Read how Gammon, one of the largest construction and infrastructure giants was able to reuse their existing ElectroMech cranes to build one of the longest flyovers in Pune.

Handling solutions from ElectroMech are undoubtedly the first choice of several leading infrastructure giants because of our domain expertise and the long-term reliability of our cranes.

Careful evaluation of existing cranes, systematic assessment of new requirements and perfect project planning in order to reuse existing ElectroMech cranes helped Gammon in saving substantial costs and reducing project implementation time.

background-logoBACKGROUND

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About Gammon India Ltd.

Gammon India is amongst the largest construction and infrastructure companies in India. It has created landmark structures right from the Gateway of India in 1911 to India’s longest river bridge at Patna. Gammon was awarded with a contract to build an 11.2 km, Kalewadi to Dehu-Alandi Bus Rapid Transit System (BRTS) corridor in Pune. The flyover near Empire Estate in Chinchwad, part of this project, is one of the longest flyovers in Pune with a total length of 1.9 km. The entire flyover has been constructed using precast segments.

challenge-logoCHALLENGES

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The handling challenges at the Empire Estate flyover project faced by Gammon

Since Gammon planned to construct this flyover using precast segments, they set up a casting yard at a nearby location in Chinchwad. For this project, handling requirements existed at two places. First, at the segment casting yard, and the other, at the actual site of the flyover, to lift and place the precast segments on the pillars. At both places, cranes were expected to handle heavy and bulky loads, while performing round the clock. It was essential to match the speed of production of precast segments and the construction of the flyover in order to meet the stipulated deadlines of the project. This requirement also obviously meant the synchronisation of handling capacities and speeds of cranes at both the locations. Gammon intended to check the possibility of reusing existing cranes which were used on its earlier projects, with the intention of reducing project cost and procurement time for new cranes.

solution-logoSolutions

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Solutions from ElectroMech

The ElectroMech project team together with the engineers from Cranedge – our service subsidiary - carefully studied the new requirements and analysed the condition of the existing cranes available with Gammon. After this elaborate exercise, we narrowed down the selection to 3 existing cranes which would be able to meet the new requirements with alterations and refurbishing. Two Gantry cranes were planned for the segment casting yard. They were to cover the entire casting yard process, which includes positioning the moulds for the manufacture of precast structures, pouring concrete into the prefabricated steel moulds and finally, placing the finished precast segments on the despatch trucks. The first crane was a 60/12MT, 19.5m span gantry crane with 15m height of lift. This was used to handle the heavy moulds and finished products. The second crane was a 15MT gantry crane with a 19.5m span and 12m height of lift. This was mainly used for handling the supporting structures during manufacture of precast structures. The third crane was planned at the construction site of the main flyover. This was a 60/12MT gantry crane with 28m span and 15m height of lift to be used to build the first phase of the flyover. The crane traversed along the length of the entire path of the flyover, lifting precast segments from the truck and placing them on the pillars. Precision positioning of the precast segments was made possible by using VFD drive controls that enable a high level of accuracy. This crane was also provided with a 12 MT auxiliary hoist which was used to install and dismantle all the supporting structures for the flyover as well as the concrete structures.

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ElectroMech Cranes - Cost-efficient solutions

For construction companies, it is the norm to write off the cost of their capital equipment such as cranes in a single project. This, of course directly affects the profitability of the project. Conversely, being able to reuse their cranes for another project offers a huge advantage in terms of profitability, a scenario that several of ElectroMech’s construction clients have been able to benefit from. ElectroMech cranes have proven themselves to be rugged, reliable and long-lasting. Several EPC companies use them over the years on a number of projects – one after the other. Admirably, we have reconfigured and modified ElectroMech cranes for several of our clients prior to shifting them to their new project site to ensure optimal performance. For this project too, Gammon reused ElectroMech cranes originally supplied to them 2009 for the construction of a bridge over the Godavari river. Through careful evaluation of the existing cranes and assessment of new requirements based on our previous experience on similar projects, we were able to help Gammon reuse these assets. This helped Gammon to substantially reduce project cost and turnaround time of the project.

Synopsis

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Construction companies typically write off the crane cost in a single project, affecting profitability. Companies that use ElectroMech cranes are able to reuse them across multiple projects, helping them boost profitability!

Challenges

  • Handling of heavy and bulky precast segments
  • Ensuring round the clock working
  • Designing a handling solution to synchronise speeds of production and construction
  • Reusing existing cranes to save project cost and time

Solutions

  • Heavy duty yet sleek cranes capable of lifting heavy loads
  • Carefully planned material handling system of 3 cranestwo at the segment casting yard and one at the construction site
  • Gantry cranes previously supplied to Gammon for the Godavari bridge project were used

Total number of cranes: 3

Sr No.SWLSpanHeight of liftApplication
160/12MT19.5m15mHandling of precast structures
215MT19.5m12mHandling of fabricated structures
360/12MT28m15mFlyover construction and support structures

Benefits

How Gammon benefited from ElectroMech solutions

  • Cost saving through reuse of previously supplied cranes
  • Considerable time saved in designing and procuring new cranes