - tallest bridges in Indian Railways. The NBaramulla rail line connecting the bridge is located near Manwal in

Jammu region with Kashmir by rail. The Udhampur district and consisted of partworks are spread in four sections: L0 civil works for pier/pier cap and threeJammu-Udhampur section (54.85 km), L1 triangulated steel girder superstructureUdhampur - Katra section (30 km), L2 (1x80 m & 2x102 m spans). The salient Katra -Qazigund (137 km) & L3 Qaziqund- features are shown below :Baramulla (120 km). Sections L0 & L1 arebeing executed by Northern Railwaydirectly while L2 and L3 are being of structural steel enabling structures wereexecuted by IRCON and Konkan Railway used in the launching works.Corporation.

On-site fabrication shop with full fledgedThe work on the Jammu-Udhampur facilities was established near bridge site forSection was completed last year and the fabricating the components. Work was doneHon’ble Prime Minister of India formally round the clock even during peak winteropened the line for passenger traffic on season to ensure the timely completion ofApril 14, 2005. The salient features of job. The entire bridge weighing 1735 t wasJammu-Udhampur Section are given fully assembled in the abutment area onbelow: Udhampur side together with nosing and

stitch girders for connecting the three spans.Total Length - 54.85 km After assembly, the entire truss was tested inTunnels - 21 Nos. Total shore by simulating the maximum cantilever

10,282 m condition to compare the theoretical andlength (19%) Originally the superstructure was designed actual deflections and to check the integrity

Bridges - 158 nos. (Major : as a double cantilever box girder with span of critical joints. After the shore test, the36) Total Length configuration of 80 m+102 m+80 m. Due superstructure was launched to final position5,140 m (9.6%) to disturbance in the geological strata on using two multi-strand jacks (2x400 t

Earthwork - 83 Lakh Cum one abutment, the superstructure was capacity) from launching side abutment.Tallest Bridge - Bridge 93 (70 m) changed to a steel trussed type with a span The maximum cantilever length duringLongest Span - Bridge 93 (102 m) configuration of 80 m+102 m+102 m. launching was 105 m.

and Tawi Bridge(102 m) The site is located in a remote area with The bridge was launched 3m above its final

Cost - Rs.500 Crore limited access only to one end of abutment level and after reaching the final position was(approx.) of bridge. After thorough investigations lowered on to bearing in stages after

and considering the site constraints/terrain disconnecting the nosing and stitch girders.The line consisted of 97 m bridges and conditions, it was decided to adopt The entire launching operation was190m tunnels per KM as against the 32.7 m “Customised Push Launching Technique” completed in 14 days' time with an averagebridges and 63 m tunnels in Konkan for the construction of superstructure. speed of 22 m per day (maximum 38 m/day)Railways work. Although push launching is used with round-the-clock working. Lowering was

extensively for concrete/steel box girder accomplished in 7 days' time.As part of this project, L&T executed bridges, adoption of this novel techniqueBridge 93 across Gambhir Khad, which is to truss type girders requires intricate With the completion of this vital link, the twothe tallest bridge (70 m pier height) with enabling works. A new skid beam system decades old dream of Indian Railways standsthe longest span (102 m) in Jammu- was designed to support the truss only on realised. After successful launch of the

its diagonal nodes during launching as per bridge, Mr. R.R. Jaruhar, General Manager,design requirements. Skid beams were Northern Railways, addressing a group ofprovided with stainless steel bottom and presspersons, said, “This is the first timemoved over PTFE track in track beams railways have constructed a bridge usingfixed on temporary foundations. such a long span. L&T has designed a new

launching scheme and gave full support toThe entire launching scheme was railways and worked like a single team. And,prepared by EDRC (TI)_and was proof- only L&T can do such a critical job on achecked by RITES. The permanent rugged terrain and deep gorges like this.”structure (designed by Span Consultants)

C.Sankaralingam K.Senthilnathanwas analysed stage-wise and checked forHead-Bridges Head EDRC-Transportationlaunching forces and extensive

modifications were carried out to initialdesign as per analysis results. About 475 t

BRIDGESBridging the Valley…The L&T Way

34

Item 80 m span 102 m span

Cross 7.30 x 9.70 m 7.30 x12.44 mSection

Node 5.53 m 7.11 mDistance

Shoprivets 1,08,000

Field rivets 95,500

No. of 5,80,000Holes

Span 435 t 650 tWeight

Total 1735 tWeight

Completed view of Bridge 93 from the river

Steel structures getting ready for the launch

he new Watrak bridge is located on

NH 8, which connects Ahmedabad,TVadodara, Bharuch and other major

cities and towns on the Mumbai side and

with Rajasthan on the Delhi side. The

Bridge is located near Kheda in Gujarat in

the vibrant industrial belt. The old bridge is

approx. 396 m long and was built in 1944

and has two lanes. It had been a bottleneck

on NH8 due to its restricted capacity.

Currently the traffic is around 40,000 PCUs

per day. In order to overcome the

congestion experienced and facilitate a

free and smooth flow of traffic and to cope

with the future increase in traffic, it was

decided by the Union Ministry of Road

Transport and Highways (MoRTH) and the

Government of Gujarat to build a second

bridge on BOT basis.

The project was executed by a SpecialProject Vehicle “L&T Western India TollBridge Limited”, a wholly owned subsidiary of Larsen & Toubro Limited.

The Project

The new bridge is 2250 m downstream from the existing bridge and is situated between 33.430 km. and 42.180 km. including the approach roads.

The bridge is approx. 335.4 m long and it has a two-lane carriageway of 7.5 m width with 1.5 m wide footpaths on either side.

BRIDGESWatrak Toll Bridge, Gujarat

View of the toll plaza

View of approach to the main bridge

35

The toll plaza is scientifically designedtaking into account the high volume of traffic.The toll collection and carried out usingmodern computers and accessories causingleast inconvenience to the public.

C.SankaralingamHead-Bridges

Agreement signed on March 1, 1999 Concession Period

Construction commenced on May 1,1999 December 31, 2009)

Development team:Construction completed on February 13,Project Developer

2001. L&T Western India Tollbridge Limited

EPC ContractorConcessionaire

L&T Western India Tollbridge Ltd. Larsen & Toubro Limited, ECC Division

EPC Contractors Design Consultants

Larsen & Toubro Limited, ECC Division L&T Ramboll Consulting

Scope of Work Engineers Limited, Chennai

Engineering Design & Research Centre,Construction and maintenance of Second

ECC Division, L&TWatrak bridge and its approaches, routine

maintenance of existing bridge and Proof ConsultantsOperations Research Group, New Delhi strengthening of its approachesand R&B Department, Government of Gujarat on behalf of MoRTH.

128 months (upto

Salient Features

armada Infrastructure ConstructionEnterprise Limited (NICE) is aSpecial Purpose Vehicle (SPV) withN

a 15-year ownership / tolling rights inrespect of design, construction, operationand maintenance of the Second Narmadabridge. L&T formed this SPV with equityparticipation from Larsen & Toubro Limited(26.71%), LTM Limited (24.28%), L&THold ings L imi ted (28 .99%) and Consolidated Toll Network India PrivateLimited (20%)

The Bridge

L&T undertook the design and constructionof this bridge located at Zadeshwar nearBharuch in Gujarat on National Highway 8between Mumbai and Vadodara. The twolane 1.37 km long bridge with 4.63 kmapproach roads starts at km 192/0 and endsat 198/0 on NH8. It is located 29 kmdownstream adjacent to the existing bridge.

The old bridge was a bottleneck on NH-8due to its restricted capacity. In order toovercome the congestion and enable freeand smooth flow of traffic and to cope upwith the future increase in traffic, the UnionMinistry of Road Transport and Highways(MoRTH) decided to build a second bridgewith private sector participation.

BRIDGESNICE Bridge on Narmada River, Gujarat

36

Completed view of the second Narmada Bridge on the right and the existing bridge on the left

L&T completed the design and construction NICE are the developers and concessionaireof the bridge in a record time of two years for this landmark project. ECC, L&T'sand the traffic is now moving smoothly. The Construction Division, were the EPCusers proceeding towards Mumbai are using contractors. The construction of this bridgethe old bridge and those travelling towards was completed with high quality using state-Vadodara are using the new bridge. of-the-art techniques.

Invitation of existing bridge andProposal strengthening of its Agreement signed - Nov. 21, approaches.Construction Length of Bridge - 1.364 kmCommencement No. of Spans - 13 spans x 96.2 m+Construction 2 spans x 56.1 mCompletion Width - Main carriagewayCommissioned on - Nov. 11, 2000 is 7.5 m wide withEnd of Concession 1.5 m footpath Period - Dec. 21, 2012 on either sideConcession - 15 years including Approach road - Two-lane road Period construction with 1.5 m hard

period bituminousScope of work - Construction and shoulder

maintenance of and 1m earthensecond bridge shoulder.across RiverNarmada and itsapproaches, routinemaintenance of

- Sep. 5, 19951997

- Dec. 21, 1997

- Sep. 21, 2000

Salient Features of Concession Agreement

· High strength concrete was used withProject Highlights Supervisor/Proof - Shirish Patel &micro silica Consultant Associates, Mumbai

· System formwork was used for · Bed Protection works with stone crated construction of wall type piersboulders / geo-fabrics

Advantages· Modern toll plaza is constructed · Approach road for a length of 4.63 kmwith control room and back-up · Construction of raised median and power facilities · Capacity augmentation withjunction improvements to make

construction of new bridge and four· Instrumentation & control systems the road a divided four lane roadlane approaches.are used for bridge monitoring· Retro-reflective road signs, thermo

· Smooth flow of traffic due to · Construction has been done to plastic road markings, crash barriersunidirectional movement of vehicles.international standards, quality, · Appropriate road furniture

speed and safety · Savings in time / fuel cost/ vehicle· Well designed drainage, including

operating costs storm water drainsDevelopment team · Relief from congestion of vehicles

· Maintenance of new bridge and its · Junction improvement and lightingapproaches

Client - R&B Department, · Twelve lane modern toll plaza to · Routine maintenance of existing bridge

Government of meet the peak hour traffic demand.i n c l u d i n g s t r e n g t h e n i n g a n d Gujarat on behalf

· Electronic toll management systemmaintenance of its approachesof MoRTH

· Area lightingEPC Contractor - ECC Division of Innovative Technology · Two wheelers and autorickshaws

Larsen & Toubro exempted from paying toll.Limited

· Segmental construction technique was · Corridor development by way of better Design - DAR Consultants,

adopted for building the superstructure. maintenance levels.Consultants U.K. (Prime

By this method, quality precast Consultants)

segments were fabricated at a casting D. DattaL&T Ramboll

yard nearby, transported to the site and Project ManagerConsulting

erected using a special launching girderEngineers,

· Well sinking for the piers was done Engineering Designb y j a c k d o w n m e t h o d o f & Research Centre, construction ECC Division

37

Completed view of the bridge showing piers and superstructure. Inset: View of the toll plaza

he Acharya Jagdish Chandra Bose(AJC) Road in Kolkata has a longThistory of acute traffic problems in

view of its central location, criss-crossingstreets with traders, businessmen andcommon public as well as vehicles surgingforth with vibrant activity. A throbbingcentre of trade and commerce, AJC BoseRoad is one of the busiest roads in Kolkataand was plagued with ever increasingvehicular traffic as well as pedestrians.Realising the severity of the problem, thegovernment and the public felt the urgentneed for an alternative arrangement to easethe traffic congestion.

