1
2
ujarat was a part of the erstwhile Bombay
state during the British rule and also for more
than a decade after India attained freedom.
In 1960, owing to popular demand from the Gujaratispeaking population the state was split into two
new states - Gujarat and Maharashtra - effective
May 1, 1960.
In the initial days the economy of Gujarat was
dependent largely on agriculture and there was not
much industrial activity to speak of. However, the
state’s policy planners brought about a balance
and set in motion the process of industrialisation.
As a result many industries came up in and around
Ahmedabad, Vadodara, Surat and Rajkot, mostly
related to textiles and its auxiliaries.
Today the industrial base of Gujarat is not only well
diversified, but fairly uniformly spread across the
State. Thanks largely to the pragmatic policies of
successive governments and the enterprising
nature of its people, Gujarat has now a significant
presence in the manufacturing sector in the
country. Gujarat is one of the most prosperous
states of India and is the largest producer of milk
(18.97 million litres per day) in India with Amul at
Anand being one of the largest milk producer cooperatives in the world. The state produces more
Jamnagar-Loni Pipeline Project
than 6 lakh tons of marine products per annum and
its major agricultural produce include cotton,
peanuts, dates, sugarcane, milk & milk products.
Industrial products include textiles, cement, and
petrol. With 4,122 million kg production of raw
cotton and 1,023 million kg of man-made fibres,
Gujarat is the leader in textiles as well and
accounts for 20 percent of textile exports from India.
Industry
Between the 60’s and 90’s, Gujarat established
itself as a leader in a variety of sectors engineering, chemicals, petrochemicals. drugs &
pharmaceuticals. dairy, cement and ceramics,
gems & jewellery, apart from textiles. Postliberalization(1994 -2002), the state’s Domestic
Laying of water supply pipeline
LPG Terminal, Dahej
Ahmedabad-Mehsana road
3
and only land-based drilling platform, in the Hazira
gas field in 1998, which produces 3.6 million metric
standard cubic metres per day (MMSCMD) of gas.
GSPC has 21 fields or blocks in the country at
present while its gas transportation subsidiary,
Gujarat State Petronet Ltd (GSPL), is developing a
gas grid across the State to supply gas to various
industrial clusters and individual customers.
Transportation Infrastructure
The state offers an excellent road and rail network,
leading to wide spread urbanization. The total length
of roads (excluding municipality roads) in the State
exceeds 74000 km. Out of this the length of surfaced
roads account for 70688 km (95.48 per cent) while
National Highways and State Highways have a
share of 2362 km and 19180 km respectively.
Treated effluent disposal pipeline, Dahej
Product rose at an average rate of 12.4% per
annum in real terms.
Gujarat is the largest producer of salt and soda ash
in the country. Surat in Gujarat is home to a thriving
diamond trade and diamond cutting industry. Alang
Ship Recyling Yard, located 50 km southeast of
Bhavnagar, on the Gulf of Khambhat, is the world’s
largest ship breaking yard. Reliance Petroleum
Limited has set up the world’s largest grassroots
refinery at Jamnagar.
Oil & Gas
Gujarat is considered the oil & gas capital of India
with 54% share in onshore crude production and
39% share in onshore natural gas. Chemicals and
petrochemicals have been the mainstay of industrial
development and account for 60.3% of the state’s
total industrial production. It is one of the fastest
growing sectors in the state’s economy.
sector. While Indian Oil Corporation (IOC) and
Reliance have established massive refineries at
Vadodara (5 MTPA) and Jamnagar (33 MTPA)
respectively, Essar Oil is setting up a 12.5 MTPA
refinery at Jamnagar. The Oil and Natural Gas
Corporation (ONGC) has also a large exploration
presence in the State.
The State government-owned Gujarat State
Petroleum Corporation (GSPC) has grown from
humble beginnings to an emerging petroleum sector
giant in just six years. Buoyed by the opening up of
the oil exploration sector, GSPC has been highly
successful in its efforts to strike oil and gas. To
GSPC goes the credit for constructing India’s one
There are eleven airports in Gujarat, the highest in
India, including an international airport at
Ahmedabad. Gujarat is endowed with a third of the
total coastline of India - 1,600 km - and has ports
and port-related facilities. Some of the best
maritime locations in the country are located in the
Gulf of Kutch and Khambhat. Gujarat boasts 41
ports, the highest number for any State, which
handle more than 20 per cent of India’s cargo. The
installed port infrastructure in the country stands
at 140 million metric tonnes per annum (MMTPA)
and the total cargo handled in 2004 was 90 MMTPA.
