National Report on Concrete Structures in India 2006 - 10

NATIONAL REPORT ON
CONCRETE STRUCTURES
IN INDIA 2006 - 2010

The Third International fib Congress

Washington DC, U.S., 2010
Presented by the Indian Member Group

The Institution of Engineers (India)

8 Gokhale Road
Kolkata 700020, India
Ph : +91-33-22231979
E-mail : president@ieindia.org
Website : http://www.ieindia.org
1
 MESSAGE
The Institution of Engineers (India), IE(I), founded in 1920 and granted a Royal Charter by the British Crown in
1935 is internationally one of the largest multi-disciplinary bodies of engineers’ having a membership of over
646000 out of which Civil Engineers form the largest group of approx. 40%. It is mainly to give international
exposure to our civil engineers that IE(I) has taken membership of the fib [fédération internationale du béton]. In
the year 1986, IE(I) had organised a Congress of the FIP (Fédération Internationale de la Précontrainte) which
was attended by about 2600 delegates. It was perhaps the biggest Congress in the history of the FIP.

During the 2nd fib Congress, at Naples, Italy in 2006, the President of IE(I) had invited fib to hold the fib-Congress
in India in the year 2014. The Presidium of fib has been kind enough to realise the importance of holding the next
congress in India (after the fib-Congress 2010 at Washington) in light of the accelerated developmental efforts in
a country where the economy is growing at a pace of 8 to 9% annually, and concrete technology is contributing
immensely in these efforts. India as a country is already the second largest consumer of cement.

I am confident that the national report which is being presented will showcase the developments which had taken
place in last four years in India from 2006 to 2010 which is indicative of even greater development that will be
coming up in next fours years before the next Congress in 2014.

I hope that our National Report will be of great interest to the international construction industry who are invited
to join us in our efforts.

MADAN LAL

______________________________________________________________________________
“PRATIKSHA”, Vatika Parisar, Vijaynagar, Rukanpura, Patna 800 014
Ph: (0612) 6570612, Mobile: 9934333598, E-mail: mlal74@yahoo.com
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 National Report on Concrete Structures in India 2006 - 10

FOREWORD
I take the opportunity of the 3rd International fib Congress being held in Washington to present the National
Report on Structural Concrete in India covering the period between successive fib Congresses 2006 and 2010.
This period is very important to India from the point of view of the growth of basic infrastructure in the fields
of Roads, Railways, Hydro-Electric, Thermal and Nuclear Power Generation, Ports and Urban Infrastructure
apart from conventional applications to the Industrial and Housing sector. The morale of the Indian Construction
Industry is very high at the moment and it is facing the future with confidence while entering into a new era of
economic betterment. This is in spite of some difficulties faced by them due to the economic crisis which arose
all over the world in 2008. Their enthusiasm is heartening and it reminds me of early years in India after winning
its independence in 1947. The period 1950 to 1956 covered by the first five year plan of the Govt. of India was
the beginning of planned development of infrastructure in the country. The Indian Construction Industry joined
National efforts keeping high hopes and belief in the fruit of its efforts. The then Prime Minister of India, Pandit
Jawaharlal Nehru, had called major infrastructure projects: ‘Temples of India’. Through subsequent successive
five year plans, which outlined and guided the Master Plan of development, these efforts continued relentlessly till
the present stage. Very soon, we will be completing the 11th five year plan and start with the 12th five year plan.
Looking back to these 60 years, one can see the results of the enormous efforts put in by the Indian Engineer
whose main tool of construction was structural concrete in all its manifestations like plain concrete, reinforced
concrete, pre-stressed concrete and high performance concrete. We learnt new technologies like pre-stressed
concrete from the developed countries and adopted them for our use. The process of sharing knowledge and
know how is still continuing and it will continue into the future.

This national report covers the period mentioned above and seeks to inform the international community through
a sample of large projects that we have completed during this period. The construction scenario is upbeat. We
are already the second largest consumer of cement in the world, next only to China. The dynamic leadership of
our current Prime Minister Dr. Manmohan Singh - who is the architect of the opening of the Indian economy to the
world, has resulted in a very large inflow of investments from abroad to the Indian economy and has also given
opportunities to many international consultants and contractors to participate in our developments and obtain
business for themselves. The Government of India have added their own funds and borrowing from the World
Bank and the Asian Development Bank.

The Prime Minister, Dr. Manmohan Singh promises the country, that in spite of the set back to the world economy,
India will achieve a growth rate of 9% in GDP before the next financial year and this will be maintained. This
promise of a non-political economist who got his Tripos at Cambridge and who is at the helm of affairs is the basis
of our confidence in anticipating that many more structural concrete and other projects will come up in the near
future, which is inevitable given the urgent need to upgrade the quality of life of our people and the economic
prosperity of the country, which is expected to be a Developed Country by 2020.

The prediction of Mr Laxmi Mittal (of Indian Origin), who works and operates from London, the biggest Steel
Industry in the World, is that the rate of growth of the GDP of India will rise to 10% as the present policy of Public
Private Partnership takes a fuller participation in Building and operating Infrastructure Projects in India.
______________________________________________________________________________
Off: STUP Consultant P. Ltd, 1004-5, Raheja Chambers, Nariman Point, Mumbai - 400 021
Ph: 91 (22) 40868686 email: headoffice@stupmail.com

3
The fib has recognised the primary position of the Indian Construction Industry in the coming years and has awarded
the fib-Congress 2014 to Mumbai, India. This decision, I hope will be formally announced at the end of the fib-
Congress 2010 at Washington. The main highlight in the Indian construction scenario in the last 60 years is its
striving for economy of use of materials and so minimising the cost of projects. European, American and other
developed countries had also started with a similar approach of economising materials just after the conclusion of
the Second World War in which period reconstruction of war affected infrastructure and national building activities to
achieve higher standards of living called for a large number of projects to be taken up in a relatively short period of
time. However, unlike in India, these countries had a shortage of labour, and they had resorted to minimising cost of
the project by minimising the labour component and maximising the mechanisation of construction. After a gap of two
or three decades, this trend is again voluntarily changing. There is serious discussion amongst engineers about the
sustainability of construction as per the Developed country Model and optimising use of materials - looking at it from
the angle of environmental impact of the overuse of natural resources. This is evident from the number of papers in
many international conferences, highlighting this need.

In India we had all along followed this policy of conserving materials, and only in the last few years have resorted
to a higher degree of mechanisation in major projects, which have to be completed within a short period of time.
In earlier years the typical construction period for medium to large sized projects was in the range of 3 to 5 years,
which now is being targeted to be within 2 to 3 years. Our nuclear power projects have already achieved a record
of sorts, by going on stream from, ground break-up to commissioning within five years, which favourably compares
with international achievements. The relevance of these thoughts and the opportunities the country offers to the
international construction industry will be clear on perusal of the National Report which is submitted in the subsequent
pages.

The President of the Institution of Engineers and I take this opportunity to invite the International Community of
Educational Institutions, Researchers, Consultants, Contractors and Investors to join us In our efforts for lifting the
standard of living and quality of life of over 118 million people, which represents 18% of the world population. The
Indian Population is expected to stabilize at 150 million people by the year 2050, while China would have already
stabilized at 120 or 125 million people.

In the last century, the USA was the World’s largest economy and also had the World’s largest Construction Industry
because it had 5 times the population of the larger Nations who now form the European Economic Community –
essentially because of the USA’s greater Population size.

This is also why India is expected to become the World’s largest Economy towards the third quarter of this Century
and its Construction Industry will then also become the largest in the World.

With best wishes and regards to all reading this report,

C.R. Alimchandani

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 National Report on Concrete Structures in India 2006 - 10

SECTORS
GROUP GROUP TITLE AND PROJECTS PG. NO.

GROUP I : URBAN INFRASTRUCTURE 7 - 11

(METROS / MONORAILS / ELEVATED CORRIDORS / FLYOVERS / SATIS / ISBTs)
• Railway Station Area Traffic Improvement Scheme (SATIS) for Thane Railway 7
Station (Maharashtra)
• Construction of Grade Separator at Mukarba Chowk, Delhi 8
• Lajpat Nagar Flyover, Delhi 9
• Underpass Along West of Chord Road at The Intersection of Magadi Road 19
–Chord Road, Bangalore
• Panipat Elevated Highway 10
• P.V.Narasimha Rao Elevated Corridor at Hyderabad (11.6kms.Length) 11

GROUP II : WATER SUPPLY / IRRIGATION / HYDRO POWER PROJECTS 12 - 15

• Ghatghar Pumped Storage Scheme Lower RC Dam 12
• Gosikhurd Spillway, Maharashtra 13
• IIIA Mumbai Water Supply Project, Mumbai 13
• Concrete Volute Pump Houses 14
• 400 MW Vishnuprayag Hydropower Station of JPVL 14
• Tala Hydro Power Dam, Bhutan. 15
• 1000 MW Karcham- Wangtoo 15

GROUP III : THERMAL / NUCLEAR POWER PROJECTS 16 - 22

• Induced Draft Cooling Towers at Bhilai 16
• Construction of Inner Containment Dome Reactor Building - Kaiga Atomic Power 16
Project
• Kudankulam Nuclear Power Project, Tamil Nadu 17
• Containment Structures of Rajasthan Atomic Power Projects (RAPP) 18
• Two 173 m Tall Natural Draught Cooling Towers for 2 x 600 MW Thermal Power 19
Project at Hisar, Haryana, India
• Two 107 m Tall Natural Draught Cooling Towers for Rajasthan Atomic Power 19
Project, India
• 275 m Tall Triple Steel Flue RC Chimney for 6 x 600 MW Sasan Ultra Mega 20
Power Project, Madhya Pradesh, India
• Indira Sagar Dam, Irrigation and Hydro-electic, Madhya Pradesh 21

GROUP IV : AIRPORTS 22 - 23
• Bengaluru International Airport 22
• Hyderabad International Airport 23

GROUP V : MARINE PROJECTS / PORTS 24 - 26

• Offshore Platforms 24
• Construction of Mooring Terminal Facility at Cuddalore 24
• Development of Second Container Terminal at Chennai Port 25
• Ethylene Terminal Jetty at Karaikal 26

GROUP VI : BRIDGES / VIADUCTS 27 - 34

• Second Vivekananda Bridge Tollway – Sister Nivedita Setu 27
• Railway Bridge Over River Mayurakshi (Jharkhand) 28
• Balason Bridge at Darjeeling 28
• Siddapur Bridge, Coorg, Karnataka 29
• Pir Panjal Railway Tunnel, Jammu & Kashmir 29
• Major Bridge Across River Krishna 30
• Major Bridge Across River Tungabhadra 30
• Ganga Bridge at Allahabad 31
• Grade Separated Interchange at Junction of NH-45-IRR at Kathipara, Chennai 32
• Perambur Flyover, Chennai 33
• Interchange at Padi, Tamil Nadu 33
• Rail Connectivity from Idapalli to ICTT at Vallarpadam 34

