NHSRCL achieves first steel bridge milestone

09 Oct 2023 CW Team

This accomplishment marks the inauguration of the initial among 28 steel bridges that will form an integral part of the MAHSR corridor, a project of immense national importance. Approximately 70,000 metric tonnes of specified steel are anticipated to be employed in the construction of these steel bridges, varying in span length from 60 meters with 'simply supported' designs to over 130+100 meters with 'continuous spans.'

This achievement highlights India's commitment to leveraging its indigenous technical and material capabilities in tandem with Japanese expertise to realize the vision of Make-in-India. The utilization of steel bridges in this project showcases India's competence in fabricating structures suitable for high-speed and heavy-haul trains, with speeds ranging from 100 to 160 kilometres per hour. Importantly, this marks the first instance where a steel bridge has been engineered to support a Shinkansen Bullet train travelling at a remarkable speed of 320 kilometres per hour.

The journey of the steel structure, comprising nearly 700 individual pieces totalling 673 metric tonnes, commenced at a workshop in the Hapur district, situated approximately 1200 kilometres from the bridge's installation site. On location, the steel bridge, standing at a height of 12 to 14 meters, was meticulously assembled atop 10- to 12-meter-high piers. Subsequently, the assembly process included the attachment of a launching nose weighing approximately 200 metric tonnes to the main bridge structure. With utmost precision and expertise, the Bridge Assembly was then seamlessly manoeuvred to its intended span through a specially designed pulling arrangement, all while ensuring a complete traffic block on the National Highway.

Stringent quality control measures were enforced throughout the manufacturing process, with each production batch of steel undergoing Ultrasonic Testing (UT) at the manufacturer's facilities. The fabrication of these steel bridges involved a series of high-tech operations, including cutting, drilling, welding, and painting, all in accordance with design drawings meticulously prepared by Japanese engineers. Notably, the contractors were required to employ welders and supervisors certified by International Welding Experts, with the welding process being closely monitored by Japanese International Welding Experts (IWE) stationed at each workshop. The fabricated structure also underwent a rigorous Check Assembly process, followed by a sophisticated five-layered painting procedure, utilizing a first-of-its-kind technique in India. This painting system conforms to the Japan Road Association's "Handbook for Corrosion Protection of Steel Road Bridges" under the C-5 Painting system.

Key Technical Details: 1. Length of the main bridge: 70 meters 2. Weight of the main bridge: 673 metric tonnes 3. Launching nose length: 38 meters 4. Launching nose weight: 167 metric tonnes 5. Steel used for the main bridge: 673 metric tonnes

The successful erection of the first steel bridge represents a remarkable step forward in the realization of the Mumbai-Ahmedabad High-Speed Rail Corridor, underscoring the nation's dedication to advancing its infrastructure and transportation capabilities for a more connected and efficient future.

Surat, Gujarat - In a significant milestone for the Mumbai-Ahmedabad High-Speed Rail Corridor (MAHSR), the National High-Speed Rail Corporation Limited (NHSRCL) successfully erected its first steel bridge, spanning 70 meters in length, across National Highway-53 in the city of Surat, Gujarat. This accomplishment marks the inauguration of the initial among 28 steel bridges that will form an integral part of the MAHSR corridor, a project of immense national importance. Approximately 70,000 metric tonnes of specified steel are anticipated to be employed in the construction of these steel bridges, varying in span length from 60 meters with 'simply supported' designs to over 130+100 meters with 'continuous spans.' This achievement highlights India's commitment to leveraging its indigenous technical and material capabilities in tandem with Japanese expertise to realize the vision of Make-in-India. The utilization of steel bridges in this project showcases India's competence in fabricating structures suitable for high-speed and heavy-haul trains, with speeds ranging from 100 to 160 kilometres per hour. Importantly, this marks the first instance where a steel bridge has been engineered to support a Shinkansen Bullet train travelling at a remarkable speed of 320 kilometres per hour. The journey of the steel structure, comprising nearly 700 individual pieces totalling 673 metric tonnes, commenced at a workshop in the Hapur district, situated approximately 1200 kilometres from the bridge's installation site. On location, the steel bridge, standing at a height of 12 to 14 meters, was meticulously assembled atop 10- to 12-meter-high piers. Subsequently, the assembly process included the attachment of a launching nose weighing approximately 200 metric tonnes to the main bridge structure. With utmost precision and expertise, the Bridge Assembly was then seamlessly manoeuvred to its intended span through a specially designed pulling arrangement, all while ensuring a complete traffic block on the National Highway. Stringent quality control measures were enforced throughout the manufacturing process, with each production batch of steel undergoing Ultrasonic Testing (UT) at the manufacturer's facilities. The fabrication of these steel bridges involved a series of high-tech operations, including cutting, drilling, welding, and painting, all in accordance with design drawings meticulously prepared by Japanese engineers. Notably, the contractors were required to employ welders and supervisors certified by International Welding Experts, with the welding process being closely monitored by Japanese International Welding Experts (IWE) stationed at each workshop. The fabricated structure also underwent a rigorous Check Assembly process, followed by a sophisticated five-layered painting procedure, utilizing a first-of-its-kind technique in India. This painting system conforms to the Japan Road Association's Handbook for Corrosion Protection of Steel Road Bridges under the C-5 Painting system. Key Technical Details: 1. Length of the main bridge: 70 meters 2. Weight of the main bridge: 673 metric tonnes 3. Launching nose length: 38 meters 4. Launching nose weight: 167 metric tonnes 5. Steel used for the main bridge: 673 metric tonnes The successful erection of the first steel bridge represents a remarkable step forward in the realization of the Mumbai-Ahmedabad High-Speed Rail Corridor, underscoring the nation's dedication to advancing its infrastructure and transportation capabilities for a more connected and efficient future.