Adani Port Limited, Mundra (situated just 40 km from
Kandla Port) is a joint venture between the Adani
Group and the Gujarat government. This private
sector port is a star performer among efficiently
With several new oil & gas exploration ventures, a
gas grid and two brand new liquefied natural gas
(LNG) terminals in addition to the two terminals
already existing at Hazira and Dahej, Gujarat pitches
itself as the petroleum hub of India. Several public
sector companies and private companies too have
announced a slew of huge investments in the
Cement loading Jetty, Rajula
Precast conveyors, RPL Jamnagar
Gas sweetening unit, ONGC Hazira
Ethylene pipelines, RPL Hazira
4
managed ports that can respond quickly to market
requirements and offer the best deal to customers.
When it comes to special economic zones in India,
Gujarat again leads the way. The SEZ s provide an
internationally competitive environment for exports
and encouraging investment for generation of
economic activity, employment and technical
knowledge. The state has received proposals for
setting up 19 SEZs with a combined investment of
over US$ 1 billion.
Pharmaceuticals
Pharmaceuticals is another segment of industry
where too Gujarat is a leader, accounting for 55%
of the total Indian pharmaceutical production and
23% of the country’s exports. Large pharma
companies like Alembic, Torrent, Zydus, Cadilla,
Claris Lifesciences, Sun Pharma, etc. not only have
their production units in the State, but also carry
out extensive R&D work. Gujarat’s biotech industry
has evolved because of a convergence of the
traditional industries thriving in the State.
Tourism
Of late, Gujarat has been pitching itself as not just
an industrial hub, but also as an attractive tourist
destination. The State is situated between the two
golden triangles of Delhi-Agra-Rajasthan and
Mumbai-Goa-Aurangabad. It boasts a host of
ancient archeological sites, historic architecture,
natural history, religious places, wildlife sanctuaries
Piping on racks, ONGC Hazira
and handicrafts centres. While prohibition seems
to be a deterrent to the growth of tourism in the
State, it continues to attract a large number of
religious tourists to the ancient temples of Dwaraka
and Somnath and wildlife/animal lovers to the Gir
National Park (the only habitation of the Asiatic
lion), the Porbandar-Dwaraka coast (where whale
sharks abound), sloth bear and wild ass sanctuaries,
and several lakes that play host to a large number
of species of migratory birds.
IT & ITES Industry
It is a boom time for IT & ITES Industry in Gujarat,
which has grown at CAGR of 28% during the last
five years. Software exports registered a growth
of 47% CAGR during the same period. The
Gandhinagar-Ahmedabad Knowledge Corridor and
Vadodara are poised to become major IT
destinations with big developers setting up IT Parks.
L&T Technology Park, Baroda
L&T will be setting up a new facility - L&T Technology
Park - at Baroda in a sprawling 112-acre area on
the Ahmedabad-Mumbai Highway that will entail
an investment of Rs.500 cr. in infrastructure and
buildings over a five-year period. When fully
functional, the facility is expected to have around
6,000 employees and will create indirect
employment to a large section of local populace.
Business-friendly environment and the incentives
provided to entrepreneurs are accelerating the pace
of industrialization in Gujarat that has become a
truly vibrant state and is setting a benchmark for
other states to follow.
LNG Terminal for Shell, Hazira
MEG Plant, RPL Hazira
RPL Jetty, Hazira
Gujarat Narmada water supply project
5
Region
oreseeing rapid industrial development in
Gujarat and the Government’s strategic
investment initiatives, ECC opened a Regional
Office in Ahmedabad in 1996 to coordinate the entire
spectrum of its construction activities in Gujarat.
In course of time, the state of Rajasthan also was
brought under the jurisdiction of Ahmedabad Region.
Mr. S.C. Vakil was the first Regional Manager of
Ahmedabad Region and was succeeded by Messrs.
M.A. Radhakrishnan, P. Dasgupta and Mr. Arabinda
Guha. Currently, the Region is headed by R.
Chandrasekharan (RCS).
ECC has been playing an active role in the industrial
and infrastructure development of Gujarat and
Rajasthan and today, it is in a commanding position
with a sales turnover of Rs.1,168 cr. for the year
ended March 31, 2006. The Region is likely to
achieve an order booking of Rs.2,300 crore for
year 2006-07. Speaking to ECC Concord at his
office on the banks of river Sabarmati in Ahmedabad,
RCS said that with a healthy order backlog, his
Mr. R. Chandrasekharan, Regional Manager, Ahmedabad
hands are full with multifarious activities and
challenging assignments. “Geographically, my
operations stretch beyond Gujarat and extends as
far as Jaisalmer in Rajasthan. A lot needs to be
done to fine-tune the systems and keep the wheels
of the region moving smoothly and dynamically.”