It was decided that building a flyover on theroad between Rabindra Sadan and BeckBagan, one of the busiest commercial hubsconnecting Park Circus gyratory in the Eastto Victoria gate on the West, would be along-term solution for this critical problem.

The Government of West Bengal with loanassistance from JBIC, pressed into service and box girders are supported on hollow lengths. These were then assembled atthe Hooghly River Bridge Commissioners steel columns decked with reinforced ground and erected using heavy lift cranes.(HRBC) for implementing this flyover. concrete slabs and topped with bituminousYachiyo Engineering Co. Ltd., Japan was concrete. Shear studs were provided to resist appointed to provide the design and horizontal shear at the junction of concrete consultancy services and ECC, the deck and top flange of girders. This was Sub-structureConstruction Division of Larsen & Toubro done by using a row of large stud dowels 150 Limited was entrusted with the task of its mm long x 19 mm dia with a club head of 32 The steel columns capped by steel construction. mm dia, welded to the top flange of the crosshead are supported on bored cast-in-

girders. Stringent quality control and quality situ piles of 800 mm and 1000 mm dia assurance checks including NDT was West Bengal’s longest flyover having depth varying from 34 m to 47 m.carried out at different stages during Steel anchor frames with anchor bolts arefabrication of the structural steel membersembedded in 2.0 m thick pile cap forfor substructure as well as the superstructure.transferring forces and moments from theHaving a length of 2.9 km with

steel superstructure to the foundation.approaches, this is the longest flyover in theIn-situ concrete was pumped on to formsstate of West Bengal and forms an resting on steel girders to cast the deck.The hollow steel columns and crossheadsimportant intra-city corridor for vehiclesWearing course of bituminous concrete wasfabricated in a nearby fabrication yard weremoving into and out of Kolkata. This alsolaid on top of the deck using pavers. Striptransported separately to site, spliced paves way for better utilisation of theseal type expansion joints were used fortogether with high strength friction gripsecond Vidyasagar Sethu bridge across50/70/90 mm gaps for linear expansion of(HSFG) bolts and erected as one piece onHooghly. The location, geometry, length,the deck along with the steel superstructure.top of the anchor frame. The base was thenroute alignment, physical constraints

filled with M-30 grade concrete upto an above and below the ground, safety of men The approach to the bridge is provided by average height of 2.5 m. and machinery, safety of pedestrians and ramps made of RCC cantilevered retaining continuously fleeting vehicles posed wall construction. The east bound ramp has several challenges. However, ECC Superstructurea length of 82.5 m and the west bound ramp overcame all these constraints with its is 89.9 m long from the gradient.meticulous planning and successfully Composite steel concrete construction was

executed this landmark structure on adopted for the superstructure. StructuralAt - grade improvementsschedule - in 29 months. steel plate girders fabricated with an

average depth of 1.5 m was designed for ECC's efforts to bring the at-grade road to Consisting of four lanes, this flyover has simple support spans ranging in length from world class standards with elegant kerbs, two separate carriageways each having a 25 m to 33 m and continuous spans of 75m. medians and footpath with pedestrian hand-width of 7.3m separated by architecturally Box girders of 45 m were obligatory spans rails have been well appreciated by the designed elegant parapet walls. The for bridging at six major intersections. Steelcitizens of Kolkata.superstructure is built with composite girders fabricated in a yard close by were

steel-concrete construction. Steel I-beams transported to site in individual span

Consultant

38

The four lane AJC Bose flyover, passing through the heart of Kolkata

BRIDGESAJC Bose Road Flyover, Kolkata

the clock, in a systematic manner with theUnderground Realitiesactive support of Kolkata Traffic Police andco-operation of the people of Kolkata. ECCMore difficult than the complexity of thethus excelled in its community out-reachflyover construction was the relocation ofand scripted a success story with underground utilities - some known and involvement of all concerned.others unknown. ECC had to go deep

underground tracing the century old sewer The AJC Bose Road Flyover will allow one lines, water mains and dry utilities like gas to speed across the breadth of Kolkata and lines, electrical and BSNL cables and re-at the same time, enable the at-grade route them in a structured way, to facilitate commuters reach their destinations in a the construction of foundation works. relatively shorter time. Surely this is another L&T landmark which makes theSpecial mention has to be made of thecountry proud.construction of 2000 mm diameter RCC

hume pipe sewer line adjacent to theexisting 125 year old egg shaped bricksewer (3530 mm x 2971 mm). Adequateprecautionary measures were taken tominimise the chances of disturbing thisage-old brick masonry structure. Continuous interaction was made with KMC, CESC and BSNL to ensure that the re-located services are acceptable to them for future maintenance.

The construction work in the middle of the D.Dattabusy stretch demanded highest standards Project Managerof safety to pedestrians and moving vehicles. ECC managed the traffic round

39

A carriageway leading down on one end of the flyover

An aerial view of AJC Bose flyover

Steel columns and girders seen from the underside of the bridge

Commencement - March 2001Completion - August 2003Length of - 2.9 km including flyover approachesCarriageway - Dual carriageway

each of 7.3 m widthseparated byPrecast / in-situcrash barriers.

Substructure - Bored cast-in-situpiles of 800 mmand 1000 mm dia(max. depth of pile47 m). Structuralpier connected toanchor frame, ontop of the pile cap.

Superstructure - 45 m spanstructural steel boxgirders on majorintersections withroad crossings and25 m span Igirders in all otherlocations.

No. of spans - 63 (25 m x35+32 mx5+33 mx6 +45 mx6 +75 mx11Nos.) 200 mm thickRCC deck Slabscovered withbituminous concreteas wearing course

Project Highlights

angalore, once a pensioners' cons t ruc t th i s acous t ica l ly sa fe , phase of the flyover, stretching 1.3 km from paradise, not only due to its aesthetically pleasing road furniture, in Sirsi to TOM Royan Road, was completed salubrious climes but also a association with UK-based design and opened to traffic on April 23, 1999.B

leisurely life style thanks to old world consultant Dar al-Handasah.Crowd Stopping Technologycharm, moved into the fast lane of

commercial growth in the 80s, having The flyover takes off 170 m west of Sirsi The novelty of the project is that there are nodonned the country's Silicon Valley Circle and runs above the Mysore Road todiversions or cluttering material to disruptmantle. Globalisation of the economy in descend at Silver Jubilee Park, nearthe stream of life and traffic flowing below,the 90s pushed India's Garden City further Townhall Circle, full 2,647 m from where iteven as the flyover construction aboveinto the super highway of information started. India's longest urban viaduct, theprogressed at a hectic pace. This was madetechnology. A fallout of this transformation flyover is 16m wide. It has a dual, four-lane possible, thanks largely to the state-of-the-artwas the exodus of business professionals superstructure designed for a cruising speedand tremendously time saving operations,and entrepreneurs to Bangalore, leading to of 45 km, four times the prevailing speed on such as precast technology which took 10a quantum leap in vehicular traffic, thereby the road below. Size and speed apart, the days to construct a segment, compared to theposing a threat to the engines of growth and Sirsi Flyover will go down as a world classconventional in-situ concrete casting, whichdevelopment. landmark for its ecofriendliness, aesthetics,would have consumed 90 days. Anothercomplex road geometry and uniqueinnovative technology adopted was the useBangalore Mahanagar Palike, the city technology of long-line, match-castof the Titanic overhead-launching machine.corporation, in a bid to ease the chaotic, segmental construction technique,It helped lift, hold and position the 65 t8,000 vehicles per day traffic mix of employed for the first time in India.precast deck segment in an intricatetwo/four wheelers, cars, autorickshawsoperation that left the crowds marveling. Theand pollution belching trucks on its major The alignment follows the existing roadmain flyover comprises 853 precast deckarterial Bangalore-Mysore Road, decided geometry, allowing for gentle transitions onsegments, longitudinally post-tensioned forto commission a 2.65-km flyover on to sharp curves making driving on the viaductself-support at spans of approximately 12which at least 50% of the traffic could be a pleasure. It is possible to get off/on thesegments per 36 m, mounted on 67 singlediverted. ECC bagged the order, as a flyover at TCM Royan Road, Convent Road,piers.turnkey contract, at Rs.94 crore, to KR Market and Victoria Hospital. The first

A view of the flyover showing the curve

BRIDGESSirsi Flyover in the Heart of Bangalore

40

I5 m to 25 m, determined by detailed soilinvestigation. The foundation of the ramppiers was of 0.75 m dia.

Though the permissible differential settlement between piers was 15 mm, FCCmanaged to keep it down to 6 mm.Designed as stepped type, the pile cap wasof 5.5 m x 4.5 m x 1 m size and over thatwas the pier plinth of size 3.5 m x 3.5 m x0.5 m.

Pile drilling was done by imported rotaryboring machine Bauer Rig-14 as also theconventional winch-and-tripod method. Irregular ground conditions hampered piling progress but were overcome by ECCwith determination and its vast expertise.

