EMPOWER :2014-15

Our contribution in building two of
India's latest landmark infrastructure projects

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Gammon, a leading infrastructure development player in India has often placed its trust in ElectroMech as its one-stop material handling solutions provider. ElectroMech has always contributed its best by getting involved with Gammon right from the initial project planning stages to help achieve the smoothest possible project execution. Designing a precise engineering solution, taking into consideration the complexities and challenges of respective projects has always been the key strength of ElectroMech, a fact proven by the number of ElectroMech cranes performing at the various milestone projects undertaken by Gammon and other infrastructure companies simultaneously across the world. Gammon is currently executing two gigantic and unique infrastructure projects, one in Patna and the other in the nation’s capital, Delhi. Both these projects will create a landmark in the respective cities through their distinctive design, apart from their functional role in enhancing the transportation network within the city. ElectroMech is proud to be associated with these projects.

A glimpse of the landmark projects

Signature Bridge, Delhi

Delhi Tourism & Transport Development Corporation Ltd. (DTTDC) has undertaken the construction of Signature Bridge in New Delhi which will connect Wazirabad to the inner city via a bridge across the Yamuna river. The project involves the construction of a 0.675km eight lane bridge, a water sports and recreational centre and a tourism park adjacent to Signature Bridge site.

The aim of the project is to reduce the traffic on the existing Wazirabad Bridge as well as market the location as a tourist destination. Once operational, this Signature Bridge will dramatically improve access between north and west Delhi. It is also expected to become one of Delhi’s key attractions, encouraging domestic and international tourism to the capital city of India.

Signature Bridge is an unsymmetrical cable-stayed bridge. The boomerang-shaped pylon consists of two inclined columns, which are rigidly connected to the driving lanes and bend mid-way. The height of the steel tower is approximately 150m. The upper portion of the pylon anchors the back-stay cables as well as the main span cables, arranged in a harp like manner. Graphics on the bridge structure are featured for the 'first-time' in the world. The pattern chosen reflects Indian culture and at the same time symbolises a modern and progressive India. The tip of the pylon is created by a 30m high steel and glass structure, which will be illuminated to create a landmark visible from afar at night.

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Ganga Path Project, Patna

This is one of the prestigious projects commissioned by Bihar State Road Development Corporation (BSRDC).

This project involves development of a 11.9km long 4 lane elevated road corridor between AIIMS and Digha in Patna. Once concluded, the road will provide much relief from the traffic congestion in the city, particularly on the narrow Ashok Rajpath as it will connect the Loknayak Ganga Path at Digha end. This project is undertaken for the construction of 2 lane semi-elevated and 4 lane elevated highway over Patna canal as approach road of rail-cum-road project across the Ganga at Digha.

It will have 2km of 2 lane semi-elevated and 9.90km of 4 lane elevated roads. This elevated road will have major crossings at Bailey Road and Ashok Rajpath and will have connectivity with important places like Danapur railway station, proposed Patliputra railway station and AIIMS. Besides, it will also have connectivity with the Loknayak Ganga Path and one railway bridge at Khagaul (Patna-Delhi) line.

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The project requirements

Gammon has been appointed as the construction contractor for Signature Bridge and Loknayak Ganga Path elevated road projects, which are being executed simultaneously. Both projects use precast segments to construct the bridges, hence heavy-duty gantry cranes are required for handling precast segments and girders. Being equally prestigious, critical and time-bound projects, Gammon was looking for a competent and reliable crane solution provider. Considering the solutions capability and reliable performance of ElectroMech cranes for various other challenging projects executed by Gammon, they selected ElectroMech as a partner for these prestigious projects too.

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The project requirements

Gammon has been appointed as the construction contractor for Signature Bridge and Loknayak Ganga Path elevated road projects, which are being executed simultaneously. Both projects use precast segments to construct the bridges, hence heavy-duty gantry cranes are required for handling precast segments and girders. Being equally prestigious, critical and time-bound projects, Gammon was looking for a competent and reliable crane solution provider. Considering the solutions capability and reliable performance of ElectroMech cranes for various other challenging projects executed by Gammon, they selected ElectroMech as a partner for these prestigious projects too.