With the nation poised for a giant economic leap
and firmly set on the path to becoming a major
world power, RCS is confident that Ahmedabad
Region would contribute significantly to the country’s
all-round development. With a staff strength of 93
in the Regional Office, depot and around 850 across
various sites, Ahmedabad Region is executing
several major projects. The three road packages
secured recently would do well and set a new
benchmark in the transportation infrastructure.
ECC has done exceedingly well in some prestigious
projects like the G.K. General Hospital in Bhuj,
Sujalam Sufalam water supply, treated effluent
disposal works at Vilayat and Dahej for GIDC in
the Gulf of Khambhat (the world’s second worst
rough tidal zone). In Rajasthan too, we continue to
have a strong presence with clients like Hindustan
Zinc Limited giving us repeat orders. All these
have helped enhance the reputation of L&T among
government as well as private clients including the
general public.
At the time of the 2001 earthquake disaster as well
as during the severe floods of 2006 L&T, as a
responsible corporate citizen, readily came forward
and joined the Gujarat State Government in providing
succour to the affected people. The Region has
done exemplary work in earthquake
reconstruction at Bhuj and flood relief operations
in Surat, and lent a helping hand in propagating
the Swasthya Varta programme through distribution
of educational material and donation of medical
equipment.
Mr. Chandrasekharan acknowledged the
contribution of his predecessors and thanked them
Sanghi Cements Gujarat
Gas sweetening unit, ONGC Hazira
A bulk material handling plant
Precasting yard for Gujarat schools
6
for laying a firm foundation for ECC’s operations in
the region and and building up a very good rapport
and cordial relations with all customers. He also
thanked his colleagues in the Region and said, “I
look forward to keeping the L&T flag flying high in
Ahmedabad Region and taking the organization to
greater heights in line with Project Lakshya.”
Panorama of projects
ECC has made significant contribution to the industrial
development of Gujarat and Rajasthan and has
executed many major projects for the core sector
industries as well as private entrepreneurs. Some
of the projects that ECC has executed in Gujarat
include:
Fertilizers
IFFCO-Kandla; Gujarat State Fertilizer CorporationBaroda; KRIBHCO-Hazira; and Gujarat Narmada
Valley Fertilizer Company Limited at Narmadanagar
in Bharuch.
Oil & Gas
Gujarat Refinery’s expansion project at Koyali,
IOC’s Salaya-Viramgam-Rajkot-Koyali crosscountry pipeline involving erection of equipment,
fabrication and erec-tion of piping and tank farms,
includ-ing electrical installation and instru-mentation
works; turnkey construction of the gas sweetening
pro-ject (Phase II) at Hazira for ONGC; Kandla–
Bhatinda Pipleline; ONGC-Gandhar, Jamnagar-Loni
gas pipeline for GAIL; IOCL terminal at Gulf of
Kutch; Tapti offshore oil basin works for Enron Oil
and Gas India; Essar oil refinery at Vadinar; LPG
import terminal at Pipavav for Bharat Shell Limted;
ESSAR Sponge iron plant, Hazira
220 kV switchyard at Mehsana for ONGC; IOC’s
Gujarat Refinery at Baroda; Vadinar–Kandla
pipeline for Petronet/IOC; LNG terminal for Shell
International, UK; Sidhpur- Sanganer pipeline and
the world’s largest grassroot refinery for Reliance
Petroleum at Jamnagar.
Petrochemicals
Gujarat Olefins project of Indian Petrochemicals
Limited, Baroda - erection of equipment, machinery,
piping and steel structure, site assembly of columns
and Horton spheres; erection of equipment and
piping for the LDPE plant as well as electrical
installation for the integrated off-site project and
acrylate plant expansion project of IPCL, Baroda;
petrochemical project (phase I & II) for Reliance at
Hazira.
Power
Toll plaza at Second
Narmada bridge, Zadeshwar
Power plants for Gujarat State Electricity Board at
Ukai, Dhuvaran, Gandhinagar, including
transmission line tower works between Kawas and
Valthan; erection of 35m long, 530 t heavy isotopic
exchange towers for the Heavy Water Project at
Baroda; lignite based power plant at Surat for
Gujarat Industrial Power Corporation Limited;
power plant for Tata Chemicals Limited at
Mithapur; combined cycle power plant of GACL,
Dahej.