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SECTORS

GROUP VII : REPAIRS / REHABILITATION PROJECTS 35 - 36

• Rehabilitation of Mahanadi Bridge 35
• Rebuilding of Bridge No.586 on Western Railway at Vishvamitri, Vadodara 35
• Rehabilitation of Mahatma Gandhi Setu, Patna 36

GROUP VIII : ROADS / HIGHWAYS / EXPRESSWAYS 37

• Four - laning of Satara – Kolhapur State Border Section of NH-4 from Km 725 to Km 37
592 / 240 – Package V
• Outer Ring Road (Four lane) Between Mysore Road to Magadi Road, Bangalore 37

GROUP IX : LARGE PROJECTS 38 - 43

• Bandra-Worli Sea Link,Mumbai 38
• Jogeshwari Vikroli Link Road (ICB Contract : World Bank Funded) 39
• Metro Rail, Mumbai 40
• Elevated Road Along Ambedkar Road, Mumbai 40
• Design of Elevated Viaduct- 5.225kms. and Five Elevated Stations – BC-7 41
• Viaduct Portion of Stretch Adjacent to Sultanpur Station to Qutab Minar – BC-20 42
• Pragathi Maidan Bridge 42
• Construction of Extradosed Bridge for Metro Rail Project at Indraprastha 43

GROUP X : BUILDINGS 44 - 49
• Cognizant Campus at MEPZ, Chennai 44
• TCS Technopark, Siruseri, Chennai 45
• Construction of a new complex for Tamilnadu Legislative Assembly at Chennai, India 46
• Vidhana Soudha South Block – Vikas Soudha at Bangalore 47
• Shiv Chhatrapati Sports Complex at Balewadi, Pune 47
• Mass Housing Project at Versova, Mumbai 48
• Rajiv Gandhi AC Indoor Stadium, Guwahati, Assam, India 48
• Corporate Office Building for Patni Computer Systems at Airoli, Navi Mumbai 49
• Development of IT Campus, Chandigarh, India 49

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GROUP I : URBAN INFRASTRUCTURE
GROUP I : URBAN INFRASTRUCTURE
Railway Station Area Traffic Improvement Scheme (SATIS) for Thane Railway Station
(Maharashtra)
Thane Railway Station located immediately
north of Mumbai is used by over two
million passengers everyday from the
mainline and suburban rail services. It is
connected to large industrial, commercial
and residential areas of Thane City,
spread over 100 Sq.kms, by public and
private road transport. In absence of
sufficient space outside the station, extra
area was created by constructing over
10,000 sq.ft. of deck area at higher level,
Segregation of public transport system
like buses and private transport system
like rickshaws, cars, and pedestrians was
achieved. This facility is integrated with
Railway footover bridges for pedestrian
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National Report on Concrete Structures in India 2006 - 2010
piles anchored in rock
Substructure: Reinforced Concrete
Superstructure: Pretension ‘U’ Girder
with touching soffit.
Owner: Thane Municipal Corporation,
Thane, Maharashtra State
Contractors: Nagarjuna Construction
Co. Ltd..
Engineering Consultants: Structcon
Consultants
Project Management Consultants:
Consulting Engineering Services (I) Pvt.
Ltd
Completion Time: 24 months (2009)
Award Received: ‘Best Project’ funded
under Jawaharlal Nehru National Urban
Renewal Mission (JNNURM)
benefits.
The deck is constructed using precast
prestressed ‘U’ girders pretensioned in
yard. Over 400 pretensioned girders
were used to create 1.10 km long 2 lane
vehicular bridge and 0.35 km long foot
bridge. Girders are kept touching each
other to create clean look at soffit level.
Girders are supported on reinforced
concrete piers without conventional pier
caps through cross diaphragms giving
additional road width at lower level.
Salient features
Foundation : 1.0 m dia cast in-situ bored
GROUP I : URBAN INFRASTRUCTURE National Report on Concrete Structures in India 2006 - 2010

Construction of Grade Separator at Mukarba Chowk, Delhi

The work involves the Construction of

Main flyover including Loops, Slip Roads,
Bridges, Subway, Bus bays, Cycle Tracks,
Drainage, Electrical, Landscaping and
Allied Works

Total numbers of Piles (Nos): 835

Total numbers of Pile caps (Nos): 53
Total numbers of Piers (Nos): 44
Total numbers of Pier caps (Nos): 16
Total length of Slip roads (RM): 2759
Total length of Loop roads (RM): 2057
Total length of Main Flyover (RM):
635.50
Total length of Voided slab (RM): 843.36
(32 spans)
Total area of Voided slab (SQM): 7593
Total length of Ground Supported Box
(RM): 519
Cycle Track (RM): 2500
Crash Barrier (RM): 11810

Highlights: diameter piles in a month using

Owner: Public Works Department, Delhi
Contractors: Afcons Infrastructure
Limited, Mumbai.
Engineering Consultants: Tandon
Consultants Pvt. Ltd, New Delhi
Third Party Inspection Consultants:
Engineers India Ltd.
Completion Time: 24 months (2009)
• 1450 cum of continuous concreting integrated hydraulic rig.
of voided slab in the loop of 4th
quadrant in a record time of 24
hours.
• Successful use of Slip Form Paver
technique for construction of RC
crash barrier (approx 10 Km).
• Achieved a peak progress of
constructing 200 nos. (Average
length = 25 m) of 1200 mm

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GROUP I : URBAN INFRASTRUCTURE National Report on Concrete Structures in India 2006 - 2010

Lajpat Nagar Flyover, Delhi

This flyover from Lajpat Nagar to
Srinivaspuri covers three intersections
at Lajpat Nagar, Captain Gaur Marg
and Srinivaspuri, decongesting the
area to a large extent. Three pedestrian
subways at the aforesaid intersections
and developed the service roads in the
project corridor are also constructed.

The flyover is designed for six-lane traffic

with a divided carriageway width each
of 9m. The total length of the flyover is
1180m with a 823m on stilts.

The typical superstructure is Four Span

Continuous Unit of 42-m, Constructed by
Span by Span Segmental Construction
Method and the retained approach
embankments are by Reinforced Earth
Walls.

Owner: Delhi Tourism & Transportation

Development Corporation – (DTTDC)
Contractors: Gammon India Limited.
Consultants: Larsen & Toubro Ramboll
Consulting Engineers Limited

Underpass Along West of Chord Road at the Intersection of Magadi Road-Chord Road, Bangalore

The site is located in the western part of

the Bangalore and is at the intersection of
Chord Road with Magadi Road ,Magadi
road and Chord Road Junction is a
four legged skew type intersection. The
underpass is a four lane divided two way
underpass along Chord Road and 2 Lane
one way flyover with an up ramp from
Vijayanagar towards Majestic (Bangalore
Bus Station)

Client: Bangalore Development

Authority, Bangalore
Contractor: East Coast Constructions
and Industries Limited
Consultants: STUP Consultants P.Ltd.
PMC : STUP Consultants P.Ltd.

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GROUP I : URBAN INFRASTRUCTURE National Report on Concrete Structures in India 2006 - 2010

Panipat Elevated Highway

Panipat Elevated Highway is a part of

National Highway No. 1 connecting
Delhi to Amristar and going up to Indo -
Pakistan border. It connects the Northern
part of the country including states of
Jammu and Kashmir, Punjab, Himachal
Pradesh and Haryana with Delhi and
rest of the country. The project section
through Panipat is a serious bottleneck
to the speedy, smooth and safe flow of
traffic mainly on account of congested
junctions and mixed traffic pattern of
Panipat.
The project road covers a length of about
10 km. This includes 3.4 km long 6 lane
elevated structure (3048m of viaduct and
360 m of ramps).
The foundation of this bridge consists
of 1282 piles done by rotary rig method
over which pile caps and piers are built.
I-Girders are pre cast and transported to
site in specially modified trailers, where
the erection work was completed using
Gantries and high capacity cranes.
The precast deck slabs, in addition to the
usage as shuttering, have been used as a
load bearing member in combination with
cast-in-situ concrete. This has led to the
time and cost reduction for completion of
the project.
Owner: NHAI
Concessionaire: Larsen & Toubro
Ltd Panipat Elevated Corridor Limited
(Larsen & Toubro Ltd PECL).
Contractors: Larsen & Toubro Ltd ECC
Division.
Contractor’s Consultant: Larsen
& Toubro Ltd Ramboll Consulting
Engineers Limited.
Consultants: Larsen & Toubro Ltd
Ramboll Consulting Engineers Limited.

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GROUP I : URBAN INFRASTRUCTURE National Report on Concrete Structures in India 2006 - 2010

P. V. Narasimha Rao Elevated Corridor at Hyderabad (11.6 kms. Length)

This Elevated Expressway of 11.670

Kms is from Mehidipatnam to Aramghar
Junction on NH 7 along with a trumpet
interchange for the approach road to the
International Airport .

The project basically comprises (a)

Construction of Elevated 4-lane divided
carriageway with median of 1.2m, from
Sarojini Devi Eye Hospital, Mehdipatnam
to Aramgarh junction on NH-7 (along the
ring road) along with main /intermediate
ramps and Underpass at Aramgarh
junction. (b) Construction of Trumpet
interchange on NH-7 for the approach
road to the proposed International Airport
at Shamshabad and (c) Strengthening,
widening of Inner Ring Road (from
Rethibowli junction to Aramgarh junction)
from 4-lane to 6-lanes.

The method of construction is by

assembling match cast segments by
prestressing using overhead lauching.

Client : Simplex Infrastructure Ltd /

HUDA
Contractor : Simplex Infrastructure Ltd
/ HUDA
Consultants: STUP Consultants P. Ltd.
PMC : SPAN Consultants Ltd.

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GROUP II : WATER SUPPLY / IRRIGATION / HYDRO POWER PROJECTS National Report on Concrete Structures in India 2006 - 2010

GROUP II : WATER SUPPLY / IRRIGATION / HYDRO POWER PROJECTS

Ghatghar Pumped Storage Scheme Lower RC Dam

Ghatghar Pumped Storage Scheme

(GPSS) located in the State of
Maharashtra and is owned by the State’s
Water Resources Department. GPSS
involved construction of two reservoirs,
having head of 500 m, Underground
Powerhouse housing 2 units of 125 mw.
The scheme with 250 mw generation will
be used as Peak Power Station. Power
Station is designed to generate 6 hrs of
daily power and 7 hrs of daily pumping
back to the upper reservoir.