The salient features of this landmark superstructure, a technique introduced forproject are detailed below: the first time in the country. The survey

station checked the accuracy of each 65 tsegment plotted to occupy its preordainedConstruction Site: For operational slot along the length of the main deck.effectiveness, work was synchronised

between the constantly advancing flyovererection and the factory like construction Piling: Foundations for each of the site spread over an area of 2.4 ha, which is supporting piers of the main flyoverthe nodal centre of activity. Formerly a comprised four bored piles of 1m dia (largerlake, the area had to be dredged and at some locations) and lengths varying frombackfilled. Piling was done to support the twin L&T gantry cranes, each weighing 80 t and meant to handle the material requirements of the two 36 m casting beds.

3The site also housed a 40 m per hour concrete batching plant, a reinforcement bay for cutting steel, storage space for the precast elements as also machinery spares, a material testing lab, a survey station, and the site office.

Segments/elements: The requirement is 853 main deck segments of 16 m width and 263 ramp deck segments, each 8 m wide. The dimension of the ramp deck segments is 8 m x 2.917 m, with mid section height of 1.06 m. The segments are manufactured in the two designed-to-perfection, 36 m casting beds. A fulcrum on the central axis and jacks at end and midpoints enabled the casting beds to be tilted/rotated on a universal axis. This helped match-cast the 853 deck elements for segmental construction of the flyover

Row of piers constructed for the flyover for supporting the viaduct segment.

Inset: Close-up view of the fluted design concrete piers

A boom placer in action pouring concrete without disturbing the traffic

41

machine. Supported on two piers, the 105 mlong, 5 m wide Titanic rests its rear third on atrestle above the pier at the end of thecompleted deck section. Its front end isplaced on a stabilising Omega frameclamped to the next but one pier with a forceof 560 t. A winch moving longitudinallyinside its box section lifted the decksegments brought on a trailer from theprecast yard. The segments were suspendedvia Macalloy hangers from movable trolleysstationed on top of the launching machine.The hangers were tightened/slackened forvertical alignment. Jacks and beams mounted on the trolleys enabled furtheradjustments so those 12 segments comprising a 36 m span were preciselymatched to the ones preceding and adjoining one another. Glued together withepoxy resin, the segments were post-tensioned for self-support with a curvedprofile cable comprising 19 stress relievedsuper strands. The Macalloy hangers weredetached from the segments and the Titanicwas propelled forward to the next Omegaframe reinforced pier for lift, hold andneedle vibrated to obtain the desired grade.Piers: Aesthetically designed as a assembly of the next set of 12 segments.The load of the main deck was transferredsculptural monolith with fluted design

to the pier through two PTFE lubricated potwhich helps mute noise pollution, eachbearings. The ramp deck piers are circularmain deck pier is of 2 m dia at base,and vary in size from I m dia at the top to 1.4extruding to a 1.5 m x 3.3 m ellipse at them dia at base, with a maximum height oftop, having a height of upto 6.5 m.8 m.Armatures for the piers made, in halves, at

the casting yard were assembled at the site.Erection:The mainstay of the erection of theCasting of the pier was done in-situ in asegments to form the flyover superstructuresingle pour, using a Schwing concretewas the 850 t Titanic overhead launchingpump to place the concrete, which was

Night view of the flyover

Undersurface of the flyover. Inset: View of the segment

42

ECC is proud to have been associated with Apart from speed and the aesthetic flutedBangalore Mahanagar Palike in the design of the piers and superstructure for construction of this prestigious flyover in visual appeal as also noise reduction,the heart of the city. Segmental uninterrupted flow of traffic on the road construction was introduced for the first below are the major advantages of this time in the country specially for technology.developing this urban infrastructure. ECC

C.Sankaralingam K.P. Sreeharipioneered this modem technique to theHead-Bridges Project Managerdesign of Dar al-Handasah.

The launching machine used for erecting the viaduct segments of Sirsi flyover.

Sirsi Circle FlyoverSalient features

2,647-metre flyover two-way, four-lane

·

· 36-m spans in general / max. span -45 m

· Design speed - 40-45 km/h (main deck).

· Riding surface asphaltic.

· Bearings - articulated pots.

· Expansion joints - elastomeric.

· Built over existing Bangalore-Mysore Road, following sinuous road geometry and designed aesthetically to set new trends in urban structures.

· Aesthetic, fluted design for visual appeal as also noise pollution control.

· Median at grade ensures safety to road users.

· Under-deck lighting adequately lights up carriageways at grade.

· Mounted on 67 main piers, 2-mdia at base flaring up to a 3 melliptical top, and concreted in situin single pour, using a speciallydesigned steel mould.

· 850- t overhead launch ing m a c h i n e , d e s i g n e d a n d constructed at ECC’s Workshop in Chennai.

· Box girder, continuous over seven spans.

View of the approach reinforced earth wall structure

43

CC secured a contract, valued atRs.14.80 cr., for construction of afour-lane flyover at Ganeshguri E

Chariali on the Guwahati-Shillong Road,Guwahati, Assam, in March 2000 fromthe Publ ic Works Depar tment , Government of Assam. The project was funded by HUDCO (70%) and by the S t a te Governmen t (30%) . The contractual completion period was 18 months. Ini t ia l ly , as per the Government's request, the first two-lanepart of the flyover was made available fortraffic on February 19, 2001. Theremaining par t was completed subsequently and handed over to theGovernment on March 19, 2003.

This 640 m long flyover is located at abusy intersection in the heart of Guwahati and consists of a 2x7 m carriageway, 0.6 m central verge and a 0.9m pedestrian footpath on either side, skewed at 20 degrees. It rests on sixteen equal spans of 30 m each with 80 m approach road on both sides. The design was provided by the Design Department

with elastomeric bearings (neoprene) and of PWD and proof-checked by IIT-single strip seal expansion joints. M.S.Guwahati.handrails of 1.20 m height are provided onboth sides to protect the vehicular traffic.Pile caps of size 6.30 m X 5.85 m X 1.80 mBoth abutments have been constructed onand 4.50 m X 5.85 m X 1.80 m rest on cast-the principle of solid type retaining wall.in-situ bored piles of 600mm dia having 16The app roach road cons i s t s o f nos. of 14.15 m length (for piers of moreembankment, sub-grade of 500 mm than 4 m height) and 12 nos. of 15.15 m thickness, granular sub base of 200 mm length (for piers less than 4.0 m in height). thickness, water-bound macadam of 150 The piling work was done by the DMC mm thickness, bituminous macadam of 75 their part carried out security exercises on a method. The sub-structure consists of two mm thickness, and semi dense carpet of 25 daily basis. Our personnel were all provided circular piers of 1200 mm and 1000 mm mm thickness. The flyover has suitably with proper photo identity cards to enable dia where the height of pier is more than designed valley curve and summit curve for them have hassle-free access to site. 4.0m and less than 4.0 m respectively and providing riding comfort and smooth pier cap of depth 1.00 m on which all thehorizontal curves. The precast kerbs with The Chief Executive Officer, Guwahatifive precast post-tensioned 'I' girdersgrooves have been fixed at the side of the Metropolitan Development Authority, wasstand. The 'I' girders of 1.32 m height weredeck slabs all along the length, to impart an very appreciative of our completing the two-cast at the casting yard at the site and wereaesthetic look to the flyover. lane part of the flyover within the stipulatederected and aligned using two 30 t

time and issued a letter of commendation.launching gantries. The post-tensioningTo reduce the cost towards de- and re-and pre-stressing works were done bymobilization of piling equipment, two lane The major quantities of work involved were:Usha-Martin Ltd., Bangalore.piling works were completed first to allowvehicular traffic over the piles after doing 1) Cast in situ piles - 6,140 RMEach two-lane carriageway rests on 5 'I'proper maintenance of the pile points. High 2) Excavation - 2,800 Cumgi rders , which a re s t i t ched by standard safety measures were taken during 3) Concrete - 8,500 Cumdiaphragms/cross girders at six places toconstruction. Special care was also taken 4) Reinforcement - 1,100 tguard against possible effects of during piling and excavation activities to 5) HT strands - 210 tearthquake (Guwahati lies in earthquakeavoid damage to public utilities like zone V). In-situ deck slabs of 180 mm underground power and telephone cables, M. Rameshthickness have been laid over these domestic water pipelines, etc. In view of Construction Managergirders, followed by asphalt wearing the insurgency situation in Assam and sincecourse. Construction joints of 30 mm gapthe site is located close to the Statewere maintained at the centre of the four-Secretariat, the State Government too onlane flyover, which has been provided

480m long four lane flyover at Ganeshguri on GS Road at Guwahati, Assam. below: Night view of the flyover

BRIDGESFirst Four Lane Flyover in the North East

44

Larsen & Toubro (Oman) LLC [LTO], theGulf-based subsidiary of Larsen & ToubroLimited, completed the construction of a3.2 km flyover at Al Khoud for MuscatMunicipality in the Sultanate of Oman inNovember, 2004. The flyover, also knownas an interchange or elevated corridor, wasbuilt by LTO, with technical support fromECC, the Construction Division of L&T.Parsons International & Co. LLC providedthe consultancy services.

The project involved construction, with ina schedule of 16 months, a dual three-lane,three-span continuous bridge to gradeseparate A'Seeb Street. Each bridgecomprises a 90m span cast in situ post-t e n s i o n e d c o n c r e t e b o x g i r d e r superstructure. The sub-structure consistsof integral abutments and piers. Columns are founded on cast in place concrete piles.

LTO also executed the first public access tunnel - a 130 metre-long and 6.16 metre dia. horse-shoe shaped tunnel - at the Barr al Jissah Resort, 11 days ahead of schedule. These projects were "technologically challenging and also provided greatervisibility to L&T in key global markets".

Al Khoud interchange, Muscatwith inset of the flyover bridge

Wadi Abdoun Bridge, Amman - Jordan

ECC is presently executing a 430 m longcable-stayed bridge in Amman, the CapitalCity of Jordan.

The bridge will have a dual three lanecarriageway for traffic with a span configuration of 1 x 63m + 2 x 132m + 1 x63m + 1 x 27m. The project is beingexecuted through a Joint Venture betweenL&T and Arab Technical Construction,Jordan, in the ratio of 70:30.

