For the construction of one of the longest sea bridges in India, ElectroMech cranes are deployed for heavy lifting in the precast yard
Tata Projects is one of the rapidly growing and most admired infrastructure companies in India. Its core competence lies in executing large and complex infrastructure projects. The company is heavily investing in urban infrastructure development to improve standards of living.
Exceptional execution ability being the key to complete projects on time, Tata Projects leverages technology, advanced construction methods and well orchestrated collaboration between diverse specialists. The company is driven to deliver flawlessly executed projects on time using world-class manage-ment techniques, advanced technology and has uncompromising standards of safety and sustainability.
The proposed Mumbai Trans Harbour Link (MTHL) is an ambitious project by Mumbai Metropolitan Region Development Authority (MMRDA). The project, also known as the Sewri-Nhava Sheva Trans Harbour Link, is an under-construction 21.8km bridge connecting Mumbai with its satellite city, Navi Mumbai. It will be a 6-lane bridge having 27m width, 25m height and design life of 100+ years. Once completed, MTHL would be the longest sea bridge in India and it is estimated that over 70,000 vehicles will use the bridge daily.
MMRDA has awarded the contract to construct the Navi Mumbai side of the sea bridge to a consortium of Daewoo and Tata Projects Limited. This 7.8-km-long bridge section including an interchange is a complex stretch. Tata Projects, together with Daewoo, will use the latest and the best construction methods and techniques to complete this prestigious project.
The project construction began in 2018 and is scheduled to be completed by 2023.
The new bridge is being constructed using precast segments and advanced technology. Tata Projects has set up a large precast yard near Ulwe village on the Navi Mumbai side of the sea bridge. To ensure highest possible quality, all the required precast segments are being manufactured in this new yard under the strict supervision of the engineering team of Tata Projects.
The complete yard consists of three casting lines. Each line is designed such that the initial 100m length is dedicated for casting operations, whereas the remaining, approx. 200m length, is allocated for stocking and despatch of the segments. Each precast segment manufactured here is massive, having maximum dimensions of 16m x 2.2m x 3.5m and weighs around 120t. The cranes were required in the formwork area as well as in the storage yard.
The cranes in the formwork area were intended to be used for handling rebars and steel structures, while the cranes in the storage yard were required for moving finished precast segments to the storage area, stacking them and further loading them onto the trailers. To optimise space utilisation in the storage yard, the customer was planning to stack three segments, one above the other, making the total height of storage nearly 11m. The crane carrying the newly cast segment was expected to travel above these stored segments and hence 'height of lift' (HOL) was a critical factor. Considering all these aspects, the customer required a clear HOL of 18m below the hook.
Safe operation was yet another important consideration while deciding on the right crane solution. With large-scale operations, there is frequent movement of people and material in the precast yard. When two or more cranes travel on the same rails in long traverse direction, it is very likely that the lifted loads or the cranes may collide. To avoid such incidences, it was extremely important to provide adequate inbuilt protection for all the cranes.
The project is on the west coast of India where heavy wind is prevalent and adversities due to storms striking the shore are likely. To cope with the harsh conditions such as heavy wind, saline atmosphere and high rainfall, provisions for safety of cranes, material and people were essential.
Considering the time period and scale of the project, cranes were expected to operate 24x7, with higher reliability, and with an assurance of prompt aftersales service support for uninterrupted operations.
ElectroMech has vast experience in providing crane solutions for precast yards across the world. Our advanced technology cranes are operational in few of the largest precast manufacturing plants such as Gulf Precast (UAE), Waskita (Indonesia), RDB-ELSEIF (Saudi Arabia), PIIPL (India) and so on. ElectroMech cranes have also played a key role in several infrastructure projects including the Signature Bridge, Mandovi Bridge, Zuari Bridge, as well as for the construc-tion of various metro rail projects in cities like Dubai, Riyadh, Doha, Mumbai, Chennai, Bengaluru, Delhi and others.
After understanding the requirements of Tata Projects, the ElectroMech team suggested using a combination of various cranes.
Cranes designed to handle future challenges as well
During the discussions while finalising crane specifications, the customer tossed an idea – could the crane be used for future projects as well. Our design team took this as a mandate and designed 30m span cranes with a splice joint at 20m (20m + 10m). This simple design thought ensured that the customer could use the cranes effectively not only for the current project but also for future projects by easily altering the span.
At ElectroMech, we have a perfect understanding of the increasing cost pressures on EPC companies. Effective reuse of assets can save major CAPEX and hence we are always willing to work with customers to achieve this end. Our customer-centric approach is helping us to earn the trust of all major EPC companies across the world.
|Sr. no.||Type||SWL||Span||Height Of Lift||Application||Qty|
|1||DGEOT||150/15t||30.00m||18.00m||For precast storage and despatch yard||3|
|2||DGEOT||15t||30.00m||15.00m||For formwork area||3|
|1||DGEOT||10t||20.00m||8.00m||Handling rebars and allied fabrication work||1|
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