Metallurgical
Civil, mechanical, electrical installation and
instrumentation works for Essar’s sponge iron
plant at Hazira including dismantling of the plant
at Emden (Germany), shipping to India and
installation and commissioning at Hazira; copper
smelter and air separation plant at Dahej for
Birla Copper.
Industrial Projects
Mother Dairy Gandhinagar; cement plant of
Cement Corporation of Gujarat Limited; L&T
Cement at Rajula (now Ultratech Cement); Sanghi
Cements in the Rann of Kutch; nylon tyre cord
plant at Udhana near Surat for Baroda Rayon
Corporation Limited; float glass factory of Gujarat
Guardian at Ankleshwar; the heavy engineering
workshop of L&T at Hazira; Nirma linear alkyl
benzene plant in Baroda; copper smelter cable
processing shed of Standard Wire Industries
Limited; and the R&D center for Torrent
Pharmaceuticals at Gandhinagar.
Transportation
The Second Narmada bridge at Zadeshwar near
Bharuch; the Watrak bridge near Kheda village;
Ahmedabad-Mehsana Toll Road, JaipurKishangarh Road Project and Rajkot-Jamnagar
contd. on Page 10.......
Jaipur-Kishangarh Expressway
A precast school building
Adani port
7
They said it...
Resources can be bought but not talent - S.C. Vakil
When the management felt the need to have
a Regional Office in Ahmedabad in 1996, I
was appointed the Regional Manager to look
after ECC’s interests in the new-born
region. However, I could not hold the
position for long as I was posted to RPLJamnagar as Task Force Leader in April
1997. This was then ECC’s single biggest
assignment in terms of scope of work and
contract value.
To begin with, the Regional Office started
functioning from L&T-Baroda and later
relocated to Ahmedabad (Karakka
Building), closer to Gandhinagar, the capital
of Gujarat.
However, foreseeing a bright future and
high growth prospects and considering the
need to have a permanent establishment
we moved to Sakar II on Ashram Road
where we rented the entire second floor.
Not much later, we purchased the 9 th and
10 th floors in the same building, from where
we are operating our Regional Office, even
now.
Being centrally located, along the banks of
the river Sabarmati, the Regional Office at
Sakar-II offers a congenial atmosphere for
our staff. At the same time, a plot of land
was identified and purchased at
Chacharwadi for establishing a depot to
carry out all warehouse operations.
It is a matter of pride for me that during
the very first year of our setting up ABRO,
we managed to secure some prestigious
orders such as the multipurpose jetties at
Mundra for Adani Port Limited, Cement
Plant structures for Sanghi Cements,
Copper smelter for Birla Copper at Dahej,
factory buildings for SWIL-Jagadia and
Nirma Chemicals including the second
Mrs. & Mr. S. C. Vakil
Narmada bridge project executed on EPC
basis.
Focus on Gujarat
Gujarat was and continues to be the best
place to do business in view of a very
favourable investment climate that the state
provides and the high rate of GDP.
Investments have been pouring in from
within the country and abroad, strengthening
the state’s economy and creating more
employment opportunities.
In addition, it has a well-developed infrastructure
and many other locational advantages for setting
up new businesses. Hence it makes sense for
L&T to focus our efforts on Gujarat and create a
new region to expand our activities.
People
L&T has a large pool of talented,
experienced and motivated professionals,
who are its real strength in the current
competitive scenario. Only very few
organizations offer the type of freedom and
the culture of caring that L&T-ites enjoy.
Even though the attrition rate is somewhat
high today, I personally feel that resources
can be bought but not talents.
I have a special attachment to L&T and I
consider it one of the best companies to
work for. I would also urge people not to
leave L&T for pecuniary benefits but to
serve the company on a long term basis for
one’s own benefit and of the company as
well.
GSFC, Baroda
Warehouses at RPL Hazira
Ethylene storage tanks, RPL, Hazira
8
Even after retirement, people respect me
because I am an L&T-ite - M.A. Radhakrishnan
Voice of our Clients
Hindustan Zinc Limited
A
ccording to me, L&T is a highly
professional and result oriented
organization.
L&T is involved in the construction of HZL’s
Phase-I & II projects in Rajasthan and
completed the phase-I project ahead of
schedule, creating a world record in project
execution. L&T’s excellent micro-planning,
automated construction techniques coupled
with extremely good engineering made HZL
create this new benchmark apart from
implementing several cost effective solutions.