At GPSS three RC Dams were built,

8m high Saddle Dam No.1, 14.5 m high
Upper Dam and 85 m high Lower Dam.

To its record the completed Lower Dam

was 9th Fastest built RC Dam in the
world, when it was completed in 2007.
Over 600,000 cubic meters of concrete
were placed with Roller Compacted
Concrete method. With monthly RC
placement of 90103 Cu.m was achieved
averaging about 62,690 Cu.m per month.
RC placement for Lower Dam of height of
85 m was completed in record 12 working
months.

Awards: National Award for Fly Ash

Utilisation for more than 100,000 tonnes.

Owner: Water Resources Dept., Govt.

of Maharashtra, India.
Contractors: Patel Engineering Ltd,
Mumbai, India.
Roller Compacted Concrete: SENBO
Engineering Ltd.
Engineering Consultants: J-Power,
Japan in association with TCE
Engineers (P) Ltd, India & CWC, India
Owners Consultants: Malcom Dunstan
& Associates, UK

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GROUP II : WATER SUPPLY / IRRIGATION / HYDRO POWER PROJECTS National Report on Concrete Structures in India 2006 - 2010

Gosikhurd Spillway, Maharashtra

The Gosikhurd Spillway is located on
river Wainganga, in Bhandara District,
near Nagpur. The total length of dam
of the spillway is 11.35 Km, with Flood
discharge of capacity 67,300 cumecs
The project brings about 1, 90,000 Ha of
land under irrigation, which has been a
draught prone area.
The project won the “Best Performance”
for the year 2005 – 06 on the occasion
of Engineers’ day from the Vidarbha
irrigation Development Corporation
(VIDC). The project also won the ‘Best
Concrete Structure’ Award, 2008 of the
Indian Concrete Institute.
Client: Vidarbha Irrigation Development
Corporation
Contractor: Hindustan Construction
Company Ltd
Funding: Vidarbha Irrigation
Development Corporation

IIIA Mumbai Water Supply Project, Mumbai

IIIA Mumbai Water Supply Project,

Mumbai, 3.60 m dia tunnels, about 12
km. in length, were constructed using
two modern full face Rock Tunnel Boring
Machines; Reinforced cement concrete
lining with 3m finished dia using CIFA
shuttering. It extend from Bhandup
Complex to Malad reservoir and upto
Charkop in Mumbai.

Owner: Brihan Mumbai Municipal

Corporation
Designer/Consultant: Tata Consulting
Engineer
Contractor: Hindustan Construction
Company Ltd
Funding: Mumbai Metropolitan Region
Development Authority (MMRDA)

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GROUP II : WATER SUPPLY / IRRIGATION / HYDRO POWER PROJECTS National Report on Concrete Structures in India 2006 - 2010

Concrete Volute Pump Houses

Concrete Volute Pump are being

commonly used in recent years for
circulating water system of using normal
as well as sea water.

The picture shows an installation at

Saurashtra Branch Canal of Narmada
Main Cannal, which uses normal water.
Similar CW system have been provided
at Sipat Super Thermal Power Station
involving 3 Volute Pump and Barh Super
Thermal Power Station involving 6 Volute
Pump.

Sea water pump house involving 2

nos. of Volute Pumps are provided at
Kalapakkam.

Sea water pump house at Salaya

involving 4 nos. of Volute Pumps

Owner: National Thermal Power

Corporation Ltd (at Sipat / Barh) /
Bharatiya Nabhikiya Vidyut Nigam Ltd
(at Kalapakkam) / Essar Power Gujarat
Ltd (at Salaya)
Supplier of Pump: Kirloskar Brothers
Ltd.
Contractor: Hindustan Construction
Company Ltd (at Saurashtra Branch
Canal) / Kirloskar (at Sipat / Barh /
Kalapakkam / Salaya)

400 MW Vishnuprayag Hydropower Station of JPVL

The 400 MW Vishnuprayag Hydro-electric

Project (BOO) was commissioned in
October,2006, a run-of-the river project
located across river Alaknanda in District
Chamoli of Uttarakhand. The Project,
utilizing the waters of river Alaknanda,
has an underground power station
with an installed capacity of 400MW
(4x100MW).

Contractor: Jayprakash Associates Ltd

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GROUP II : WATER SUPPLY / IRRIGATION / HYDRO POWER PROJECTS National Report on Concrete Structures in India 2006 - 2010

Tala Hydro Power Dam, Bhutan.

The 1020 MW Tala Hydro Power Project
amongst the largest Hydro Power Project
in South asian region was implemented
as a part of bilateral trade agreement
between Govt. of India and Royal
Government of Bhutan.
A 92 M high concrete gravity dam
and 13.664 Km of a 6.80 m dia head
race tunnel for the project was built,
employing the most modern methods. All
the underground work was done by drill
and blast method. The fully mechanized
tunneling operation used state of the art Owner: Tala Hydro Electric Project
equipments like two boom Drill Jumbo’s, Authority, Bhutan
Boltec, Low Profile Dumper trucks, Designer/ Consultant: Water & Power
shotcreting pump etc. The lining work of Consultancy Services (India) Ltd.
the Head Race Tunnel was carried out (WAPCOS)
using the unique mobile form work system. Contractor: Hindustan Construction
It was one of the major underground Company Ltd
tunneling projects undertaken in the Funding: Tala Hydro Electric Project
unpredictable Himalayan range throwing Authority
almost all kinds challenges during Start Date: 29-Nov-98
execution. End Date: 30-Dec-06

1000 MW Karcham- Wangtoo

The 1000 MW Karcham-Wangtoo Hydro-

electric Project is located in Himachal
Pradesh and is built on BOO basis. This
is the India’s largest Private Hydropower
station in making. It is envisaged as
run-of-the-river project and is being
constructed on River Satluj in the District
Kinnaur.

Contractor: Jayprakash Associates Ltd

15
GROUP III : THERMAL / NUCLEAR POWER PROJECTS National Report on Concrete Structures in India 2006 - 2010

GROUP III : THERMAL / NUCLEAR POWER PROJECTS

Induced Draft Cooling Towers at Bhilai

Two Nos. of Induced Draft Cooling
Towers at Bhilai Thermal power Station
(2 X 250 MWe) consists of ten cells, each
having plan dimensions of 15m X 20m.
The towers are of counter flow type and
cater for flow rate of 34500 m3 / Hr.

Owner: National Thermal Power

Corporation Ltd.
Contractor: Gammon India Ltd.
Consultants: Spectrum Techno
Consultants (P) Ltd.

Construction of Inner Containment Dome Reactor Building - Kaiga Atomic Power Project

The Inner containment dome of the

reactor building is a 42.56 m diameter
prestressed concrete dome with 4
openings of 4.1m diameter to facilitate
any replacement of stream generators
during operational stage of reactor. The
dome consists of a ring beam of 4.1
meter deep and a shell of 500 mm thick.
Concrete of grade M-45 is used for the
construction of this dome. Total quantity of
concrete for dome and ring beam is 2130
cum. Concreting of dome including the
ring beam was done in nine pours using
state of the art methods of construction
including pumping of concrete to a height
of 50 meters by concrete pumps and
placers.

The Entire dome supporting steel

structure was assembled on ground
to form eight large segments and eight
small segments. Plywood shutter were
placed over the assembly. Weight of the
each assembly was approximately
65t. Thereafter the large segments were
lifted from the ground assembly and
erected in placed one by one by 650 t
capacity crane.

Concrete was transported from batching

plant to site, nearly 0.75 km away, by 4
nos. 6 cum transit mixers and one transit
mixer was kept as standby. Concrete
was placed into the structure to height 50
meters using two nos. Schwing pumps
and concrete bucket with tower crane.

Owner: Nuclear Power Corporation of

India Ltd.
Contractors: Gammon India Limited.
Engineering Consultants: STUP
Consultants P. Ltd.

16
GROUP III : THERMAL / NUCLEAR POWER PROJECTS National Report on Concrete Structures in India 2006 - 2010

Kudankulam Nuclear Power Project, Tamil Nadu

KKNPP is first of it’s kind in India, being

implemented in technical collaboration
with Russian Federation. This state of art
technology based on light water reactors,
each of which is 1000MWe capacity, and
will supply electricity to the southern grid.
These reactors have many advanced
features being implemented for the first
time in the VVER design which assures
a high level of safety and reliability in
operation. This is the first Indian Nuclear control measures are adopted during Contractor: Hindustan Construction
Power Project with steel liner on the construction to meet the design intents. Company Ltd, Mumbai
inside face of containment structure. A Funding: Nuclear Power Corporation of
view of the dome liner supporting system India Ltd.
with passive reinforcement is shown here.
The prestressing system used for the
containment is 55C15, with a breaking Owner: Nuclear Power Corporation of
load of 1535 tons per cable. Execution India Ltd.
of 55C15 Prestressing System at site Designer/Consultant: Supplier’s
is a unique experience. Strict quality Design

17
GROUP III : THERMAL / NUCLEAR POWER PROJECTS National Report on Concrete Structures in India 2006 - 2010

Containment Structures of Rajasthan Atomic Power Projects (RAPP)

A new record is set at RAPP-5&6 by

constructing Raft of Unit-6 reactor
building in 53 days from the first pour
to its completion. This was possible by
improved construction practices and use
of latest technologies in construction. The
improved design indeed helped in safe
and speedy implementation of project.

The Inner Containment (IC) is designed

by NPCIL. The IC is made of prestressed
concrete, stressed with 19K13
prestressing system, and is designed to
withstand an internal pressure of 1.73kg/
sq.cm, due to any unforeseen incidents
occurring within the building. In addition,
extreme environmental conditions,
including Safe Shutdown Earthquake
(SSE) and extreme wind and hydrostatic
uplift forces are considered as part of the
design basis.

Construction of Reactor Building of Unit-6

(in progress), is seen in this picture, with
concrete placer boom standing within
the IC building. Major embedded parts
for safety related piping, equipment are
manufactured at an off-site shop and
brought to site, and installed precisely
at the earmarked locations before
concreting. Four level quality assurance
programme is adopted at site to ensure
stringent quality control being. These ICs
are later pressure tested to ensure their
design adequacy.

View of site after completion of major

structures of Units 5 and 6 is shown
beside. Both the reactor buildings and
RC Ventilation Stack (100m height) are
seen in the front and two of the Natural
Draught Cooling Towers (NDCT) are
in the back. These two units (5&6) thus
generate 2*220MWe for the national
grid.