The con t r ac t i s va lued a t JD . 10,808,988.51 (INR.74,25,77,510) with L&T's share at INR.51,98,04,257. The project is expected to be completed by May, 2006.

The client for the project is the The Lord Mayor of Amman (Municipality of Greater Amman) and the project consultant, Dar al-Handasah, London (UK).

Al Khoud Flyover, Muscat - Oman

ROADS & BRIDGESRoads & Bridges - International Perspectives

View of lifting the segment for erection.Inset: View of erection of segments from pylons

45

With the vast experience, skills andknowledge gained over the years in roadprojects, ECC has ventured into projectmanagement consultancy (PMC). As apartner in the Joint Venture Companyformed by L&T, Progressive ConstructionsLimited (PCL) and Central Trading Company (CTC) of Sudan, ECC is offeringPMC services for a road project in Sudan.The project involves construction of a 127km two-lane road connecting Atbara in thewest and Haiya in the east. Oncecompleted, the road will provide a directlink between Khartoum, Sudan's Capital,and Port Sudan City, substantially reducing the distance and travel time and Scope of Work:resulting in fuel savings.

Present status of completion:· Construction of new 2-lane carriageway

The National Highway Authority of Sudan from km 278.590 to km 150.00· Clearing and grubbing-52 km are the clients and Ashraf & Salah

· Bridges 3 Nos.· Embankment-45 km Consulting Engineers, Khartoum, the

· Box culverts 17 Nos.· Sub-grade-40 kmconsultants for the project. While PCL will

· Pipe culverts 526 Nos.execute the contract, CTC will provide · Granular Sub-base (GSB)-35 km· Construction of junctionslocal support. · Crushed Aggregate base (CAB)-20 km· Protection work

· Primer-11 km· Provision of road signs, markings andThe work commenced on February 27,

· Binder course-07 kmfurniture2004, is scheduled to be completed in 36

· Pipe culvert-70 Nos.months. The scope of work and the present

· Box culvert-02 Nos.work status are given below:

Project Management Consultancy for Sudan Road

A completed section of the Sudan roadInset : Batching Plant and Transit Mixer

'Middle Bridges on the Trunk' in Palm Jumeirah

The Palm Islands, also referred to as The million (Rs.43.5 cr.), against stiff Palm Dubai and The Palms, are the world's compe t i t i on f r om in t e rna t i ona l two largest man-made islands, which are contractors. In this package there are 4being built on the coast of the Emirate of bridges, each of 135m length. The spanDubai, in the United Arab Emirates (UAE). configuration of each bridge was The project is being implemented by Al 40m+55m+40m. Two bridges are Nakheel Properties (Nakheel Corporation), located on the commercial side and two onwhich will increase Dubai's shoreline by the residential side.120 km (72 miles) and create a largenumber of residential, leisure and The foundation consists of 266 nos. ofentertainment areas. The two man-made 800mm dia, 20m deep cast in situ piles.freehold artificial palm tree-shaped resort The shape of the pier is shaped islands are expected to maintain Dubai's ornamentally with imprint design on all position as a premium tourist destination. sides. The superstructure is a multi-cell The Palm Islands have also come to be box girder. The box girders were cast called the 'The Eighth Wonder of the using L&T formwork and World'. staging materials in three

s t a g e s . P O T - P T F E The palm tree shape has been divided bearings were installed into three parts o n e a c h p i e r t o

a c c o m m o d a t e t h e · Trunkmovement and rotation. · 8 Spines with fronds on each sideT h e r e w e r e t w o · A crescent covering the whole expansion joints in each artificial island to protect it for a length bridge for movement of of 11 km40 mm and 120 mm. The bridges were completed The trunk portion of the island has been within the stipulated connected to the land with many bridges.con t r ac t t ime and Larsen & Toubro Limited ECC Divisionhanded over on June 28,won the contract to construct the Middle2005.Bridges on the Trunk, valued at AED 36.25

View from underside of Bridge portion.Inset: Bird’s eye view of the proposed Palm Island

46

Rs.3,771 crore during the quarterended 31st March 2005 and for thefull year, revenues amounted to Rs.11,430 crore, representing an increase of 39% over the previous year. Export sales for the quarter and for the year amounted to Rs.687 crore and Rs.2,355 crore respectively. The order backlog stood at a healthy Rs.17,604 crore as on March 31, 2005.

Electrical & Electronics

During the quarter ended 31st March 2005, the Electrical & Electronics segment achieved 14% increase in Gross revenues at Rs. 357 crore. For the full year, revenues amounted to Rs. 1,220 crore, recording a smart

L&T reported a smart increase in previous year. Of these, export orders increase of 20% over the previous Gross Sales & Service income of accounted for Rs.1,692 crore, year, reflecting consistent growth.Rs.13,269 crore for the financial year constituting 13% of the orders bookedended March 31, 2005 as against Diversified Businessesduring the year.Rs.9,807 crore for the previous year.

Among the diversified businesses, theBoth domestic and internationalThe impressive increase of 35% inConstruction equipment business wasmarkets provided opportunities for thesales is over and above the 32%the star performer. Good demandCompany in Oil & Gas, Power andgrowth in the previous year. Thegrowth and product improvementsInfrastructure sectors. The size andC o m p a n y ' s r e v e n u e s f r o m helped register 18% growth in L&T's complexity of the orders booked across international operations continue to revenues over the previous year. grow, and stand at 19% of the total Welding systems and industrial sales and service income.products also performed well duringthe year. These businesses along withProfit before tax (PBT) and Profit afterthe Ready Mix Concrete businesstax (PAT) for the year is at Rs.1,286have good growth potential in thecrore and Rs.984 crore. After coming years.excluding an exceptional income of

Rs.353 crore relating to sale of shares Consolidated Financialsin UltraTech Cement Limited, the

PBT/PAT for the year at Rs.933 crore The consolidated Gross Sales and Rs.631 crore registered an Revenues of the L&T Group for the increase of 21% and 18% respectively year, including domestic and overseas over the previous year.subsidiaries amounted to Rs.14,613 crore, registering a growth of 31.6% The Board recommended a final over the previous year. The grew dividend of Rs. 17.50 per equity share

a range of core sector industries / profit after tax at Rs.1,117 crore grew in addition to the special dividend of infrastructure sector reflect L&T's impressively by 45.6% on the back ofRs. 10 per equity share declared inpremier position in the E&C segment. good performance of most of theOctober 2004.

subsidiaries.Of the new orders booked during the

Engineering & Construction year, 32% are from Infrastructure Sector. Among the major subsidiaries, L&TSegment Hydrocarbon Sector accounted for Infotech registered a revenue growth

21%, while Power Sector and Process of 54% during the year. Other The Engineering & Construction Equipment Sectors together contributed subsidiaries such as L&T Finance(E&C) Segment booked new orders 21% of the orders booked. Limited, HPL Cogeneration Limited,amounting to Rs.13,301 crore,

etc. also reported good performances showing an increase of 14% over the The E&C segment recorded revenues of with increased revenues and profits.

L&T Posts Smart Annual Results For 2004-05

Mr. A.M. Naik (centre), Chairman & Managing Director, briefing media representatives on L&T’s Annual Results. Other Directors are Mr. R.N. Mukhija, Mr. Y.M. Deosthalee, Mr. K. Venkataramanan and Mr. K.V. Rangaswami

47

EOSC

OP

KAL

IDE

Revenues up by 35%

PAT up at Rs. 984 crore

Total Dividend at Rs. 27.50per equity share including

Special dividend of Rs. 10

th Group (EBG). As a first step, resulted in the power of teamwork,30 May 2005 was a significantAccen tu re wou ld he lp ECC the need for clear direction and landmark in the history of ECC, theimplement best practices in Supply leadership, the importance of beingConstruction Division of L&T. OnCha in Managemen t , P ro j ec t committed to the goal and how to this day, ECC, the jewel in the L&TManagement and Asset Management think “win-win”. The exercise also crown, resolved to become the and ensure IT Enablement. unearthed the creative talent of the “Kohinoor” and achieve a ROCE of

teams through scr ipt ing and 20% and PBIT exceeding 10% by theThe Kohinoor team is led by Mr. M. performing impromptu entertainmentturn of 2010, enabling L&T achieve itsSomakumaran, General Manager & skits.strategic objectives. To emphasiseHead (Materials Management & the strategic importance of ProjectV e n d o r D e v e l o p m e n t ) . M r . Fresh from the team-building Kohinoor 2010, Mr. A.M. Naik, Somakumaran brings with him a exercises, the team members plungedChairman & Managing Director, wealth of experience in the area of headlong into the task at hand andlaunched this program at ECC-HQp r o c u r e m e n t a n d m a t e r i a l s started collecting and collating data Chennai and provided the impetus.management in the organization and across all the assigned projects.Mr. K.V. Rangaswami, Member of theoutside. The team has been staffedBoard & Senior Vice-President

The Procurement Team made with over 20 people from ECC and (Operations), reiterated ECC's significant strides in conducting over 10 from Accenture. The Projectcommitment to achieve these targets'Spend and Industry Analysis' onhas been divided into three modules:and assured the wholehearted supportSteel, Cement and Electrical sectorProcurement led by Mr . A. of each and every ECC-ite.procurement items and identified Girijasankar, DGM (Materials); several avenues for cost reduction.Project Management led by Mr. B.To help, guide and steer the Accordingly vendor development, Puhazhendhi, DGM (HCP); and Assetorganization in this ambitious task,leveraging on the procurement powerManagement and Working CapitalECC engaged the services of of L&T, was made a part of theManagement led by Mr. J.J.G. Accenture, a global management Company's ambitious growth plans.Christopher, DGM (Finance & consulting, technology services and

Accounts).outsourcing company, to undertake a The Project Management Team joint exercise to identify opportunities focused on identifying the issues and The joint team “from Accenture” and and achieve operational excellence. concerns at every stage of the project “ECC” had an off-site programme on Accenture brings with it enormous management process - right from team building exercise and at the end experience in carrying out such Tendering to Close-out. The team also of the programme, they came out as a assignments in India as well as 140 initiated meetings with Business Units “single Kohinoor team” with shared countries abroad. Accenture and L&T and Regions to identify perspectives vision and objectives. The team-share a long-standing relationship of the critical issues being faced by building programme was carried out with similar work being undertaken in them in the project management through some simple exercises, which other ODs such as Electrical Business arena.