Mr. U. M. Kulkarni, GM - Projects

Loknayak Ganga Path - Patna, Gammon India Ltd.

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The solutions offered by team ElectroMech

The material handling requirement for such infrastructure projects is always challenging considering the vastness of the project and the site conditions themselves. After thoroughly evaluating all the requirements individually, the ElectroMech team suggested a 60MT double girder gantry crane with 40m span and 12m height of lift for the Signature Bridge project in Delhi. For the Patna project, 2 double girder gantry cranes of 60MT capacity with an auxiliary hoist of 6MT, spanning 33.5m and 25m height of lift were recommended.

Considering the rigorous outdoor use in extreme climatic conditions, very high quality components are used for the construction of these gantry cranes. These cranes have a unique castellated girder type design, which offers numerous benefits including:

  1. Reduction in the structural weight helps in lowering the wheel loads up to 30%
  2. Approximately 20% reduction in wind loads due to reduced surface area of main girders.
  3. Low wind load improves stability of the structure for working against wind.

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We have installed 60MT ElectroMech double girder gantry crane for our Signature Bridge project. This crane has special castellated girder type design which enables us to carry out the erection work at heights easily. This feature helps to reduce the wind force at the height during girder installations over the Yamuna river bed. This crane is very stable and firmly executes its operations. The other advantage is that it operates on DG set which has helped us to reduce the cost for cables considerably with the increase in the length of the project. I would like to appreciate ElectroMech for their excellent crane commissioning, and last but not the least, this crane has contributed a lot in the swift execution of the project and hopefully other sites will also get benefitted by this type of crane".

Mr. Lovelesh Seth, Project Engineer

Signature Bridge - Delhi, Gammon India Ltd.

Gammon benefits from ElectroMech’s modular design

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 proved 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, ElectroMech has reconfigured and modified its cranes for several of our clients prior to shifting them to their new project site to ensure optimal performance and ensure economics.

For this project too, this factor was taken into account at the design stage itself. Once the cranes have completed their duty at their respective projects, they can be easily used at other projects by changing their span or height of lift as required. In fact, at the Loknayak Ganga Path site, the site conditions necessitated different configurations of crane heights, a condition that could have warranted the use of different cranes depending on their location within the site. ElectroMech’s team of engineers came up with an ingenious solution that allowed Gammon to use the same crane to construct the complete flyover in two different configurations as well as facilitate easy modification to suit the requirement at future projects.

Three different spans in a single crane

After careful consideration of the typical projects undertaken by Gammon, the cranes were designed to allow fixing the legs and cabin at any of three different locations. With this arrangement, the crane span can be adjusted to 19.4m or 28m or 33.5m for the Loknayak Ganga Path project crane. While in the Signature Bridge project crane, the span options available are 19.4m, 28m and 40m. This arrangement will allow the crane to be configured to suit almost any future project that Gammon executes, in minimal time.

Flexibility to work at different heights

At the Loknayak Ganga Path site, Gammon had a limitation with the working height at one end of the bay due to a high tension electricity line. We offered a solution to this situation by designing height adjustable crane legs. The crane legs are designed to operate at two different height of lifts. Initially the legs are assembled for a lift height of 18m and later the leg extension sections can be added to assemble the crane for 25m lift height in order to carry out construction in the area post clearance of the electricity line.

Maximum coverage in spite of site constraints

Every project demands optimum solutions to suit the site requirements, which govern the design of any material handling equipment. At the Loknayak Ganga Path site, a canal on the side of the bridge site posed a constraint for the installation of the gantry crane. This meant that the crane legs would have to be very close to the edges of the bridge segments, leaving very little margin for error. The design was optimised for minimal hook approaches to ensure maximum coverage of the clear span between the gantry legs.

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