Owner: Nuclear Power Corporation of

India Ltd.
Contractors: Hindustan Construction
Company Ltd.
Consultants: Nuclear Power
Corporation of India Ltd.
Proof Checking: STUP Consultants P.
Ltd

18
GROUP III : THERMAL / NUCLEAR POWER PROJECTS National Report on Concrete Structures in India 2006 - 2010

Two 173 m Tall Natural Draught Cooling Towers for 2 x 600 MW Thermal Power Project at Hisar,
Haryana, India
Two 173 m tall Natural Draught cooling
towers are constructed for 2x600 MW
Thermal Power Project at Haryana, India.
The base diameter of tower shell is 129 m
and top diameter is 73.5 m. These towers
are tallest in India when commissioned.

Each cooling tower is designed to serve

one of the twin 600 MW units. Water flow
through each cooling tower is 72,500
Cu.m/hr, and it is cooled from 440C to
330C. Pre-stressed Concrete (PSC)
laths are used as an internal fill for
achieving required cooling; exchanging
heat with the up draught of air generated
by the chimney effect of hyperbolic shell
of NDCT.

These towers are designed for 180 km/h

basic wind speed as per the relevant
Indian Standards. The design of the
tower shell is based on the Indian and
British codes. The codal wind load forces
on the tower considered in the design
have been verified by conducting wind
tunnel tests. Seismically the project is in
Zone-IV as per seismic zoning of Indian
Standard, characterized by ground
acceleration 0.24g during Maximum
Considered Earthquake (MCE).
The shells of towers were constructed
using jump-form shuttering technique.
Centrally located tower crane was erected
for transporting construction material and
equipment. Each of the Cooling Towers
was completed in 18 months.
Owner: Haryana Power Generation
Corporation, Haryana
Client: Reliance Energy Ltd., Noida
Consultant: Desein Consulting
Engineers, New Delhi & Central
Electricity Authority, New Delhi
Designer: STUP Consultants P. Ltd.,
Mumbai

Two 107 m Tall Natural Draught Cooling towers for Rajasthan Atomic Power Project, India

Two 107.4 m tall Natural Draught cooling
towers are constructed for Rajasthan
Atomic Power Project, India. The base
diameter of tower shell is 88.2 m and top
diameter is 53 m.
Water flow through each cooling tower
is 36,500 Cu.m/hr, and it is cooled from
450C to 320C. PVC fill cross fluted type
is used as an internal fill for achieving
required cooling; exchanging heat with
the up draught of air generated by the
chimney effect of hyperbolic shell of
NDCT.
These towers are designed for 181 km/h
basic wind speed as per the relevant
Indian Standards. The design of the
tower shell is based on the Indian and
British codes. Seismically the project is
in Zone-II as per seismic zoning of Indian
Standard, characterized by ground
acceleration 0.1g during Maximum
Considered Earthquake (MCE).
The shells of towers were constructed
using jump-form shuttering technique.
Centrally located tower crane was erected
for transporting construction material and
equipment. Each of the Cooling Towers
was completed in 18 months.
Owner: Nuclear Power Corporation of
India Ltd.
Client: Gammon India Ltd.
Consultant: STUP Consultants P. Ltd.,
Mumbai

19
GROUP III : THERMAL / NUCLEAR POWER PROJECTS
275 m Tall Triple Steel Flue RC Chimney for 6 x 600 MW Sasan Ultra Mega Power Project, Madhya
Pradesh, India
Two numbers of 275 m tall triple steel
flue RC chimneys with diameter varying
from 24 m on top and 36.7m at base
and founded on annular raft are under
construction at Sasan, India, for 4000MW
Thermal Power Station. Each chimney is
designed to house three steel flues, each
flue serving one of the three 660MW
units.
Chimney shell is designed for basic wind
speed of 150 kmph. In order to reduce the
effects of across wind loads fundamental
frequency of the chimney shell is lowered
by gradually increasing the thickness of
shell in top portion. For seismic design,
National Report on Concrete Structures in India 2006 - 2010
Chimney is located in Zone-III as per
zoning given by IS:1893-2001, which is
characterised by Maximum Considered
Earthquake (MCE) ground acceleration
of 0.16 g.
Each of the steel flue has inside diameter
of 7.1 m. Steel flues are ‘hung type’
and are suspended in segments from
five intermediate platforms spaced 45m
apart. Expansion compensators are
provided at bottom of each flue segment
to allow relative thermal movements
between the steel flue and RC shell. The
lateral restraints to ensure consistent
deformations and transfer horizontal
forces arising from wind and earthquake
are provided at these platform levels.
For achieving comfortable working
conditions within the annular space
between chimney and flues, temperature
of air in this space is maintained below
450C.
Owner: Sasan Power Ltd
Client : Reliance Infrastructure Ltd.,
Noida
Consultant: STUP Consultants P. Ltd.,
Mumbai
20
GROUP III : THERMAL / NUCLEAR POWER PROJECTS
Indira Sagar Dam, Irrigation and Hydro-electic, Madhya Pradesh
The Narmada Hydroelectric Development
Corporation Limited (NHDC, a joint
venture of the National Hydroelectric
Power Corporation and the Government
of Madhya Pradesh) is constructing
the Indira Sagar Dam (earlier known
as the Narmada Sagar Dam) on the
river Narmada. The Indira Sagar Dam
is located in the Khandwa District of
Madhya Pradesh. It is a concrete gravity
dam, 653 m in length, with a maximum
height of 92 m. The spillway portion of
the dam consists of 20 Nos. of 20 m wide
21
National Report on Concrete Structures in India 2006 - 2010
gated spillways with 21 Nos. of piers. The
spillway gates are of the sector type, and
are lifted hydraulically. The gates are 20
m 17 m in size, and extend from pier to
pier. Each pier is 5 m in width.
Prestressed replaceable anchors are
provided for the spillway gates. Since
prestressed gate anchors and load due to Owner: Narmada Hydroelectric
hydraulic hoist had not been considered Development Corpn. Ltd
in the original design. The pier portion of Consultant: CWC and STUP
spillway has been re-engineered. Consultants P. Ltd., Mumbai
Contractor: Jaiprakash Associates Ltd.
GROUP IV : AIRPORTS
GROUP IV : AIRPORTS
Bengaluru International Airport
The Bengaluru International Airport with
its two parallel runway system, allows
the airport to grow up to 50 million
passengers a year. Spread across 4300
acres, this airport has of a terminal
building with an innovative pre- cast and
pre-stressed concrete shell roof element,
8 passenger boarding bridges, 1 double
arm aerobridge and 9 remote bus gates
with a runway of 4000m in length and an
efficient taxiway system.
National Report on Concrete Structures in India 2006 - 2010
The passenger terminal building is
based on a linear terminal concept with
Apron capacity of 18 aircraft stands
and 5 passenger boarding bridges for
Phase–1.
Expected domestic passengers and
International passengers per day is
23,400 and 7,800 respectively. The
passenger terminal building of area
31000 m2 with clear height of 15.75m
has generous spans which allow for
airport functions and commercial areas
to be laid out efficiently.
Owner: Bangalore international Airport
Limited (BIAL).
Contractors: Larsen & Toubro Limited.
Engineering Consultants: Engineering
Design and Research Centre (EDRC) of
ECC Division, Larsen & Toubro Limited.
22
GROUP IV : AIRPORTS National Report on Concrete Structures in India 2006 - 2010

Hyderabad International Airport

Constructed on a Greenfield site,

approximately 30 kilometers south of
downtown Hyderabad, the New Rajiv
Gandhi International Airport is built on an
area of 5,400 acres and has the longest
runway of 4260m with code-F features
among Indian airports and able to handle
the world’s largest passenger aircraft, the
Airbus A380. It has a capacity to handle
12 million passengers.

The passenger terminal has 100,000

Sqm. floor area to facilitate rapid transit
between its Domestic and International
concourses.

The domestic and international cargo

processing and storage facility is
designed with a clear height of 14m and
the total built-up area of 10070 Sqm.
The roof has been designed with a
seamless steel roofing system extended
upto a length of 72m and a width of
about 400mm cut using special rollers.
Smoke extraction of about 33% in PTB
is achieved by providing roof mounted
smoke extractors.
Owner: GMR Group in a public-private
partnership which also includes the state
government of Andhra Pradesh, Airports
authority of India and Malaysia Airports
Holdings Berhad.
Contractors: Larsen & Toubro Limited.
Engineering Consultants: Engineering
Design and Research Centre (EDRC) of
ECC Division, Larsen & Toubro Limited.
Owners Consultants: STUP
Consultants P. Ltd in association with
Kowi Consult

23
GROUP V : MARINE PROJECTS / PORTS
GROUP V : MARINE PROJECTS / PORTS
Offshore Platforms
Construction of Mooring Terminal Facility at Cuddalore
Design and Construction of off-shore Jetty
with all ancillary civil works and laying
pipeline both onshore and submarine as
per the following details:
Off Shore Works:
Construction of Unloading Platform –
20m x 10m
Breasting Dolphins (2 Nos) – 14m x 14m • Laying of offshore pipe line by
Mooring Dolphins (4 Nos) – 10m x 10m
Substation – 18m x 9m
Catwalk for Platform connections
Onshore structures-
Terminal Control Building
Fire Water Pump House.
National Report on Concrete Structures in India 2006 - 2010
Pipe Line Works
Offshore Pipeline works - 1.025 Km
Onshore Pipeline works - 2.826 Km
Cost of the Project (Rs Million): 660
Period of Completion (Months) : 18
Owner: Chemplast Sanmar Limited
Contractors: Afcons Infrastructure
Limited.
Engineering Consultants: IIT, Chennai
for Civil works & IMPAC for Pipe Line
Works
Facilities for off loading of off shore
Platforms of fabricated weight of 7500 T on
to Barges from the fabrication Yard. The
structure involves one monolith of 40 m x
17 m plus two additional such monoliths
of size 30mx17m with interconnections
which make a berth of 110m x 17 m; all
built by well sinking method and anchored
into the rocky strata.
Owner: Das Offshore Engineering (P)
Ltd
Contractor: Horizon Infradex (P) Ltd.
Consultants: Spectrum Techno
Consultants (P) Ltd.
Proof Consultants: STUP Consultants,
Chennai & OGI for Pipe Line Works
Third Party Inspection Agency:
Fichtner Consulting Engineer (P) Ltd.
Highlights:
• Concrete is supplied by agitators
mounted on barges.
specially designed pipe pulling
winches mounted on barges under
rough sea condition.
• On shore pipe line was pushed
from one side below the river bed
without affecting the water flow and
navigation.
24
GROUP V : MARINE PROJECTS / PORTS National Report on Concrete Structures in India 2006 - 2010

Development of Second Container Terminal at Chennai Port

This project consist of 832m long piled

wharf associated with 26hectres of
container stack yard.
This container terminal was designed
to suit a capacity of 1,20,000 DWT
vessels. Accordingly the existing sea bed
level varying from 11.00CD to 13.00CD
was dredged to 15.50CD to cater the
vessels.
The wharf having 5 rows (A to E) bored
cast in situ pile foundation, connected
with precast and in-situ beams. Both A
and E row piles are connected with crane
beams to support the crane rails. The RC
deck slab of 325mm depth is of partially
precast and in-situ to avoid staging above
water.

