The Bharat Ratna JRD Tata flyover in Pune is the first double-deck flyover in Maharashtra. AHLAM RAIS explores the construction aspect of this newly inaugurated project.
Inaugurated on February 15, 2014, Bharat Ratna JRD Tata Flyover, most famously known as Nashik Phata Flyover in Pune, is strategically positioned at the Nashik Phata junction of two national highways, NH-4 and NH-50. It is a complex integrated project of multilevel flyover, river bridge, rail over bridge (ROB) with ramps and a loop. The project has a unique location as it connects both highways, crosses the Mumbai-Pune highway stretch, the Pune-Mumbai railway line and Pavana River in one go. What's more, the design-build turnkey project has reduced travelling time for commuters by half an hour!
The flyover is a dream link for residents and industries in the region and will add value to the city. The double-deck flyover comprises two levels. The first is a six-lane bridge with two flyovers and covers a distance of 1.8 km, width of 15.30 m and height of about 11-12 m. This level is elevated as it passes over Pavana River at 206 m and includes a ROB at 110 m. Along with this, the first level provides access to ramps around 1 km, which connect the ground level to the first level and service roads, around 2 km in length. It also has a dedicated lane for BRTS that has proved beneficial to the public. The second level is about 1.1 km in length, with a width of 9.30 m (two lane) and height of 20 m. The first level is a two-way road (Nashik to Hinjawadi and Hinjawadi to Nashik) and the second level directs traffic from Pune to Nashik.
One of the major achievements of this project is the creation of piers at the second level. "We have cast piers at a height of 20 m at a single go," explains Nitin M Kadam, General Manager (Projects), BG Shirke Construction Technology. "We were equipped with a specialised formwork that was particularly designed for these piers to withstand hydraulic and wind pressures. Pouring rate with placer boom was maintained at 7 cu m per hour with concrete temperature below 20°C and specially designed poker vibrators and shutter vibrators during concrete operation with safety measures."
Advanced surveying equipment were used and a in-house well equipped laboratory was established at the project site. "For the construction of Nashik Phata Flyover, tower cranes were used to handle the materials at the construction site by avoiding hurdle to traffic of movement of equipment at ground," says Kadam. "Advanced batching plants were also utilised for mixing the concrete. To avoid the concrete from cracking during the summer season, chilling plants were used to control the desired temperature of 20°C at the time of pouring. The pouring rate of the concrete was maintained by synchronising the activities with time motion studies and planning. Decking sheets and studs were used for the construction of composite structure of the ROB; along with this, cranes with a capacity of 600 metric tonne were also utilised for the ROB. Apart from these, equipment like the sizzler lifts were adopted for painting."
Various materials have also been used to improve the quality of the flyover. Concrete from M40 grade to M60 grade and self-compacting concrete has been used in the development of this project. "The total quantity of concrete used is 61,000 cu m, cement about 4.70 lakh bags and steel about 6,900 metric tonne," adds Kadam. "High steel stands of about 360 metric tonne were used for the stretching work." Apart from this, steel girders of 33 m spans were fabricated in a well-equipped factory with lessor cutting and submerged arc welding machines. The expansion joints were also placed at the flyover to enhance the user experience and better riding quality while driving.
At the planning stage, all segments such as material, manpower and machinery were carefully researched. For the construction of this project, an in-depth study was also carried out at every stage. "We carried out a utility survey at the location to find out if there were any underground utilities such as water supply, sewerage, telephone, electrical and MNGL lines involved at the construction site. There was heavy penalty in case of disturbance," says Kadam. "The utilities and a few trees along with slums had to be shifted in a planned manner for the construction of the project."
The cost of the project is Rs 130 crore; it was funded by JNNURM and the World Bank. While JNNURM funded about 40 per cent and state government about 20 per cent of the cost, the rest came from the World Bank.
Delays and challenges
The construction of the river bridge and railway bridge was challenging, planning was carried out accordingly. "The railways had permitted us only one hour a day to work for the ROB," says Kadam. "Hence, we had to work only for one hour a day and a total of 10 days was assigned to complete the ROB work. The ROB structure was completed within 14 days. Another hurdle we faced was acquiring permission from the railways to build the ROB and relocation of the railway transmission line." Traffic was also a challenge as work had to be carried out in a close rehabilitated area amid highway traffic. As the project was developed in an urban area, acquisition of land and rehabilitation of slum dwellers was a challenge. Manpower was also a problem and a total of 4.5 lac man-days of skilled and unskilled workmen worked on the project. Maintaining Environmental and Safety aspects during construction of entire project was also a great challenge.
Despite being inaugurated early this year, Nashik Phata Flyover has already won many prestigious awards such as the "First Construction Safety Gold Award 2011-12" by "CONSTRO Pune", the "Well-Built Structure Award 2013" by Builders Association of India (BAI), the "Best Construction Project in India" by the Construction Industry Development Council Delhi for Infrastructure Category and the "Birla Super Award" in the Category of "Outstanding Concrete Structure 2013" by the Indian Concrete Institute. And the accolades only continue to pour in!
Completion: February 15, 2014
Cost: Rs 130 crore
Length: First level: 1.8 km; second level: 1.1 km; ramps: 1.03 km
Owner: Pimpri-Chinchwad Municipal Corporation. Tel: 020-2742 5511. E-mail: firstname.lastname@example.org Website: www.pcmcindia.gov.in
Architecture design: Consulting Engineering Service. Tel: 011-4139 2300. Fax: 011-2646 0409. Website: www.cesinter.com
Developer: BG Shirke Construction
Technology. Tel: 020-2670 8100. E-mail: email@example.com, firstname.lastname@example.org Website: www.shirkegroup.com;
VMMCL. Tel: 079- 2630 2531. E-mail: email@example.com, Website: www.vmmcl.com
In order to give the flyover a smooth surface finish and desired strength to the casting, Atlas Copco's fleet of light compaction and concrete equipment has been successfully used in the concreting process. Nilesh Bhavsar, Senior Manager Mechanical, BG Shirke Construction Technology, highlighting the efficiency of the range, says, "We have used the company's equipment range regularly as they offer reliable and trouble-free equipment with good service support." BG Shirke Construction Technology adopted products from the Atlas Copco Light Compaction and Concrete equipment range - motor in head pokers from Vibrastar series, frequency converters, high frequency external vibrators ER407B and walk behind roller LP6500.
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