Project Kohinoor 2010Journey to Operational Excellence

48

A section of the participants during the launch of the event at ECC-HQ, Chennai

The Asset Management Team took acomprehensive look at our assetportfolio to determine which assets toown and which to hire on an overallbasis. The team also reviewed theo v e r a l l W o r k i n g C a p i t a l management of the Company and the reasons for gaps between the plan and actuals.

Soon, the teams are likely to comp le t e t he i r p r e l im ina ry diagnostic reports and present theassessment and review plans to thesenior management during mid-August for their perusal, views and determining the next course of action plans.

An exercise of such importance and magnitude cannot succeed in isolation. The work performed and solut ions for improving the Remembering Thomas Edison's the results achieved are likely to operations of the Company as a words on Success “Success is touch and impact the daily work of whole. It is proposed to create a nothing but 1% inspiration and 99% each and every employee. It is, dedicated email id, where people perspiration!” hard work lies ahead therefore, imperative that everyone can pool their suggestions and for all of us to make the ECC jewel contributes to the cause by sharing worthwhile ideas for implementation become a Kohinoor in the crown of ideas/suggestions, and help the as part of the overall brainstorming. L&T.Kohinoor Team come up with

49

AJC Bose Road Flyover, Kolkata selected for IIBE AwardThe Indian Institution of Bridge The Award will be given away at theprefabricated, assembled on ground Engineers (IIBE) has selected the I IBE's presenta t ion ceremony nd erected using heavy lift cranes.

scheduled for August 5, 2005.Acharya Jagdish Chandra Bose Road Such construction techniques ensuredFlyover in Kolkata for the 1st prize high quality and speedy completion ofunder its 9th Most Outstanding the project.Bridge National Awards scheme.

The flyover, connecting Park Circusgyratory in the East with Victoria Gateon the West, was completed onschedule in August 2003 in 29 months. One of the most critical and difficult aspects of the project i nvo lved the r e - l oca t i on o f underground services in the middle ofthe road to vacant spaces on the sidesto make way for construction offoundations.

At a length of 2.9 km includingapproaches, it is the longest flyover inthe State of West Bengal. Consistingof four lanes, this flyover has twoseparate carriageways, each 7.3 mwide and separated by architecturallydesigned, elegant parapet walls. Structural steel plate girders fabricatedwith an average depth of 1.5 m weredesigned for simple support spansranging in length from 25 m to 33 mand continuous spans of 75 m. 45 mstructural steel box girders were obligatory for spanning across 6 major intersections. The steel girders, columns and crossheads were

AJC Bose road flyover

Another view of the participants

The Quality Rolling Trophy recently instituted by Management is an annualfeature which recognises project sites forexcellent performance in terms of thequality of their product and processescovering all Business Units.

Participation in the award process is voluntary and winners are chosen Business Unit-wise. The entries for participation are processed in stages by the Regional QMCC Coordinator, Quali ty Management Committee of the Region (QMC [R]) , a board of examiners consisting of QMC (R), internal auditors and external experts and finally the Quality Management Committee-HQ. The parameters considered in deciding the winners are : Product quality, housekeeping,procedure compliance assessment, customer complaints and redressal, construction time planned vs. actual, ACEvs. Actual cost, safety performance and costof rework. The final result is the weightedaverage of the various parameters accordingto their importance.

Winners of Quality Rolling Trophy 2003-04

WET Visakhapatnam Industrial HyderabadWater Supply Project

HCP Sidhpur-Sanganer Pipeline AhmedabadProject

I&CB Intel SRR1 Project, Bangalore BangaloreSHIS Oberoi Park View Tower, Mumbai

Kandiveli, MumbaiR & R Satara - Kolhapur Road Mumbai

Project, Mundhe, Karad.P & H Hazira Port & LNG Terminal Ahmedabad

ProjectBridges AI Khoud Interchange Project, M E & Africa

Muscat, Oman Zone

EI & C Telecommunication-PDT - 2A KolkataPackage

TLRE 200 kV D/C - Satgachia- KolkataKrishnanagar T/L job

BU Site Description Region/Zone

50

ECC wins Fourth RoSPA Award

ECC's DHDT & HGU projects atIOCL’s Panipat refinery won theprestigious Silver Award of theRoyal Society for the Prevention ofAccidents (RoSPA), UK. The awardis an apt recognition of ECC'sexcellence in occupational healthand safety performance achieved atsite during a continuous period of 3years from September 2002 toDecember 2004. In the three-yearperiod the site achieved 20 millionsafe man-hours and the workingtime loss due to injury/accident waszero.

thThis is the 4 RoSPA award won byECC. The award certificate was

thpresented on 18 May 2005 atBirmingham (U.K) to Mr. M. Ramkumar - Head HCP BU, Mr.Sharad Kumar - Construction Manager - IOCL Panipat and Mr.A.K. Tripathi - Regional Safety Co-

was also adjudged the Safest Major Site the Merit Award for Occupationalordinator Delhi Region.(In-house) for the year 2004 -2005 Safety at Jawaharlal Nehru Stadiumamong all the jobsites of ECC.The site was awarded the Construction Site, Chennai, in 1993, the GOLD

Safety Award by Indian Oil Awards for Occupational Safety at CoalCorporation Limited for the period The RoSPA Awards won earlier for Handling Plant - Paradip Site in 2002 October to December 2004. The site excellent safety performance include and TISCO Jamshedpur Site in 2003.

Left to right : Mr. M. Ramkumar, Head HCP-BU, Mr. Sharad Kumar-Construction Manager-IOCL Panipat and Mr. A.K. Tripathi-Regional Safety Co-ordinator-Delhi Region seen with the Silver Award of RoSPA, UK.

The list of winners BU-wise for the year 2003-2004 is given below :

initiative SJER was presented a CashAward and Citation by Mr. K.A.Shyamsundar, Regional Manager -HYRO.

N o r m a l l y c o n c r e t i n g a n d reinforcement lifting at the 2.4 kmGowthami Bridge was done from theriverbed via truck mounted transitmixers. During monsoon the construction activity came to a stop due to heavy flow of water, making it difficult for the Transit Mixer to ply on

Mr. S. John Edward Raj (SJER), Asst. the riverbed. Coming up with a novel Manager (P&M) at Gowthami Bridge idea, SJER modified the Transit Mixer DG set was fitted on a separate wheel site, conceived and developed a tailor- to run on rails (already laid for trolley and attached to the transit mixer made device in the form of rail- launching of pre-cast girders). The to supply the power. Two such mounted concrete mixer to enable the Mixer was disassembled from its truck modified trolley-mounted Transit site to continue work even during chassis and fitted to a specially made Mixers on rails enabled continuousm o n s o o n , t h u s c o n t r i b u t i n g wheeled trolley, having 17.5 HP work without lost time and projectimmensely to the speedy completion electric motor and gearbox. A 40 KVA completion on schedule.of the job. In recognition of his

Innovative erection method at DMRC Projectprecast segments as tunnel lining. NATM tunnels was thus completedHowever, it was found these were not successfully, thanks to the efforts of PSperforming as expected on account of and his team. He also developed a difficult rock conditions. To expedite system for grouting of erected segments the progress, IMCC decided to do the that was different and more efficienttunneling from New Delhi station to than erection through tunnel boringChawri Bazar station by using New machines.Austrian Tunneling Method (NATM)and go in for segment tunnel lining. The innovation, in addition to being

economical, helped in speedy Erecting precast segments separately completion of the job and enhanced in the NATM Tunnels was a very the profitability of the project.difficult task on account of their weight(approximately 4 tons each) and spaceconstraints. To overcome this

Mr. Palwinder Singh, Asst. Manager situation IMCC management assigned(P&M), and his team at Mumbai the task of developing a truck-successfully designed and developed mounted segment erector to ECC's Mr.truck-mounted segment erectors for Palwinder Singh (PS) who was onInternational Metro Civil Contractors deputation to IMCC.(IMCC) at the DMRC Project in NewDelhi. He was presented a Cash PS contributed immensely in Award and Citation letter. The time conceptualising and developing a bound innovation was very well system for erecting the segments. Itreceived by IMCC as well as the clients was different from the tunnel boring/ DMRC and also found a mention in applications used so far. With the cover story in October 2004 issue sustained efforts of the team, two truckof “Tunnels & Tunneling”, an mounted segment erectors were international magazine. designed, fabricated and successfully

deployed in the East and West tunnelsAt IMCC JV, two tunnel boring after field-testing in the presence ofmachines were deployed, which were DMRC and General Consultants. capable of both tunneling and erecting Precast segmental lining of both the

Mr. K.A. Shyamsundar, RM-HYRO, presenting the cash award and citation to Mr. S. John Edward Raj

Rail mounted transit mixer at Gowthami Bridge Site

Truck mounted Segment Erector

Mr. G.S.R. Murty, Sr. DGM (Projects), IMCC-JV presenting the cash award and citation to Mr. Palwinder Singh

Transit Mixer on Rails - A Novel Modification

51

Building Collapse Victims Rescued

On April 5, 2005, the SanthomePolice Station in Chennai sent an SOSto ECC seeking assistance to rescuepeople trapped in the debris of a fivestorey building that had collapsed intheir area. Immediately a team led byour Construction Manager Mr. A.C.J.Nehru (ACJN), IIT-Madras site, Chennai, rushed to the spot with gas cutting sets and concrete breakers. Within 30 minutes they joined the rescue operations. Four persons were pulled out from the rubble but only two of them were alive. Our crew then removed concrete slabs of three floors using gas-cutters and concrete breakers and saved one more person meanwhile ACJN requisitioned additional manpower as also tools and tackles. Mr. C.J.A. Davidraj (SPM-B&F, CNRO) arrived at this juncture to oversee the operations.

ECC Answers SOS Call of PWD-MizoramIn times of crisis, clients invariablyturn to ECC and seek assistance insaving the situation. We have onesuch instance from Mizoram recentlywhere, ECC made its debut some timeago securing an order for constructionof the Millennium Centre in Aizawl.