L&T employees are a dedicated team of
excellent professionals. It has the capability to
build large and complex infrastructure projects
with desired quality within the budgeted cost
and time.
Jeyakumar Janakraj
Senior Vice President
HZL, Chanderiya Complex
Mr. R. Chandrasekharan, Regional Manager, Ahmedabad (right) greeting
Mr. M. A. Radhakrishnan (left), former Regional Manager
I was inducted as Regional Manager from April1996 till I was moved to my next assignment in
April-2002. During my tenure, the region executed
prestigious orders like multipurpose jetties at
Mundra for Adani Ports, Jetty for Essar, Second
Narmada bridge, Ahmedabad-Mehsana road
project, Rajkot-Jamnagar Road project, Watrak
bridge, IOCL Baroda etc. Project wise, I would
say that IOCL Baroda was the best assignment I
executed during my tenure in the region. Similarly
I feel that Adani Ports Limited and IOCL are very
good clients and I enjoyed a lot working with them.
From business perspective, Gujarat is the best
place, as plenty of investment opportunities and
infrastructure development projects are coming
up at a rapid pace. This means that L&T also will
have ample growth opportunities and it will have a
fair share in project execution.
Whatever said and done, L&T is a wonderful
organization to work with. I loved working in L&T.
I like L&T culture very much. L&T People are
well mannered and they have a professional
approach in dealing with things. The Company as
a whole follows the guiding principles and values
set forth by our founders Larsen and Toubro.
Infact those employees who left L&T, regretted
their decision later on. Nevertheless, many people
are leaving L&T for money, just for money. But I
can assure that in L&T, one can have satisfied
life, good approach, good technology, nice people
and chances of quick growth. L&T has a high
value and brand image, this is evident from the
fact that even after my retirement, people are
giving me lot of respect, because I am an L&Tite.
Young engineers should work hard and gain hands
on experience at site during the initial learning
years and this is the only way they can gain
respect in future.
Adani Port, Mundra
Adani port
I
find L&T to be a very systematic, organized
company, dedicated to the project on hand.
In safety compliance their systems are excellent,
with an appreciable stress on creating safety
awareness through training programmes.
Once a project is entrusted to L&T, the client
can rest assured of timely completion as well
as good quality and safety standards. The
employees are well mannered, technically sound
and hardworking.
Debasis Mitra, Vice President (Marine)
Mundra Port & SEZ, Ahmedabad
I
Sujalam - Sufalam
have been associated with L&T in
Hathmati Guhai pipeline and Sujalam
Sufalam water supply projects, where progress
and workmanship are excellent. Apart from
achieving the desired milestone L&T pays
utmost attention to safety and quality during
project execution.
At Sujalam Sufalam water supply project,
L&T has been awarded 3 different packages
and this has considerably reduced our time
and efforts in co-ordination and monitoring
of the project. L&T employees are a
dedicated team and they are very courteous in
dealing with every customer.
R. G. Chandvani
Superintending Engineer, GWSSB
Hindustan Zinc Plant in Chittorgarh
9
....... contd. from Page 7
Road Project; several jetties for importing
cryogenic liquids for various clients and the
multipurpose jetty at Adani Port and the
breakwater project for Shell at Hazira.
Water & Effluent Disposal
Sardar Sarovar canal-based Drinking Water Supply
project in Amreli and Gandhinagar Districts including
the Sidhpur & Sami Harij Regional Water Supply
Schemes; sewerage network for Surat Municipal
Corporation; sea water intake and effluents disposal
system for Gujarat Mineral Development
Corporation in Kutch; conveying the treated effluents
from Dahej and Vilayat industries and disposing
them into the sea (Gulf of Khambat). The lastmentioned Dahej-Vilayat has the longest disposal
pipeline in the country.
Critical Support
ECC has always risen to the occasion to assist the
government in times of crisis like earthquake, floods,
etc. 600 prefabricated schools were built by ECC
in different parts of the state when it was shaken
by the devastating earthquake. It re-built the
Trestle piping for LNG terminal, Dahej
government hospital at Bhuj and restored the
heritage building of Alfred High School in Bhuj and
worked closely with the Surat Municipality during the
floods of August 2006 to clear tons of slush and debris.