The yard was developed to a capacity

of around 5000 ground slots and each
slot with 5 height stacks. The backup
yard was developed with pavement
concretes, concrete roads, utility services
and requisite buildings for operation and
maintenance of the terminal. One STP of
capacity 25KLD was provided to treat the
domestic sewage.
The photos shows the developed backup
yard and finished wharf with RTGC and
Quay cranes parked.
Owner: Chennai International terminals
Private Limited (Consortium of Port of
Singapore Authority – SICAL terminals
Limited)
Contractors: ITD Cementation India
Limited, Mumbai.
Engineering Consultants: STUP
Consultants P Limited, Mumbai - Off-
shore works; & Consulting Engineering
Services (P) Limited, New Delhi -
Onshore works
Project Management Consultants:
Consulting Engineering Services (P)
Limited, New Delhi
Independent Engineer: Ocean
Engineering Department, IITM, Chennai.

25
GROUP V : MARINE PROJECTS / PORTS
Ethylene Terminal Jetty at Karaikal
The Ethylene terminal is located at
Karaikal, Union Territory of Pondicherry
on the east coast of India. The project
involved the construction of 1300 m long
and 2.4 m wide single piled approach
trestle, service platform, 2 berthing
dolphins and 4 mooring dolphins.
The project was challenging as the
construction was to be carried out in
open sea.
The 1300 m long pipe line trestle, 2.40m
National Report on Concrete Structures in India 2006 - 2010
wide, connects the Service Platform to
the shore and supports the pipes and
walk way of about 1.2 m width. There are
two rows of piles at the loop locations,
which are spaced at 160 m c/c. Service
Platform (15m x 13.5m) with an RC deck
of 1m thick supported on bored cast-in-
situ RC piles (6 nos - 1m dia + 1 no – 1.2m
dia) and it acts as an area for transferring
of ethylene from the ship to pipeline.
Berthing Dolphin (8m x 14m) with an RC
deck of 1m thick is supported on bored
cast-in-situ RC piles (7 nos – 1.2m dia)
and is provided with rubber fenders for
berthing of ships. Mooring Dolphin (8m x
8m ) with an RC deck of 1m thick is also
a RC structure and is supported on bored
cast-in-situ RC piles (4 nos – 1.2m dia).
The construction of piles in the inter-
tidal zone was carried out by spudded
piling platform moving over already
installed piles. The balance piles were
constructed using an innovative tubular
frame platform which is similar to a jack
up platform. Superstructure construction
was cast in-situ for a part of the approach,
service platform and the dolphins. Major
stretch of the approach trestle was
executed as part precast and partly cast
in-situ to enable faster completion. The
superstructure of the approach trestle up
to inter-tidal zone was constructed using
movable formwork system. The remaining
superstructure was precasted in barge
and erected using floating crane.
Owner: Chemplast Sanmar Ltd,
Chennai, India
Contractors: Larsen & Toubro Limited
Design Consultants: Larsen & Toubro
Ramboll Consulting Engineers Limited,
Chennai
Proof Consultants: IIT Madras
26
GROUP VI : BRIDGES / VIADUCTS / ELEVATED CORRIDORS National Report on Concrete Structures in India 2006 - 2010

GROUP VI : BRIDGES / VIADUCTS / ELEVATED CORRIDORS

Second Vivekananda Bridge Tollway – Sister Nivedita Setu

The SVB Tollway is a 6.1 km –long

integrated six lane stretch of National
Highway -2 which includes the main
structure “Nivedita bridge” ----a 880
meters long , 29 meter wide “Extra dosed
Bridge”.

Six-lane viaducts connect the

dispersal ramps and access roads on
embankments. The Howrah Approach is
3.67 kms long and, the Kolkata Approach
is 1.56 kms long.

The approach via ducts consist of

combination of two- lane and three lane
precast segments erected by span-by-
span and externally pre-stressed to form
the superstructure of the dispersal ramps
having 4.5 KM linear length.
Main Bridge : Cable Supported Extra-
dosed Design Pre-cast segmental
construction Supported by Post-
Tensioned pre-stressed stay cables2X8
nos per span from 8 nos short pylons
14 m high
Span details : 7 x 110m + 2 x 55 m
Foundation : 2 Nos - 8m dia land wells
+ 8 nos 11m dia-steel caissons) .45
to 50 m deep
Rail under Bridge (RUB): One -2-lane –
60m and One-6 lane – 53 m
Rail over Bridge (ROB): One New – 4-
lanes – 65 m added to existing—4-
lanes – 65 m
Owner: Second Vivekananda Bridge
Tollway Company Private Limited –
under PPP Concession with National
Highways Authority of India.
Contractors: Larsen & Toubro Limited
–ECC Division.
Consultants: Consulting Engineering
Services – Parsons Brinckerhoff
Consortium (in association with
International Bridge Technologies, Inc.
for the Main Bridge)
Commencement date: Design and
construction started on 1st April 2004
Completion Time – 39 months (29th
June 2007)
Date of Commissioning: 4th July 2007
Award Received: Bridge Award of
Excellence -2007 from American
Segmental Bridge Institute , Arizona,
USA

27
GROUP VI : BRIDGES / VIADUCTS / ELEVATED CORRIDORS National Report on Concrete Structures in India 2006 - 2010

Railway Bridge Over River Mayurakshi at Jharkhand

Railway Bridge over 350 mtr. long

on Mayurakshi river on new rail line
connecting Deoghar with Dumka.

River with sandy bed is subjected to

strong currents and is prone to flash
floods and scour. Embankment protection
with launching apron was required.

The bridge has 10 spans, 33.18 mtr. c/c

of piers. Superstructure consisting of a
single prestressed box 6m wide carrying
a single ballasted rail line.

The superstructure is resting on single

circular pier through POT / PTFE
bearings. Foundation consist of 8/9 mtr.
dia wells sunk on average 15 mtr, through
sandy strata and resting on rock.

Construction Period: 2 Years

Owner: Eastern Railway.
Contractors: GPT Infraprojects Ltd.
Consultants: Structcon Consultants
Project Management Consultants:
Eastern Railway

Balason Bridge at Darjeeling

There is no evidence to the fact that
bridges being considered for the
aesthetic treatment till the middle of 18th
century. Till the time of the inception of
engineering establishments including
military engineering establishment in Paris
around 1750, bridges were considered
to be structures spanning and providing
passage over road, waterway or gorges
and they were synonymous with either
vaulting or hanging wooden passage
on tensile fibers. In a sense the concept
of bridge being functional and yet to be
beautiful is a recent recognition of last one
and half centuries. Since then the story
of bridge building has become the yard
stick for the progression in civilization of
Nations according to Franklin Roosevelt.
The structures of a particular era reveal
the idiosyncrasies of the rulers and
technologists, the degree of sophistication
in technology and material sciences
i.e. state of the art research and finally
financial health of the state at that time.
The bridge building being such a serious
business, which stands as a testimony
of the mental state of engineers of a
particular time, to the future generation, it
is imperative for us to make our posterity
believe that we engineering fraternity
possessed healthy, aesthetically
pleasant, creative minds. In India, as we
reminisce our past by beautiful mandirs,
(Temples) masjids (Mosques) and mahals
(Palaces), our posterity should remember
us by the bridges, we create.
Owner: Gorka Hill Council.
Contractors: Gammon India Ltd..
Engineering Designers: Gammon India
Ltd

28
GROUP VI : BRIDGES / VIADUCTS / ELEVATED CORRIDORS National Report on Concrete Structures in India 2006 - 2010

Siddapur Bridge, Coorg, Karnataka

The long span segmental cantilevered

construction bridges over rivers and
creeks were started in India way back
in nineteen sixties, interestingly a bit
earlier than in United States. After having
achieved 165m central span by this
method, presently 185m longest span
girder bridge is designed and being
executed in the sub-continent.

Mean while a concept of extra-dose

bridge an evolution between girder and
cable stay bridge introduced by Christian
Menn and J.Mathivat in their typical
but classical styles has been admirably
exploited by Japanese up to the span
of 250m.The authors improvised the
concept further by staying the central
span beyond the extra-dosed spans by
cables from the same Pylon housing
extra-dose cables in one of the recent India, in tune with the conference theme has been presented in detail aided by
competitive biddings. This is an extra- of global thinking and local building. Siddapur Extra-dose Bridge at Coorg and
dose bridge partially supported by cable Balason Girder Bridge at Darjeeling.
stays. In the paper followed, the cost benefit
analysis of extra-dose bridges over the Owner: Karnataka Road Development
Siddapur Bridge at Coorg, Karnataka girder bridges including design and Corporation Ltd.
is the first indigenously designed and construction aspects and other features Contractors: Gammon India Ltd.
built first time by cast in situ cantilever like increased spanabilty with small Engineering Designers: Gammon India
construction method Extra-dose Bridge in deck depths, aesthetic characteristics Ltd

Pir Panjal Railway Tunnel, Jammu & Kashmir

Pir Panjal Rail Tunnel project is part of

the ambitious, 345-km-long Udhampur-
Srinagar-Baramulla rail link that will
provide an alternative and reliable
transportation system to Jammu &
Kashmir (J&K) by joining the Kashmir
Valley with the Indian Railways network.
This railway line will strengthen available
transport facilities to J&K and provide an
all-weather means of transport in an area
that is snowbound for a significant part
of the year.

Post completion it would be the longest

tunnel in India, around 11 Km long and
8.50 m in dia, passing through the most
difficult terrains of Himalaya.