The commendation certificate issuedby Mr. Ramhluna Khiangte, Engineer-in-Chief and Secretary, PWD, Government of Mizoram, gives fulldetails of the service rendered by ECCfollowing a landslide in Aizawl. Itreads, “This certificate is awarded tothe Team of L&T, ECC Division,Millennium Centre, Aizawl for theircontribution in restoration of communication by erecting 140 feetextra wide Bailey Bridge on the road

construction and just in front of the contribution by working day andto Babutlang within a record time ofth th I.G. Prison office building caused by night, the road was opened to traffic three days from 14 -16 April 2004.

thexcessive flow of storm water on the on the night of 16 April 2004 (Friday)The road communicat ion to th

evening of 12 April, 2004 greatly and the I.G. Prison Office was saved Babutlang within the heart of Aizawlendangering the I.G. Prison office from danger.”City was cut off by a landslide abovebuilding. Because of ECC's devotedM i l l e n n i u m C e n t r e u n d e r

A view of the collapsed building

Rescure team (from left to right) : Mr. R.C. Rajan, Mr. S. Swamynathan,Mr. AS. Lalchandani, Mr. S.Sekar, Mr. A.C.J. Nehru, Mr. L.S. Mathrubutam,Mr. R. Rangarajan, Mr. N. Sivakumar.

Tamil Nadu Ministers Mr. O. Panneer operations to extricate four moreSelvam, Mr. C. Ponnaiyan, Mr. D bodies still caught under the debris.Jayakumar and Mr. Nainar Nagendran However as the remaining structureswitnessed the rescue work along with also started collapsing CJAD and ACJNDeputy Mayor of Chennai, Mr. R. recommended temporary stoppage ofThiagarajan, Director of General of rescue work and suggested evacuationPo l i ce Mr . A .X . A l exande r , of the adjacent residential apartments. Comissioner of Police, Mr. R. Natraj, Mr. Dhogra organised the evacuationMr. VijayaKumar, Commissioner, thus facilitating continuance of the Corporation of Chennai, Mr. Dhogra rescue operations, after which ECC(Director and Chief of TamilNadu Fire personnel stayed back to assist theServices Unit) and Mr. C. Sylendra Police and Fire Service Department inBabu (Deputy Commissioner of Police dismantling the structure. The Chennai- Chennai South). Police, The Chennai Corporation and

the residents have highly appreciatedThey consulted CJAD on continuing ECC for the swift and timely help.

52

New Orders

L&T Consortium Bags L&T to Build India's Longest Rs.1,864 Crore ONGC Order Flyover at Panipat

L&T Bags Rs.278 crore NationalHighway Contract

L&T Bags $19 Million Order forCement Plant in Oman

construction and erection. The newunit will boost capacity at OmanCement's existing 1.2 million tonnesper annum capacity cement plant.A consortium of L&T and Global L&T has secured a contract from

Industries Offshore, leading USA National Highways Authority of India The order was secured by L&T againstb a s e d p r o v i d e r o f o f f s h o r e (NHAI), New Delhi, for constructing a stiff competition from internationalconstruction services, has won a 6-lane dedicated flyover on Nationalbidders and will enhance the Rs.1,864 crore order from Oil & Highway No. 1 (NH-1) in Haryana.c o m p a n y ' s e n g i n e e r i n g a n d Natural Gas Corporation (ONGC) for The contract also includes wideningconstruction business prospects in thethe replacement of pipelines and the existing 4-lane, 10 km stretch (km field of cement projects in the Middlemodification of platforms at Bombay 86 to km 96) -- that passes through the East.High. The project was bagged by the historic city of Panipat -- to 6 lanes. The

consortium against stiff international project , secured against s t i f fL&T is presently executing a 1.2competition. international competition, is estimated million tonnes per annum capacityto cost Rs.418 crore. It will becement p lan t fo r La fa rge in As consortium leader, L&T will executed on build-operate-transfer Bangladesh.execute jobs worth around Rs.930 (BOT) basis through a Special Purpose

crore. L&T's scope includes all the Vehicle to be formed for this purpose.engineering, procurement, onshorefabrication, and offshore modification The total length of the 6-lane elevated of platforms. Global Industries section is 3.4 km (3048 m of viaduct

L&T has bagged a road contract valued Offshore has been entrusted with the and 360 m of ramps) covering theat Rs.278 crore from the National installation of offshore pipelines and central built-up Panipat section. WhenHighways Authority of India (NHAI).risers. completed, this will be India's longest The Asian Development Bank funded 6-lane flyover on the Nationalproject, secured against internationalThe project involves replacement of Highway network. A separate 2-lanecompetition, involves upgrading andold submarine pipelines and laying of peripheral road with paved shouldersfour-laning of a 70-km section of NHnew pipelines, in 40 segments will be provided on either side of the 76 in Rajasthan.aggregating to 185 km, over a 3-year access controlled 6-lane highway for

period. Associated modifications are the local Panipat traffic, which will not The road forms part of the Nationalalso to be carried out on 78 existing use the elevated structure. The roadHighway Development Programmewell and process platforms. The first- will have a 20-lane toll plaza to collect (Phase-I I ) of NHAI, and willyear schedule is critical since about toll fees using semi-automatic tollsignificantly enhance the link to Kota45% of the work is to be completed by collection system including aon the North-South and East-West April 2006. dedicated automatic lane in eitherCorridors. The road will be completed direction. The total concession periodby L&T's Construction Division, ECC , These pipelines and platforms were including construction period of threein 30 months.originally installed by ONGC over the years will be 20 years. L&T Ramboll

last 30 years and this project is Consulting Engineers Limited is theECC has contributed substantially todesigned to extend the life and design consultant for the project. the ambitious Golden Quadrilateralreliability of these facilities. The Earlier in 1997, ECC had executed a Project, aimed at strengthening the project covers ONGC's major World Bank-aided project for thelinks between the country's four majorproduction areas in the Western P u b l i c W o r k s D e p a r t m e n t ,metros. Under NHDP Phase I, ECC Offshore - Bombay High North, South Government of Punjab, that involvedbagged orders valued at Rs.2,362 crore as well as Heera fields. four-laning of 24-km stretch on NH-1for 11 sections involving an aggregate(km 228 to km 252.25) from Rajpura to

Member of distance of 416 km of roads and Mr. K. Venkataramanan, Sirhind.the Board & bridges. Of these, nine projects have President (Operations)

already been completed by ECC, andL&T, said, "This order is a recognition two are in advanced stages ofof L&T's increasing acceptance forcompletion.world-scale projects in India and

abroad, building on its recent projects L&T has bagged an order valued at US Recently, ECC had completed thein Africa and the Middle East. This $19 million from Oman Cement construction of the 40-km-long section latest success further asserts L&T's Company for a cement grinding plant of India's first six-lane BOT toll road project delivery strengths, and allows at Rusayl, Oman. The 1 million tonnes project between Jaipur and Kishangarhit to leverage its capabilities into the per annum capacity plant will be on NH-8. The prestigious road project submarine pipelines and platform executed by L&T on a total turnkey was completed six months ahead ofrenewal business, which offers a lot of basis and is expected to be schedule and dedicated to the nationpotential.” commissioned in a year. L&T's Oman-by the Prime Minister, Dr. Manmohanbased subsidiary, Larsen & ToubroSingh, on May 23, 2005.(Oman) LLC, will carry out on-shore

53

Ranchi - Maithan 400 kv D/CTransmission Line

1X300 MW Power Plant, DPLDurgapur

Paint Shop for Maruti Udyog

MIOT Hospitals

Water Supply to 239 coastal /rural habitations in Tamil Nadu

Civil, Structural and Architecturalworks for 2X125 MW CaptivePower Plant, Duburi L&T to build 2 MTPA Iron Ore

Sinter Plant for Tata Steel

Panvel Jasai- Jawaharlal Nehru PortTrust Line

Nigam Limited for supply and treatment, 5,330 Cum of brick work, installation of track, signalling and 49,640 Sqm of plastering, 850 Sqm of electrical (OHE & General) works in supply and fixing of doors, 2,500 Sqm connection with doubling of Panvel of glazed windows, 13,000 Sqm of Power Grid Corporation of IndiaJasai- Jawaharlal Nehru Port Trust Line ironite flooring, 1455 RM of supplyLimited has awarded ECC a contracton Central Railway. To be completed and fixing of PVC pipes.valued at Rs. 97.03 crores for supply,in 12 months from May 2005, theerection, inland transportation, scope of work includes supply and insurance, delivery of equipment / installation of 3,815 t of rails, 75,000 materials, survey, foundation, Cum of ballast, handling, paring, layings t r i n g i n g a n d t e s t i n g a n d and linking of 32,220 track metres ofcommissioning of tower package for Dongfang Electric Corporation hasBG tracks, 335 t of OHE structures, 546400 kv D/C transmission line between awarded ECC a contract valued at Rs. nos. of OHE brackets, 2 switchingRanchi and Maithan associated with 22.95 crore for the construction of stations, 38 km of OHE wiring, 1,306Kahalgaon II phase I transmission foundations of main power house for nos. of relays, 157.5 km of cabling, 66system. To be completed in 26 1X300 MW Power Plant at DPL,nos. of electric point machines, 2 nos.months from March 2005, the scope Durgapur. To be completed in sixof high mast lighting.of work includes supply of 9,348 t of months from April 2005, the major

galvanised tower and stubs, 426 Km quantum of work involves 53,000of galvanised steel earthwire Cum of excavation, 25,000 Cum of (7/3.66mm), 2800 sets of suspension backfill, 3,100 t of reinforcement,fittings, 1900 sets of tension fittings, 10,060 Cum of concrete, 80 Cum of 565 nos. of earthing materials (pipe masonry and 140 t of embedded parts.