Rajasthan
Amongst many major projects executed by
L&T in the state of Rajasthan, following are
shining examples of some high quality
projects:
♦ Zinc smelter (Phase-I) at Chittorgarh in
Rajasthan for Hindustan Zinc Limited
♦ Six-lane road between Jaipur and Kishangarh
on NH-8
♦ BPO building for GE Capital at Jaipur
♦ 220/33 kV switchyard and 220 kV transmission
line for Enercon at Jaisalmer
Projects under execution
Currently the following projects are under
execution:
♦ Vadodara-Bharuch Road Project on BOT basis
♦ Palanpur-Swaroopganj Road Project on
Annuity basis
♦ Jetty expansion for GAPL at Mundra
♦ Mora-Vapi Pipe Line Project for GSPL
♦ Anand-Rajkot Pipe Line Project for GSPL
♦ 400 KV transmission line from Ratangarh to
Merta
♦ NCD5 Water Supply scheme for GWSSB
♦ RJ11 road project in Kota, Rajasthan
♦ Zinc Smelter Plant (Phase-II) for Hindustan
Zinc at Chittorgarh, Rajasthan
♦ Bisalpur-Jaipur water supply project in
Rajasthan
♦ APDRP Projects in Rajasthan
K.Sridharan
CCD, ECC-HQ
Petrochemical plant for RPL Hazira
Mother Dairy, Gandhinagar
Pipe laying for Anand Rajkot gas line
RPL Jamnagar
10
Project
Kohinoor 2010
ohinoor 2010 is an operational excellence
program initiated in June 2005 with the
objective of achieving a ROCE of 20%
and PBIT of 10% in ECC’s operations. The
scope of the Project was defined as Delivering
Operational Excellence in three focus areas
(work streams) – Project Management,
Procurement and Assets, Subcontracting &
Working Capital Management. After seven
months of detailed analysis, interviews, site
visits, Idea Generation workshops and pilots
by the project team, a number of solution
themes emerged across the three work
streams.
In February 2006 ECC embarked on the
implementation phase of Kohinoor 2010
spanning 30 pilot projects across the seven
regions.
The two pilot projects identified in the
Ahmedabad Region were the Vadodara-
Bharuch Road Project (R & R Business Unit)
and the Jaipur-Bisalpur Water Supply Project
(WET Business Unit). The approach of Kohinoor
2010 in each region was to focus on the
implementation of the Project Management
solution themes in the selected pilot projects,
while solution themes of the other two work
streams (Procurement & Assets,
Subcontracting & Working Capital
Management) were to be implemented across
all applicable projects.
Significant progress has been made in
Subcontracting & Working Capital Management
solution themes in the Ahmedabad Region
through use of standardized cost sheets to
conduct fact-based negotiations. This theme
has been implemented for key subcontract
items at the RJ 11 project and the VadodaraBharuch Road Project. Further, an interactive
cost sheet workshop was conducted by the
Kohinoor team on July 19, 2006 to share
learnings from cost sheet based negotiation
and extend use of cost sheets across
Business Units in the Region. Another solution
theme where good progress has been made
is use of furnace oil for heating bitumen in hot
mix plants. This initiative is being implemented
at all the three road projects in the Region
(RJ 11, Vadodara-Bharuch and SwarupganjPalanpur). Aggregate re-use, the process of
recovering aggregate from existing pavement
and using this in the production of fresh
asphalt pavement, is another high impact
initiative, and implementation of the same is
being led by the Vadodara-Bharuch Road
Project team.
In the Procurement work stream, key
initiatives taken up for implementation in the
Ahmedabad Region are use of high strength
steel bars (Fe 415 to Fe 500) and use of rebar couplers for mechanical splicing. These
initiatives are currently under implementation
at the Vadodara-Bharuch and the SwarupganjPalanpur road projects.
Another procurement initiative being rolled out
across the Region is use of fuel additives to
reduce the fuel consumption of key assets
(like DG sets, pavers, motor graders, cranes,
etc.). Other key initiatives that the Kohinoor
team is currently working on are global
sourcing of HR coils for the Jaipur-Bisalpur
Water Supply Project and global sourcing of
bitumen for the Vadodara-Bharuch and the
Swarupganj-Palanpur road Projects.
The key project management solution themes
being implemented in the Vadodara- Bharuch
Road Project are Execution Risk Management,
Cross Functional Kickoff, Quantity Estimation
& Survey and Execution Look-ahead Planning.
Another key Project Management initiative
taken up for implementation at the SwarupganjPalanpur Road Project is Wastage–Norms &
Reduction for Diesel through the development
of a robust diesel control tool.