The tunnel design adopted for the

construction is the New Austrian
Tunneling Method (NATM). For the
excavation purpose, Roadheader has
been engaged which is relatively new
machinery to the Indian construction.
Heavy support system along with regular The work commenced in June 2004 and Owner: Ircon International Limited
monitoring of the tunnel deformation was is expected to be completed in 2011 Designer: Consultant:Geoconsultant-
implemented to achieve the job smoothly. Rites JV
The photograph shows here the water Contractors: Hindustan Construction
proofing membrane provided along with Company Ltd.
supports to restrict the seepage. Funding: Ircon International Limited

29
GROUP VI : BRIDGES / VIADUCTS / ELEVATED CORRIDORS National Report on Concrete Structures in India 2006 - 2010

Major Bridge Across River Krishna

Year of construction: 2008 – 2009

Span arrangement: 1x 22.25 + 1 x 33.825
+ 24 x 34.75 + 1 x 28.65 + 1 x 22.25
Total length of bridge: 940.975 m
Discharge: 27200 Cumecs
Height of Pier: 22.32 m (max)
Type of Superstructure: Four Nos of
precast PSC girders with cast in situ RC
deck slab
Girder erection system: Over head
launching using Auto launching system
Weight of PSC girder: 132.0 T (max)
Weight of launching girder: 160.0 T

Client: National Highways Authority of

India
Concessionaire: Andhra Pradesh
Expressway Ltd
ECP Contractors: KMC Constructions
Ltd.
Contractors: Associated Engineering
Enterprises
Independent Consultants: Aarvee
Associates, Hyderabad

Major Bridge Across River Tungabhadra

Year of construction: 2008 – 2009

Span arrangement: 1 x 40.0 + 14 x 38.8
+ 1 x 40.0
Total length of bridge: 623.20 m
Discharge: 15255 Cumecs
Type of Superstructure: Four Nos of
precast PSC girders with cast in situ RC
deck slab
Girder erection system: over head
launching using Auto launching system
Weight of PSC girder: 153.0 T (max))
Weight of launching girder: 175.0 T

Client: National Highways Authority of

India
Concessionaire: Andhra Pradesh
Expressway Ltd
ECP Contractors: KMC Constructions
Ltd.
Contractors: Associated Engineering
Enterprises
Independent Consultants: Aarvee
Associates, Hyderabad

30
GROUP VI : BRIDGES / VIADUCTS / ELEVATED CORRIDORS National Report on Concrete Structures in India 2006 - 2010

Ganga Bridge at Allahabad

The Allahabad Bypass Project, forming

part of the NH-2 Golden Quadrilateral
corridor from Delhi to Kolkata, comprises
of two road packages and two bridges.
The work under this package covers
construction and completion of Major
Bridge across river Ganga from Km
+163.280 to Km +164.300 of NH-2 in
the state of Uttar Pradesh, India. The
construction period for total project was
30 months.

The alignment of proposed bridges

running parallel to each other, have
two independent carriageways, each
accommodating a 7.50m wide two lane
carriageway and 1.50m pedestrian
footpath. The bridges are located at
a clear distance of 12m to facilitate
independent well sinking. Each bridge
has two 6-span continuous units with
span lengths of 62+4x95+62m. The total
length of each bridge was 1010.2m.
Bridge superstructure is supported on
well foundations. The superstructure
comprises of precast post-tensioned
segments of varying heights (2.50 to
5.5m) and lengths (2.50m to 4.0m)
weighing between 50MT to 91 MT.
The foundations consist of large diameter
(10m dia.) well foundations of depths
of 38.80m and 43.80m below LWL, and
Jack down methodology was adopted
for well sinking. The sub-structure was
of rectangular piers with pier cap. The
superstructure consists of precast
segmental box girders (post tensioned)
of varying weights. This segmental
bridge was constructed using Balanced
Cantilever Method with epoxy glued
joints and internal bonded prestressing.
This was the first bridge in India to
have Shock Transmission Units (STU’s)
in it to transfer the seismic load from
superstructure to sub structure.
Owner: National Highways Authority of
India
Contractors: Larsen & Toubro Limited
Designe Consultants: SNC LAVALIN
International Canada in association
with Gherzi Eastern Limited India and
Tandon Consultants Pvt. Ltd. India
Supervision Consultant: Scetauroute
International & Frischmann Prabhu
(India) Pvt. Ltd. JV

31
GROUP VI : BRIDGES / VIADUCTS / ELEVATED CORRIDORS National Report on Concrete Structures in India 2006 - 2010

Grade Separated Interchange at Junction of NH-45-IRR at Kathipara, Chennai

NHAI along with State Government of

Tamil Nadu programmed to develop
access to the Golden Quadrilateral
Corridor by providing free flow facilities
in highly trafficked areas in Chennai. The
Kathipara flyover involves design and
construction of a clover leaf interchange in
the heart of Chennai City. The Structural
portion involves 600m. long dual 12.0m
wide decks for the main via duct spans
connecting the Inner ring road to Airport.
Four loops of approx.200m. length each
connect to main via duct from Guindy
– Poonamallee Road .All the structural
spans are resting on aesthetically shaped
piers founded on open footings at 3 to 4
m depth.

Voided slab superstructure in PSC

and RC have been adopted for super
structure.

Owner: National Highways Authority of

India
Contractor: Somdutt and Simplex (JV)
Consultants (Design and Supervision):
STUP Consultants P.Ltd.

32
GROUP VI : BRIDGES / VIADUCTS / ELEVATED CORRIDORS National Report on Concrete Structures in India 2006 - 2010

Perambur Flyover, Chennai

The Perambur Flyover involves Rail

Over Bridge over an existing vehicular
subway to facilitate free movement of
traffic in and around Perambur Railway
Station in Chennai. The total length of
the flyover is 650m. The flyover consists
of four lane for 400m. Length , three
lane for 200m length and single lane
for 300m length. The flyover has 12 RC
spans with 15.25m width, seven spans
with 13m width and 11 spans with 5.25m
width. The superstructure comprises
some spans simply supported and other
continuous box sections. The PSC post
tensioned girders with RC deck slab is
adopted for the two spans with 15.25m.
All the structural spans are resting on
aesthetically shaped piers founded on
open footings at approx.3.5m depth .

Owner: Corporation of Chennai.

Contractor: IVRCL Infrastructure and
Projects Ltd.
Consultants (Design): STUP
Consultants P.Ltd.
Consultant and Proof Checking: Anna
University.

Interchange at Padi , Tamil Nadu

The interchange at Padi is at a location

of present level crossing which is to be
replaced by ROB. The junction is very
close to the Railway Lines which does
not allow ROB to come to the ground
level properly. Also the road running
parallel to railway at a close distance also
needs to have an access in all directions.
The solution was found by raising the
interchange at high level and connecting
the ROB at higher level and raising the
three roads meeting at the junction also
at high level.

Client: NHAI/TNRDC
Contractor: Simplex –Somdutt (JV)
PMC: STUP Consultants P.Ltd.
Consultants: STUP Consultants P. Ltd.

33
GROUP VI : BRIDGES / VIADUCTS / ELEVATED CORRIDORS National Report on Concrete Structures in India 2006 - 2010

Rail Connectivity From Idapalli to ICTT at Vallarpadam (Longest Rail Bridge In India).

Rail connectivity from Idapalli to ICTT
at Vallarpadam for works of elevated
structures, major and minor bridges
and earthwork as per the details given
below:
Length of Elevated Structure: 4620 m
Length of Embankment: 3380 m
Piles ((1.2 m dia. Avg. Boring length)
50m) : 1275 Nos.
Pile Cap: 141 Nos.
Pier and Pier Cap: 140 Nos.
‘I’ Girder ( Twin ‘I’ Girder Owner: Rail Vikas Nigam Ltd – Delhi.
system): 200 Nos
‘U’ Girder : 34 Nos.
Launching (Spans): 134 Nos.
The structure is constructed across three
stretches of creek back waters, two
islands and densely populated main land
making the logistics of the project very
complex.
Contractors: Afcons Infrastructure
Limited, Mumbai.
Design Consultants: RVNL and Afcons
Proof Consultants: IIT, Mumbai
Highlights:
• Longest Railway Bridge (4.62m) in
India.
• Total 133 Spans (233 Nos. PSC
girders) were erected within a span
of 14 months.
• Constructed in short span of
27months.
• Pumping of concrete for 2.2 Km
with multi stage high pressure
pump.

34
GROUP VII : REPAIRS / REHABILITATION PROJECTS National Report on Concrete Structures in India 2006 - 2010

GROUP VII : REPAIRS / REHABILITATION PROJECTS

Rehabilitation of Mahanadi Bridge

This 2300 Meter long bridge across River

Mahanadi is on NH-5 near Cuttack in
Orissa State. This bridge was severely
damaged due to distress in concrete
on account of saline and environmental
effects. There was severe damage to
the appurtenances such as Bearings,
wearing coat, bearings and concrete
in the decking. The superstructure of
this bridge comprising of 47 spans of
49 Meters each with 2 end spans of
smaller length rests on RC piers and well
foundations. The structural system of the
superstructure is balanced cantilever 2 ‘I’
girders with articulated ends supporting
the suspended spans.

Intensive survey and Non-destructive

tests were carried out to assess
the damages on the basis of which
replacement and repairs were carried
out to various components of the bridge.
With the rehabilitation work carried out,
the bridge is now geared up to take the
present intensity of traffic which increased
substantially over the years.
Owner: Chief Engineer, National
Highways, PWD, Bhubaneswar, Orissa..
Rehabilitation Contractors: The
Freyssinet Pre stressed Concrete
Company Ltd. Worli, Mumbai

Rebuilding of Bridge No.586 on Western Railway at Vishvamitri, Vadodara

This railway bridge constructed in 1896

carries 2 tracks Broad Gauge and falls
on the arterial route between 2 important
capitals of India – Delhi and Mumbai.
The original bridge comprising of steel
fish belly type plate girder resting on cast
iron piles, was severely affected due to
corrosion of the piles and scouring of the
shallow foundations.

This bridge was to be re-built without

suspending the traffic. The new
foundations and substructure was
constructed between the two existing
piers. The superstructure comprising
of PSC girders were precast and were
launched in position during the traffic
blocks. The original bridge was having
3 spans of 26 Meters each and was
converted to 4 spans of 19.35 Meters
each. Independent PSC girders
were provided under each track. The Owner: Deputy Chief Engineer, Western
abutments were replaced by RC boxes Railway, Vadodara..
which were launched in position pushing Main Contractor: Gammon India Ltd.
through the embankment under the track. Mumbai
The handling of PSC girders was done Sub Contractors: The Freyssinet Pre
by using cranes and hydraulic jacking stressed Concrete Company Ltd. Worli,
system. Mumbai

35
GROUP VII : REPAIRS / REHABILITATION PROJECTS
Rehabilitation of Mahatma Gandhi Setu, Patna
This is the longest River Bridge in India
having a length of 5525 Meters. This
bridge constructed in seventies has 2
carriageways resting on one common
pier supported by well foundations. The
piers are integral with the decking which
is in pre-stressed concrete box girder
with ‘T’ arms. Each ‘T’ arm is about 120
Meters. The cantilevers are connected at
the tips by means of steel Central Hinge
Bearings.
The stability of the bridge was affected
due to sagging of cantilevers resulting in
National Report on Concrete Structures in India 2006 - 2010
damage to the Central Hinge Bearings.
The box girder is constructed with
precast segments. Apart from sagging
of cantilevers, some joints were found to
be open. It was established that loss of
prestress was the main factor attributing
to the distress in the bridge. To overcome
this, external cables were provided to
augment the prestress to the required
level. After the prestressing work, the
damaged bearings were then replaced.
46 spans have been strengthened in this
manner.
Owner: A) Chief Engineer, Ministry of
Shipping, Road Transport &
Highways, Transport Bhavan,
New Delhi.
B) Chief Engineer, RCD,
Bihar at Patna
Contractors: The Freyssinet Pre
stressed Concrete Company Ltd. Worli,
Mumbai
Consultants: M/s Structcon Consultants.
Borivali, Mumbai
36
GROUP VIII : ROADS / HIGHWAYS / EXPRESSWAYS National Report on Concrete Structures in India 2006 - 2010

GROUP VIII : ROADS / HIGHWAYS / EXPRESSWAYS

Four - laning of Satara – Kolhapur State Border Section of NH-4 from Km 725 to Km 592/240 –
Package V
The project comprises of four-laning the
existing two lane NH-4 between Satara
to Shivade – Package V (28 Km).