Maruti Udyog has awarded ECC atype), 210 km of detailed survey andcontract valued at Rs. 35.07 crores forcheck survey, 585 locations (21,600the design and construction of paintCum) of stub setting and concreting,shop at Manesar. To be completed in585 location of tower erection, 21015 months from June 2005, the majorkm of laying, stringing, testing andscope of work involves 72,000 Cum ofcommissioning of ACSR Moose, MIOT Hospitals has awarded ECC aearthwork, 13,150 Cum of concrete1760 t of supply and placement of contract valued at Rs. 18.07 crore forworks (PCC & RCC), 987 t of reinforcement. construction of nursing college, reinforcement, 3,523 t of structural extended care building and bridge forsteel, 1,820 Cum of brick work, 18,423 their hospitals at Chennai. To beSqm of roof sheeting, 12,231 Sqm of completed in 10 months from Mayslide cladding, 17,000 Sqm of roof 2005, the scope of work includeswater proofing (cellular concrete with 12,400 Cum of excavation, 3,042 SqmTamil Nadu Water Supply and 3mm APP membrane), 19,000 Sqm of of water proofing, 5,391 Cum ofDrainage Board has awarded ECC aVDF flooring, 17,000 Sqm of epoxy Concrete, 697 t of reinforcement,contract valued at Rs. 47.46 crores forflooring, 1 package of internal 9,386 Sqm of flooring, 2,950 Cum ofproviding water supply to 239 coastalplumbing and sanitary works. block masonry, 56,000 Sqm of / rural habitations in Pudur,

plastering, 19,000 Sqm of painting,Vilathikulam, Ottapidaram, Kayathar1,820 Sqm of false ceiling and 1,940and Kovilpatti unions in ThoothukudiSqm of road work.district including maintenance of the

scheme for 12 months. The work to becompleted in a tight schedule of 12months involves 3,00,000 Cum ofexcavation, 6,000 Cum of concreting, Jindal Stainless Limited has awarded29,000 Sqm of formwork, laying of ECC a contract valued at Rs. 37.59

L&T continues to enjoy the trust ofPSC pipes (600 mm to 350 mm Dia) crores for executing civil, structuralTata Steel. To implement its expansionfor 135 Km, PVC pipes (160 mm to 63 and architectural work for its 2x125programme in line with its vision ofmm Dia) for 628 Km, CI pipes (600 MW capitive power plant at Duburi,becoming a 15 million tonne steelmm to 80 mm Dia) for 135 km, AC Orissa Jaipur. To be completed bycompany by 2010, Tata Steel haspipes (250 mm to 150 mm Dia) for 76 December 2006, the major civil andembarked on a 2 million tonnes perkm, 900 t of reinforcement, 54 nos. of structural works involve 225200 Cumannum capacity iron ore sinter plantoverhead reservoirs, 42 nos. of of excavation, 1,00,000 Cum of (Plant No.4) project at Jamshedpur.underground reservoirs. disposal, 87,000 Cum of backfilling, L&T and its technology partner 38,725 Cum of concrete (PCC&RCC),Outokumpu of Germany have been3,700 t of rebars, 1,04,100 Sqm ofawarded a contract worth Rs.360shuttering, 75 t of anchor bolts & crore to build and erect the plant in 24inserts, 10,000 t of structural steel, 50 tmonths commencing from July 1,of MS bolts. The architectural worksECC has bagged a contract valued at2005. L&T’s share in this project isinclude 20,000 Sqm of anti-termiteRs.49.47 crores from Rail Vikas Rs. 288.65 crore.

54

L&T Concrete Launched in Trichy

fully automated central batching plants and delivery on-site through transit mixers.”

Technical Solutions

L&T Concrete provides concrete solutions for every segment of construction, every complex designand speci f icat ion, and meets customers' specialized needs and applications. L&T undertakes design and supply of concrete for different applications as required by its customers for major commercial, industrial and infrastructure projects including individual residential homes and apartments. Where projects call for specialised applications, technical

th s taf f are deputed to provide L&T inaugurated its 40 ready mix pumps operating in four Metros and 17 comprehensive on-site solutions.concrete plant in Trichy on June 19, major cities across the country. Put

2005 to produce L&T Concrete for together, L&T manufactures andIn short L&T concrete brings mee t ing t he e ve r - i nc rea s ing supplies two million Cum of L&T technology to the doorstep of the construction needs of the town Concrete per annum. With a market common man at an affordable price.including its suburbs. share of 32% L&T has emerged the

market leader in RMC in India.Inaugurating the 30 Cum per hour capacity plant at Gundur village, Mr. Rangaswami said, “In the next five Sembattu, 3 km off Trichy Airport, Mr. years L&T is planning to set up and K.V. Rangaswami, Senior Vice operate 100 plants all over the country President (Operations), L&T, said that by deeper penetration into the existing

th market and spreading its wings to other “this is the 8 plant in Tamil Nadu and centres. Progressively more plants are the fifth center after Chennai, being established in Tamil Nadu and theCoimbatore, Madurai and Tirupur”.rest of the country.

With this the tally of L&T ConcreteRMC plants goes up to 40 and this is Ready mix concrete is the fastest andthe maximum any single company has most convenient way to pour concrete.so far installed in India. In addition, it Quality is assured from proper selectionhas a fleet of 340 transit mixers, 3 of the mix design, procurement ofplacer booms including 58 concrete quality raw materials, production at

Mr. S.J. Stephen, GM, (SystemHousing & Indl. Structures), ECCand Mr. P.L. Safaya, Director andCEO, Asahi India Glass signingthe agreement for design andconstruction of a float glass factory by ECC for Asahi IndiaGlass at Roorkee. Looking on aresenior ECC- i tes Mr. K.V. Rangaswami, Mr. V.B. Gadgil andMr. K.P. Rag avan among others. The contract is valued at Rs.110crores.

h

Agreement Signed with Asahi India

30 Cum per hour capacity Ready Mix Concrete Plant at Gundur Village,Trichy

Mr. K.V. Rangaswami inaugurating the office of RMC Trichy. Others seen are Mr. R.Doraiswamy (right), Mr. R. Anbalagan (left)

55

new trends inthe building constructioni n d u s t r y ,highl ightedv a r i o u stechniques ofcon se r v ingw a t e r i n b u i l d i n g s .R V Nelaborated on

“Green concepts” dealing with specialized design of building elements like rain water harvesting Mr. S. Virapan, Engineering Manager,systems, use of low-flow water Building Utilities Competency Cell,fixtures, on-site water and waste water presented a paper at the third IndianMr. Rajan Venkateswaran (RVN),treatment systems, storm water Plumbing Conference held at NehruChief Architect, and R. Nagalingammanagement, re-use of treated water Centre, Worli, Mumbai on February(RNL), Architect, both from EDRC,for flushing and irrigation purposes 26, 2005. His paper dealt with theECC HQ, Chennai, co-authored aa n d u s e o f a r c h i t e c t u r a l Technical paper on “Water Efficiency importance of valves and joints and elements/forms for conserving energy highlighted the selection and in Buildings” and “Architectural consumed in buildings. application of new generation pipes Design for Energy Efficiency.” It was

and fittings covering the maintenance presented by RVN at the International Over 1,000 delegates and experts in tips, quoting the systems adopted for Conference and Expo on “Intelligentconstruction from the world over Public Health Engineering by L&T in and Green Building Technology and a t t e n d e d t h e E x p o . R V N ' s various projects. This is the third yearSustainable Development” held in

th th presentation was highly appreciated in a row that Mr.Virapan presented aBeijing from 28 to 30 March 2005.and showcased the “Water and Energy paper at the National Plumbing The presentations at the Conference,efficient” practices followed in L&T. Seminar.dedicated to advancing/integrating

At Global Conference in China

At Plumbing Seminarrd

3 Year in a Row

Mr. Rajan Venkateswaran presenting his paper at the expo in China

Mr. R. Nagalingam

Components of Rain Water Harvesting - Focus on Quality of WaterGood Governance India Foundation in collaboration with All India Council of Mayors organized a conference 'Municipalika' on “CityDevolopment and Management Strategies-Problems and Prospects” at

ththe 4 International Conference andNational Convention of Mayors from

rd th3 to 5 March 2005 in New Delhi.

It was attened by 400 delegates fromall over India including eminent Engineers, Architects, Policy makers,C o u n c i l l o r s , A c a d e m i c i a n s , Consultants and Builders of repute.The seminar brought together the bestof engineers, policy makers, architectsand builders to evolve best cityp l a n n i n g p r a c t i c e s a n d t o recommend to the Government theirimplementation.

Rain Water Harvesting with a focus water being harvested.on Quality of Water”. His technicalMr. R. Venkatesa Perumal, Designsarticle was also published in the This was highly appreciated by theM a n a g e r ( P u b l i c H e a l t h & proceedings volume. The paper participants and the audience. The Environmental Engineering-EDRC describes various components of rain committee also presented him aB&F), an invited speaker represented water harvesting and the techniques memento in appreciation of his article L&T in the seminar and presented an of maintaining the quality of the and presentation.article on the topic “Components of

Mr. R. Venkatesa Perumal presenting his paper at the conference ‘Municipalika’ during March 3rd - 5th, 2005 in New Delhi

56

and Messrs. K. Rama Raju and levels at higher floors. The FVDs with K. Muthumani, Scientists at Structural toggle brace mechanism are found toEngineer ing Research Centre, be more efficient and economical than Chennai, and Mr. D.R. Jagadish. An any other type of placement of FVDs abstract of the paper is given below: such as chevron and diagonal

bracings. The results further suggestThe paper demonstrates the usefulness that the bracing system proposed in of Fluid Viscous Dampers (FVDs) with this paper can be effectively used in toggle bracing mechanism in retrofitting of existing buildings and in controlling the vibration of 3-storey performance-based design of newsteel frame models by comparing their ones subjected to earthquake loads.performance with buildings having This study clearly reveals that given a only diagonally placed FVDs. The structural scheme, optimum number,

Ms. R. Amuthasheela, Sr. Engineer optimum distribution of FVDs with location and the capacity utilization of EDRC, has done ECC proud. Her toggle bracing mechanism in 3, 9 and FVDs is essential for achieving desiredproject paper (M.E.Thesis) titled 20-storey moment resistant steel dynamic response.“Optimum Distribution of Viscous framed buildings has been studied. For Fluid Dampers in Benchmarked 3-storey building frame, the placement The Conference provides a forum for Bui ldings” was selected for of FVDs with toggle brace mechanism presentation of recent advances inp re sen t a t i on i n t he “Th i rd along the height of the building is various aspects of theories, analysis,In te rna t iona l Conference o f found to be effective. For 9 and 20 experiments and designs related toS t r u c t u r a l S t a b i l i t y a n d storey buildings provision of FVDs structural stability and dynamics,Dynamics”held at Florida, USA, with toggle bracing mechanism at advanced materials and computationalduring 19-22 June 2005. ground floor level is efficient and they mechanics. In particular it reflects the

would act as vibration dampers by state of the art in computationalThe paper was co-authored by Prof. dissipating energy at ground floor level methods, new and advanced materialsA. Meher Prasad (Structural and engineering applications .Engineering Laboratory, IIT-Madras) This results in controlling the vibration

EDRC engineer co-authors paper selected for US Conference

Mr. K. Vijay Kumar, Asst. Manager, C o m m i s s i o n i n g , W E T - B U , delivered a lecture on “Operation and Maintenance of Effluent Treatment Plant” at EngineeringStaff college of India (ESCI), Hyderabad during April 19-22,2005 as a part of the trainingp r o g r a m m e o n “ I n d u s t r i a l Wastewater Treatment - Design,Operation and Maintenance withReuse and Recycle Options”. Thisis the second lecture in a row thatMr.Vijay Kumar has delivered atthe ESCI campus.