Rs. 471 crore cheque being presented by Mr. Chandrashekhar Damle and Mr. Awadh Vashista (second and third from right)
to Prime Minister Dr. Manmohan Singh and Mr. T.R. Baalu, Union Minister for shipping, Road Transport and Highways in
connection with Vadodara Bharuch Tollway Project, negative grant
11
Health Safety
and Environment
afety is of paramount importance to the
construction industry as it employs a cross
section of workforce for different activities.
A safe work zone with proper systems and
procedure ensures a conducive atmosphere.
Keeping the basic aim of “Zero Accident”, Safety
Engineering Dept. was established in 1996 in
Ahmedabad Region under the leadership of Mr.
R. N. Tripathi (RSC), with the guidance of Mr. S.
C. Vakil (RM) and Mr. R. K. Poddar (Head – SED
at HQ). Over the last ten years, the department
has spread its wings towards Health &
Environment aspects and is now renamed as
Health Safety and Environment Department (HSE).
Mr. A. K. Das, Regional Health Safety &
Environment Manager is ably assisted by 27
Safety professionals to meet the HSE challenges
in the region.
Challenges
Most of the projects executed in Ahmedabad
region are cross-country in nature like water &
gas pipelines, roads, sewerage lines,
transmission line and APDRP. As the work
progress through rural areas, the workmen are
prone to biological hazards (attack by animals,
weather condition, local problems etc.). Since
activities are of temporary nature and change of
work place happens more frequently, meeting
HSE requirements in different areas is a very
tough exercise and requires more involvement
for controlling and monitoring the workforce.
Imparting safety education to the illiterate and
unskilled workmen (having agricultural
background only) drawn from different villages
of Rajasthan and Gujurat is a challenging and
arduous task. In addition to this is facilitating the
necessary resources and safety materials to the
working gang deployed at remote locations where
the major constraints are transportation and
communication. Coming under the belt of adverse
climate with extreme summer and winter,
implementation of safety aspects during these
seasons becomes more difficult.
The challenges in managing safety were taken
up with the sprit by dedicated team members
and handled carefully. This has resulted in
achieving several accident free man-hours at
Safety programme for workmen at L&T Hazira
different project sites and convinced the clients about
L&T’s high safety standards and priorities. Safety as a
way of life is imbibed among all staff at ABRO and this
has ensured the region to establish a safe working
culture and achieve targets on time.
Awards
“Safety Pays Dividend” – Listed are some of the
safety awards - Inter regional and national, bagged by
ABRO.
♦ American Society of Concrete Contractors
awarded ABRO the safety award twice during
2001 and 2002 for safe practices
♦ ABRO was adjudged as the safest region for
successive years from 1999 to 2004
♦ Ahmedabad - Mehsana Road Project was
adjudged as the safest major job site for the
year 2001-2002
Safest medium jobsite trophy
GCP – Rajula – 1998-99
JLPL – Spr. II – 1999-2000
Watrak Bridge – 2000-2001
Petronet LNG Terminal, Dahej – 2003-2004
Safest minor Jobsite Trophy
APL, Mundra – 1999-2000
CII, Bhachau – 2002-03
Good HSE practices followed
♦ Integration of HSE system and requirement in
work methodology
♦ Job Safety Analysis (JSA)/Group Risk Analysis
(GRA) for all the critical activities.
♦ HSE Induction for new staff at RO before
posting at site
♦ Workmen screening and HSE Induction at job
sites
♦ HSE Training for all levels is ensured
♦ Safety gang leader concept has been
implemented for better monitoring of HSE
aspects
♦ Regular safety inspection by SPM/RPM/
RHSEM at site
♦ Evaluation of HSE aspects by visiting officials.
♦ Weekly balance points are escalated to RO if
not implemented at site
♦ Implementation of “scaff-tag” system for
system formwork at site
♦ Display of HSE rules at the entrance for visitors
♦ Conducting regular health camp in labour colony
♦ Conducting road safety awareness program
at villages and schools during the execution of
road projects
♦ Use of mobile scaffolding for internal finishing
work of building jobs
♦ Inspection and certification of power driven
and heavy equipments before using in
construction activities
♦ Display of work permit and safety precautions
to be taken in the work area
♦ Automated housekeeping in all major building
sites
A.K. Das
Regional Health Safety &
Environment Mangager
In addition to implanting the regular system (ISO –
9001 for HSE system) these following systems have
been implemented at all sites in the Region.