It was decided to have concrete pavement

for the new carriageway. There are
3 major bridges in Package V and an
elevated road structure in Umbarj town.
The road will be semi access controlled.
Use of fly ash has been made for making
pavement quality concrete in M40.

Owner: Maharashtra State Road

Development Corporation Limited
(MSRDC)
Contractors: Mahavir Infrastructure –
NCC (JV).
Consultants: STUP Consultants P. Ltd.

Outer Ring Road (Four lane) Between Mysore Road to Magadi Road, Bangalore

The Purpose of the Outer ring road is to

upgrade the existing Peripheral Road
connecting Magadi Road to Mysore Road
via Nagarbhavi ,Ambedkar Engineering
College and Kengeri Satellite circle and
60feet from Hoysala circle and 60feet Client: Bangalore Development
from Hoysala circle to Mysore Road also Authority, Bangalore
under scope of work includes road and Contractor: Maytas Infra Limited.
cross drainage work .Total Length of the Consultants: STUP Consultants P.Ltd.
road is 11.5Kms. PMC: STUP Consultants P.Ltd.

37
GROUP IX : LARGE PROJECTS National Report on Concrete Structures in India 2006 - 2010

GROUP IX : LARGE PROJECTS

Bandra-Worli Sea Link,Mumbai

India’s first and longest open sea, cable

stayed bridge, Bandra - Worli link is
the first phase of west freeway sea
link (WFSL) project, linking the city of
Mumbai with its western suburbs, aimed
at upgrading the road transportation
network of greater Mumbai.

The Bandra-Worli Sea Link has a

total length of 4.7 kms and has dual
carriageways of 4 lanes each. The project
comprises:
1. Approach road of 540 m.
2. 54x2 pre-cast segmental approach
spans of 50 m length
3. Bandra cable stay bridge on 126 m
high single pylon with 500 m clear
span
4. Worli cable stay bridge on 54 m high
twin towers with 150 m clear span
5. 811 m link bridge
6. 16 lane Intelligent Toll Plaza

At peak time, the project deployed 165

engineers and staff and 2800 workmen.
The project management team had
the requisite experience and skill
levels for segmental construction and
marine sub-structure works. The project
demanded application of state-of-the-art
technologies of global standards.

Owner: Maharastra State Road

Development Corporation
Designer/Consultant: Dar
Consultants India Pvt. Ltd
Contractors: Hindustan Construction
Company Ltd.
Funding: Maharastra State Road
Development Corporation

38
GROUP IX : LARGE PROJECTS National Report on Concrete Structures in India 2006 - 2010

Jogeshwari Vikroli Link Road (ICB Contract : World Bank Funded)

MMRDA has developed a Master Plan

for integrated road development with an
objective of strengthening and widening
of existing road network of the island city
of Mumbai and its Western and Eastern
suburbs under Mumbai Transport
Infrastructure Development Project.

The work of widening Jogeshwari - Vikroli

Link Road from 2 lanes to dual 3 lanes
is included in Non-Rail (Road and other
work) component of MUTP-II, aided by
World Bank. Jogeshwari – Vikroli Link
Road (JVLR) is a vital link in Mumbai City
and connects Western Express Highway
and Eastern Express Highway.

The total length of this link is 10.70 km,

which is divided in 3 sections. Out of
these, Section 2 (Approx. length 4.40
km.) has already been developed to a Before
dual 3 lane configuration in some parts.

The work involves construction of

concrete pavement, bituminous
pavement, widening of existing cross-
drainage works and bridges, construction
of flyover and retaining walls, ground
improvement, improvement of geometry
of existing road, road furniture, pavement
markings etc..
Owner: Maharastra Metropolitan Region
Development Authority / Maharastra
State Road Development Corporation.
Contractors: Mahavir Infrastructure –
NCC (JV).
Consultants: STUP Consultants P. Ltd.

39
GROUP IX : LARGE PROJECTS National Report on Concrete Structures in India 2006 - 2010

Metro Rail, Mumbai

Nine Lines in 3 Phases

Total Length: 146.5 km
Versova-Andheri-Ghatkopar
Charkop-Bandra-Mankhurd
Colaba-Mahim-Bandra

Charkop - Dahisar
Ghatkopar – Mulund
BKC-Kanjur Marg via Airport

Andheri(E) - Dahisar(E)
Hutatma Chowk - Ghatkopar
Sewri – Prabhadevi

Owner: Maharastra
Metropolitan Region
Development Authority

Elevated Road Along Ambedkar Road Mumbai

Ambedkar Road is one of the three

main corridors running North-South and
serving both long distance commuter and
local traffic. A series of long stretches
along the road are being elevated to
high level road to serve the fast moving
commuter traffic and thus by flying over
number of junctions with cross-roads,
reduce the commuting time. From the
elevated road at J.J. Hospital at southern
end to Chunabhatty railway station at the
northern end, is a series of 10 flyovers
and elevated roads. The elevated road at
Lalbaug is 2.0 km, the flyover at Dadar
is 1.2 km. and that at King Circle is 1.2
km long. Adding these to the existing
flyovers at other junctions this vital north-
south link will have about 8.6 km. length
at elevated level, which will contribute in
a major way to ease north south through
traffic on this vital artery of Mumbai’s
traffic.

Owner: Maharastra State Road

Development Corporation. / Muncipal
Corporation of Greater Mumbai

40
GROUP IX : LARGE PROJECTS National Report on Concrete Structures in India 2006 - 2010

Design of Elevated Viaduct- 5.225kms. and Five Elevated Stations – BC-7

The Inderlok –Mundka corridor of Delhi

MRTS is an elevated viaduct of length
5.225km with five elevated stations.
There are as many as 148 spans of
different lengths arranged all through the
viaduct with the span length ranging from
16m to 37m. Also there is a 75m long
continuous span placed over an existing
railway track alongwith two side spans of
length 62m.The superstructure system in
the viaduct is of prescast prestressed type.
The piers supporting the superstructures
are either circular or elliptical and owning
to the eccentricity of the centre line of
alignment with the centre line of piers,
the piers are categorized as concentric,
cantilever and portal piers

The five elevated stations are located

at Inderlok, Ashok Park, Punjabi Bagh
East, Shivaji Park and Madipur. At each
station there are two floor levels, namely
the Concourse level and the Platform
level. The spans placed side by side
to the platforms are RC cast –in-situ
whereas the ones placed on either sides
of the RC cast-in-situ spans are Precast
prestressed. The columns supporting the
structure are circular, rectangular or half
elliptical. The foundation adopted is pile
foundation type and piles used are either
of diameters 0.8m or 1.2m
Owner: Delhi Metro Rail Corporation
Client : DMRC-IDEB-SUCGJV – Joint
Venture, New Delhi
Design Consultants: STUP Consultants
P.Ltd. in association with CPG Singapore
Highlights
• The First Standard Gauge Corridor
In the Country.
• Two Stretches of 3 continuous span
system of 62-75-62m. Each above
Punjabi Bagh Flyover and Northern
Railway Line at Zakira.
• One Span of 45m in Steel.
• Viaduct with Segmental
Construction as well as Cast in Situ
RC voided Deck slab.
• Station and Viaduct On Pile
Foundation.
• Sub Structure of Single Pier with
Pier caps Centric and Cantilever
Pier Cap, Portal Beam type.

41
GROUP IX : LARGE PROJECTS National Report on Concrete Structures in India 2006 - 2010

Viaduct Portion of Stretch Adjacent to Sultanpur Station to Qutab Minar – BC-20

The Qutub Minar – Gurgaon corridor of

Delhi MRTS has an elevated viaduct of
length 0.883km near Sultanpur Station
for supporting multiple tracks of Broad
Gauge Coridor. There are as many as
32 spans of different lengths arranged all
through the viaduct with the span length
ranging from 16m to 24m.

The superstructure system in the viaduct

is of precast girder with cast in situ slab.
The girders are supported on portals
and piers depending upon the location
and number of tracks. The piers of
superstructures are either circular or
elliptical and owing to the eccentricity of
the centre line of alignment with the centre
line of piers, the piers are categorized
as concentric, cantilever and portal
piers. The type of foundation adopted in
viaduct portion is pile foundation with pile
diameter fixed to 1.0m.

Owner: Delhi Metro Rail Corporation

Contractor: Delhi Metro Rail
Corporation - Simplex Infrastructure
Limited
Design Consultants: STUP
Consultants P.Ltd.

Pragathi Maidan Bridge

The long span segmental cantilevered

construction bridges over rivers and
creeks were started in India way back
in nineteen sixties, interestingly a bit
earlier than in United States. After having
achieved 165m central span by this
method, presently 185m longest span
girder bridge is designed and being
executed in the sub-continent.

Mean while a concept of extra-dose

bridge an evolution between girder and
cable stay bridge introduced by Christian
Menn and J.Mathivat in their typical
but classical styles has been admirably
exploited by Japanese up to the span
of 250m.The authors improvised the
concept further by staying the central with it’s U trough deck configuration. Both
span beyond the extra-dosed spans by these were built by pre cast segmental
cables from the same Pylon housing cantilever construction method.
extra-dose cables in one of the recent
competitive biddings. This is an extra-
dose bridge partially supported by cable
stays.