“Operation and Maintenance of Effluent Treatment Plant”

Mr. K. Vijay Kumar

Mr. V.S Ramana, Head, o r g a n i s a t i o n s , t h e Corporate Communications, Government sector, public L&T-ECC Division, has been u t i l i t i e s , N G O s , P R u n a n i m o u s l y e l e c t e d consultants, advertising Chairman, Public Relations p ro f e s s i ona l s and PR Society of India (PRSI), educationists.Chennai Chapter, at its Annual General Meeting It provides a forum for PR held on June 18, 2005. professionals to meet,

interact and enhance theirThe Chennai Chapter of PRSI professional skills and keepis one of the 27 chapters spread all abreast of emerging concepts and toolsover the country. Started 33 years ago, of PR and recognise excellence andthe Chapter is considered among the promote PR education. It does this bymost active of the regional chapters. organising seminars, workshops andIts membership is largely drawn from other programmes.private and public sector business

V.S. Ramana elected Chairman,Public Relations Society of India (PRSI),

Chennai Chapter

Mr. V.S Ramana

Ms. R. Amuthasheela

57

salient features of the work were:

· Use of modern technology whichwas adopted in the construction ofthe tunnel under the English channel connecting England and France

· Underground work in Chawri Bazar, the most crowded business and residential area of Old Delhi

· The New Austrian Tunneling method and tunnel bor ing machines used in India for the firsttime

· Construction of cut-and-cover tunnel structure of 500 m length

When fully operational Delhi Metrowould not only provide clean, comfortable and punctual alternativemeans of transport to the people butalso save travel time for the commuters

T h e K a s h m e r e G a t e - Ce n t r a l stations and a twin tunnel system. besides reducing pollution and Secretariat section of Delhi Metro was congestion. It has already eliminated inaugurated on July 3, 2005 and The project is being executed by the need for adding 1,000 buses to the thrown open for use by the public. International Metro Civil Contractors, a existing fleet of Delhi Transport The section has six underground joint venture company of L&T. The Corporation.

Kashmere Gate-Central Secretariat section ofDelhi Metro inaugurated

A gigantic reactor weighing 475 t was erected at theVisakha Refinery of Hindustan Petroleum Corporation Limited on June 9, 2005. The erectioncarried out by L&T’s ECC Division, will enable therefinery to produce diesel with ultra low sulphur formeeting the Bharat Stage-II and Euro-III equivalentproduct.

The 35 meter-long reactor with a diameter of 5.8metres was manufactured and supplied by L&T,Hazira works. The reactor is expected to go on streamin August as part of a Rs. 80 crore revamp projecttaken up by the Visakha Refinery management.

The erection was carried out with a relatively newtechnique called strand jack system with a tailinggantry and chariot arrangement. HPCL’s ExecutiveDirector and GM (Projects), who were present duringthe erection, were extremely happy and appreciatedL&T’s planning and engineering ability in executingsuch a critical feat .

The process was monitored through a computer withthe latest state-of-the-art technology. The totalerection was completed in the Diesel Hydro De-Sulphurisation Unit in a record time of 10 hourswithout affecting the normal operations.

Mega reactor erected at Visakha Refinery

Underground tunnel for Delhi Metro

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475 t mega reactor being erected

HHL Memorial Lecture Series launched

th4 of July is the birth anniversary ofMr. Henning Holck-Larsen (HHL),co-founder of India's leading engineering, construction and IT conglomerate L&T. It is two years since HHL, a doyen among industrialists, passed away at the ripeage of 96. His memory, however,lives on in the minds of thousands ofpast and present employees of thisIndian Private Sector “navratna,” thatis L&T, a legacy the legendary HHLhas bequeathed to Indians. To

thcommemorate HHL's 98 birth anniversary ECC launched the Henning Holck-Larsen Memorial Lecture Series on July 4, 2005.

ECC has in the past hosted lecturesand presentations by leaders, industry doyens, experts and

Mr. K.V. Rangaswami, Member of the tackle this problem, particularly byprofessionals (including Dr. A.P.J.laying emphasis on good practices.board and Senior Vice-PresidentAbdul Kalam and Dr. J.J. Irani among

(Operations), L&T, said the launch of theothers) who have addressed the staff Communalism is another threat to thelecture series was a befitting tribute toon topics of vital interest. It was country's stability. Despite having athe late Mr. Holck-Larsen in the desired that henceforth these secular Constitution, the country faces centenary year of the other founder, late addresses be brought under the ambit communal conflicts, which should not Mr. S.K. Toubro.of the Holck-Larsen Memorial Lecture be allowed. Similarly, stability is also

Series. It can start initially as a under pressure due to separatist We carry here excerpts from the mediaquarterly initiative and rise to movements. The other challenges report on the address by Mr. Ram:prominence as a public event that facing the country include measures tocould be held once a year. This will ensure social justice, gender equalityWith coalition governments set to hopefully provide long-term learning and popularising education in ruralbecome a permanent feature, especiallyand enrich the knowledge of the areas. A reality check is necessary forat the Centre, the most important younger generation of L&T-ites.

all these issues.challenge before the country is to ensuresocio-political stability as stability was Such a reality check has becomeDelivering the first Lecture under theessential since governments had a huge necessary as there is a need to establishSeries at the ECC Convention Centre,role to play in shaping policy.Manapakkam, Chennai, Mr. N. Ram, vital linkages bridging the divide

between those dependent on theEditor-in-Chief of the Hindu Group of Corruption "remains a chronic problempredominant agrarian economy andPublications, spoke on “Some for India" and poses a major threat to

Challenges before India”. The event those in the upcoming services sector.political health and stability of thewas well attended by L&T veterans, The emphas i s should be on country. There is a need for measures to media and staff of ECC. manufacturing and job creation. "Let us

not make a fetish of the new economy,” as otherwise the country will not be able to catch up with other nations without taking measures for broad based growth.

The late Mr. Henning Holck-Larsen, who co-founded L&T, contributed to modernisation and development of India and was a professional of integrity and meticulousness.

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Mr. N. Ram delivering the first Henning Holck-Larsen Memorial Lecture at ECC Convention Centre on July 4, 2005

Mr. K. V. Rangaswami Member of the Board and Sr. Vice President (Operations) taking Mr. N. Ram, Editor-in-Chief of The Hindu, around HHL Centre and briefing him on the display

L&T - India's Most Admired

Construction CompanyQual i ty work , an exce l len t big league or introduce new performance and strong bullish technologies in the building process.prospects helped Larsen & Toubronotch up the No.1 position as India's In a nutshell the survey indicated thatMos t Admi red Cons t ruc t ion to be successful, companies should:Company in the Construction World 2005 survey. Construction World is a · Define a clear vision and hand over premier construction magazine that roles and responsibilities to people speaks for the construction industry while ensuring they meet deadlines and chronicles its milestones and and work diligentlylandmarks.

· Bring in superior corporate governance

The 'most admired' tag arises out of a · Adhere to the social responsibilities

number of factors including the track expected of a companyrecord of a company, consistency of

· Ensure employee orientationFactors like parameter scores, parameteroperations, the relationship that it · Ensure the interest of minority weights and number of votes were used maintains with various stakeholders,

shareholdersto arrive at the final scores, which growth achieved, qual i ty of · Offer value to customersultimately decided the ratings. The m a n p o w e r , s k i l l - s e t s a n d · Develop core competence in theirsurvey indicated that most of the top 10technological superiority, focus on

field of workcompanies have, at some point or thehuman resources development, other, tied up with foreign companies or extent of diversification of operations, institutions to propel themselves into the financial stability and management

quality. Since the survey was on construction companies, the focus also included execution strengths and eng inee r ing p rocu remen t & construction (EPC) capabilities.

In addition the survey focussed onkey areas such as flexibility andability to adapt to change quickly andtackle market realities. The surveyfindings revealed L&T's strengths as:“Moves aggressively to capitalise ontrack record and scale up order-book;well-placed to ride the constructionboom in the West Asian region; ableto win orders at competitive rates inb idd ing w i thou t s ac r i f i c ing profitability.”

Construction World's in-house teamof researchers sent out forms toreaders across 49 cities in over 14states and analysed and interpretedthe responses in a methodical way.Respondents were asked to name andrate the top 10 companies on eightparameters: Brand Value, CorporateGovernance, Social Responsibility,Eco-friendly and Customer-friendlyPolicies, Employee Benefits and Welfare, Consis tent Growth, Transparency in Dealings, Quality & Reliability.

peaking on the factors whichhave built brand value forL&T, Mr. K.V. Rangaswami,S

Member of the Board and Sr. VicePresident (Operations), L&T, said,“ There are four factors that driveus: customer focus and our abilityto identify with the customer'sneeds, quality in construction,e x c e l l e n c e i n c o r p o r a t e governance and quick responsetime on projects.”

Printed by Srusti A & C, # 37, Venkataramana Colony, Khairatabad. Hyderabad-500004. Mobile : 98850 91119. Edited by Mr. V.S. Ramana for Larsen & Toubro Limited-ECC Division, from ECC-HQ., Manapakkam, Chennai-600 089. The views expressed in this magazine are notnecessarily those of the management of Larsen & Toubro Limited. The contents of this magazine should not be reproduced without the written permission of the Editor. Not for sale-only for circulation among the employees, business associates and customers of ECC-L&T ’sConstruction Division.