In the Indian context, while 2nd

Vivekananda bridge is a first extra-dose Owner: Delhi Metro Rail Corporation.
bridge, Pragati Maidan extra-dose bridge Contractors: Systra.
which was being built at the same time Engineering Designers: Gammon India
for Delhi Metro Rail Corporation is unique Ltd

42
GROUP IX : LARGE PROJECTS National Report on Concrete Structures in India 2006 - 2010

Construction of Extradosed Bridge for Metro Rail Project at Indraprastha

India’s first extra-dosed bridge to be

comissioned, has been built by Gammon
India Limited between Pragati Maidan
and Indraprastha towering over Indian
Railways tracks. This bridge is 196.343
metres long and the main span over the
railway lines is 93 metres. In addition, the
bridge has a 302-metre radius curvature.
Prior to this the first such rail over bridge
was constructed in Japan..

The extradosed bridge is a variant/hybrid

of the cabled-stayed bridge and the
segmental pre-stressed concrete girder
bridge, combining features of both. Similar
in appearance to a cable-stayed bridge,
but with shorter towers, the extradosed
bridge’s structural performance is similar
to that of a post-tensioned bridge.
A cable-stayed bridge usually has a deck
that is sufficiently rigid to spread local
loads and to prevent undue flexure and
torsion, but the deck is unable to support
itself without the cables.
The pre-stressed concrete bridge, by
contrast, has no external supports apart
from the piers, and the forces in it are
controlled by tension in the tendons and
compression in the concrete.
Owner: Delhi Metro Rail Corporation.
Contractors: Gammon India Limited.
Consultants: Systra

43
GROUP X : BUILDINGS National Report on Concrete Structures in India 2006 - 2010

GROUP X : BUILDINGS
Cognizant Campus at MEPZ, Chennai

The site is located at MEPZ Campus;

Chennai .The site is fairly rectangular
in shape with a total plot area of 57223
Sq.m. The total built-up area is about
186,000 sq.m.

It has been deigned in such a way that it

can occupy 9000 to 10,000 persons and
has car parking facility of about 1300 cars
and 2000 two wheelers.

The project is designed as an eco-friendly

project.

The major highlights are minimized

impervious surface areas on the site,
maximized positive effects of solar
orientation and wind patterns and
minimized the urban heat island effect,
preserve natural site features and use
topography of the site. Moreover Green
building concepts (Sustainable design
approach and solar passive architecture)
are widely used in this project.

Owner: Cognizant Technology

Solutions India Pvt. Ltd.
Contractors: Larsen & Toubro Limited
–ECC Division.
Engineering Consultants: Engineering
Design and Research Centre (EDRC) of
ECC Division, Larsen & Toubro Limited

44
GROUP X : BUILDINGS National Report on Concrete Structures in India 2006 - 2010

TCS Technopark, Siruseri, Chennai

The TCS Techno Park IT Project, one of

the large IT Parks, accommodates around
30,000 professionals and is located along
East Coast of Chennai Suburban on a
sprawling 70 acres of land. This facility
with 465,000 sq.m. area faces the Bay of
Bengal. Phase-1 of the project occupies
232,500 sq.m.

The highlight of the project is its efficient

concrete structural system to support
the complex Structural steel roofing. The
butterfly shaped roof adorns the top of
Engineering Buildings while a magnificent
dragon shaped Central Spine covers the
Podium standing erect between the two
rows of General Service buildings.

The two structures - The Mini-spine

- 6 nos and The Central spine play a
significant role in the structural system.

The Mini-Spine resembles the body of

a butterfly spreading its two wings on
either side in north south of Engineering
Buildings. It measures 15 m high at the
mid span with overhang on both sides
and rests neatly over two concrete core
structures specially designed to withstand
the mini-spine.

The Central spine stands on 16 pairs of

heavy legs otherwise known as Portals
with a length of 400m in east west
direction and tails on both ends nearly
touching the ground.

Owner: TATA Consultancy Services.

Contractors: Larsen & Toubro Ltd.
Architect: Carlos OTT Architects in
association with Carlos Ponce de León
Architects.
Local Architect: C.R.Narayana Rao
Engineering Consultants: TCE
Consulting Engineers Ltd.

45
GROUP X : BUILDINGS National Report on Concrete Structures in India 2006 - 2010

Construction of a new complex for Tamilnadu Legislative Assembly at Chennai, India

The Assembly building covering a plinth

area of 22000 Sq.m and resting on 1636
bored cast in situ piles is a mommoth
concrete structure seven storeys tall
rising to 37 m and crowned with a 30
M structural steel conical dome . The
façade is with combination of 20000
sq.m structural glazing and 10000 sq.m
sapphire bule granite panels covered
with perforated aluminium sheets.

The structure consists of four circular

buildings to accommodate the offices
of the State Chief Minister, elected
representatives of the Legislative
Assembly, a Library and a Public Plaza
which provides free access to the public
to the Assembly complex.

All the offices of the various departments

with their Departmental Heads are
housed in this complex with all needed
infrastructural facilities. Very careful
measure were followed not to cut trees,
but transplant them wherever possible.
This is one of the few large Government
Buildings to earn “GREEN LEED
CERTIFICATE”

Cast in Situ bored piles of Dia (500 to

1000mm): 1636 No.
Concrete: 80000 cum
Rebar: 10000 MT
Shuttering: 600000 sqm
Prestressing strands / Cables: 520 MT
Cladding: 10000 sqm

Owner: Public Works Department,

Government of Tamilnadu.
Contractors: East Coast Constructions
& Industries Limited, Engineers &
Contractors.
Architect: GMP International GMBH,
Architects & Engineers
Local Architect: Archivista Engineering
Projects Pvt Ltd
Engineering Consultants: Y.S. Sane
Associates

46
GROUP X : BUILDINGS National Report on Concrete Structures in India 2006 - 2010

Vidhana Soudha South Block – Vikas Soudha at Bangalore

The building which houses Legislature-

cum-Secretariat, Government Offices, is
planned to match the existing Vidhana
Soudha in the architectural style and its
grandiose.

The Monumental Building is Reinforced

Concrete Structure with 3 Basements +
Ground + 4 Storied costing about Rs.100
crores. The scope of work consists
of Civil, Internal Sanitary, Plumbing,
Electrical and External Services including
all Electro-Mechanical Services such as
HVAC, Electrical, Fire Fighting, Public
Address System, Elevators etc.

The outstanding features of the two

monumental buildings are ornamental
motifs, floral patterns and chiseled
geometric designs are all distinct and not
a single design has been repeated. The Major Quantities:-
Concrete: 41277 Cum Owner: Karnataka Public Works
floral motifs of the stone-carvings are
Formwork: 325000 Sqm Department (KPWD).
Dravidian in style and are drawn entirely
Reinforcement: 4597 MT Contractors: B.G. Shirke Construction
from the temple-craft of Karnataka and
Built up area: 627261 Sqft Technology Pvt. Ltd., Pune.
Tamil Nadu. The Domes are having
Granite Stone for Ornamental & Masonry: Architect / Structural Designer:
diameter of 9.7 m.
21523 Cum Karnataka Public Works Department

Shiv Chhatrapati Sports Complex at Balewadi, Pune

The Sports Complex was planned to
conduct 3rd Commonwealth Youth
Games 2008. All the Sports Facilities and
buildings are of International Standards
and finishes such as structural glazing,
false ceiling, alco panels, granite flooring,
Galvalume sheet roofing and cladding
etc. The project costing Rs.320 crores
was completed in a record time of 17
months.
The Sports complex consists of various
structures such as Badminton Hall,
Wrestling hall, Fitness Centre, Shooting
Range complex, Tables Tennis hall,
Center tennis court etc. The total seating
capacity is 39,100.
The project contains facilities for all the
games of International Standards are
located at one place in area of about 140
acres.
Major Quantities:-
Concrete: 46863 Cum
Reinforcement: 3146 MT
Structural Steel: 3781 MT
Galvalume Sheet Roofing System: 46658
Sqm
Built up area: 950000 Sqft.
Owner: Directorate of Sports and Youth
Services, Pune.
Contractors: B.G. Shirke Construction
Technology Pvt. Ltd., Pune.
Architect / Structural Designer:
Shashi Prabhu & Associates, Mumbai

47
GROUP X : BUILDINGS
Mass Housing Project at Versova, Mumbai
The project is executed on Turnkey
Lumpsum Basis Planning, Design,
Construction, obtaining permission from
statutory authorities etc.
The planning, design and construction
of the entire project is done to satisfy the
eco-friendly norms.
The building is designed with ‘3-S’ Prefab
System consisting of precast column,
beam, slabs etc. The scope includes
Stilt+15 storied 16 buildings including
civil, infrastructure, internal and external
services, electrical, sanitary plumbing,
lifts, fire fighting etc., costing Rs.108.70
crores.
Rajiv Gandhi AC Indoor Stadium, Guwahati, Assam, India
The project involved construction of a AC
Indoor Stadium at Amingaon, Guwahati,
Assam. The seating capacity of the
stadium was 25000. The stadium has
been built to International Standards and
are capable of holding world standard
games.
National Report on Concrete Structures in India 2006 - 2010
Prefab System consisting of precast
elements:-
Column: 10363 Nos.
Beam: 67799 Nos.
Slab: 60464 Sqm
No. of Buildings: 16 consisting of 1088
HIG units
Built up area: 1077756 Sqft. Owner: Mumbai Housing & Area Dev.
Board, Mumbai.
Contractors: B.G. Shirke Construction
Technology Pvt. Ltd., Pune.
Architect / Structural Designer: B.G.
Shirke Construction Technology Pvt.
Ltd., Pune
Owner: Guwahati Metropolitan
Development Authority Govt. of Assam
Contractors: Larsen & Toubro Ltd.
Architect / Structural Designer: STUP
Consultants P. Ltd.
48
GROUP X : BUILDINGS National Report on Concrete Structures in India 2006 - 2010

Corporate Office Building for Patni Computer Systems at Airoli, Navi Mumbai
The corporate office building is located at
Airoli is spread over a plot of 50 acres.
The proposed officebuilding is stilt + 4
storeyed structure, RC framed having
built up area of 49418 sq.m. with all
modernfacilities for a software block. The
office building houses software blocks,
training centre, canteen andan employee
care centre.

Client: Patni Computers

Contractor: N.C.C
Designer/ Consultants: STUP
Consultants P. Ltd.

Development of IT Campus, Chandigarh, India

Design and Development of IT Park,

comprising IT, Commercial, Residential
and Recreationalsegments with support
infrastructures on the plot area is Appx.
About 10 acres, FAR ratio 2.50Permissible
Built up area 10,10,000 Sq.ft.

Owner: Bharti Airtel Ltd.

Contractor : Top Line
Designer/ Consultants : STUP
Consultants P. Ltd.

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 National Report on Concrete Structures in India 2006 - 10

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 National Report on Concrete Structures in India 2006 - 10

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 National Report on Concrete Structures in India 2006 - 10

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