12
Construction Skills
Training Institute (CSTI)
Ahmedabad
onstruction Skills Training Institute,
Ahmedabad, is located in the Main Depot
premises of ABRO at Chacharwadi, 25 km
away from the Regional Office. It commenced
functioning from October 15, 2005.
Strategic Objectives
♦ To have trained workforce in our job sites to
meet the growing requirement of skilled
workmen
♦ To test, ascertain the skill levels and certify
♦ To fill perceptible gaps through appropriate
training
♦ To enhance safety, quality and productivity
♦ To develop Frontline Supervisors (Foremen and
Chargehands)
The Set-up
CSTI campus consists of three blocks in an area of
2.8 acres. The Academic Block (size 21m x 6m)
has two class rooms, one library and a store room
while the Administrative Block (size 15m x 6m) has
a display room and a staff room with utilities. The
Hostel Block (size 33m x 9m) accommodates 60
workmen and has a kitchen, dining room and toilet
block.
Trainees learning column shutter alignment
Training facility
Deployment
Practice Yard (size 65m x 65 m) covers 4,225 Sqm
area and has mock-ups for various trades.
CSTI-trained workmen were deployed at various
sites
♦ Sanskardham, Gandhinagar
♦ RJ 11, Samrania
♦ Hindustan Zinc, Chittorgarh
♦ RPL, Jamnagar
♦ HEW Heavy Fabrication Shop, Hazira
At present, basic training is imparted in the following
trades:
♦ Formwork Carpentry
♦ Bar Bending and Steel Fixing
♦ Scaffolding
Candidates for individual trades are selected through
a process of entrance test (written and practical)
and viva-voce.
Training is being imparted in languages like Gujarati,
Hindi, Bengali and Oriya, in addition to English.
Other trades like electrical wiremen, masonry,
plumbing and sanitary, hot mix plant operator,
grader operator, assistant carpenter, assistant bar
bender will be added in the near future.
Site-based Training:
As part of overall training in all areas and to facilitate
implementation of proper work procedures and
systems to achieve high quality products in all
operational areas, newly inducted staff as well as
subcontract-workers undergo site based training.
They get the desired exposure to working methods
with a special emphasis on safety and quality.
Workers are recruited from villages in the vicinity
of CSTI-Chacharwadi as also other parts of Gujarat
and Dungarpur, Kota districts of Rajasthan. People
from UP, Bihar and Bengal also have started
attending the training programmes in search of
future gainful employment. Subsequent to the
training, these workmen are deployed at our
project sites.
L&T is conscious of its larger social obligations and
is committed to the upgradation of common man.
Towards meeting this end, CSTI plays a major role
in providing training to the unskilled and less
experienced people to enhance their competency
and improve their quality of life. This helps the
construction industry as well in getting a highly
competent and capable workforce.
In its activities CSTI interfaces with the academia
and construction industry.
Trainees working at wood planer machine
S.R. Shah
CSTI, Ahmedabad
13
Surat Flood
Relief Operations
A Mammoth Risk
Management Project
urat faced one of its worst floods ever during
the first fortnight of August 2006, leaving
the city completely inundated. The floods
left their mark on the city with deposits of acute
slush all over apart from damage to materials
(including food grains), heavy loss of cattle and
other domestic animals, causing untold misery
to the citizens.
When the deluge hit Surat on 07th August 2006,
ECC had about 63 of its engineers in the city,
most of them living with their families. In the
tense 3-4 days that followed, when the surge in
Tapi River failed to recede due to the onset of
spring tide (Full Moon) in the Arabian Sea, all
communication channels and means of transport
broke down completely.
The management at the Regional Office at
Ahmedabad was deeply concerned with this
sudden turn of events, which put the staff
members and their families at grave risk. True
to the culture of caring and trust the organization
is known for, the Regional Manager sent a relief
team which waded through waist-high water and
provided the affected staff and their families with
necessary food and potable water.
Subsequently, when the water receded leaving
behind a huge deposition of slush and animal
carcasses, the city faced an outbreak of
epidemics. In such a critical situation the
Government of Gujarat (GoG) and Surat Municipal
Corporation (SMC) approached L&T and the
management responded promptly in undertaking
relief work.
Bacgkround
The city of Surat is located on the banks of river
Tapi and it has the Ukai Dam upstream. During
this monsoon season, unprecedented rains hit the
upstream catchment area, resulting in heavy inflow
of water into the dam and raising its level above
the danger mark. In order to protect the dam
from damage and to prevent possible breach the
authorities concerned were constrained to
discharge excess water into the river, as a result
of which, Surat city got inundated.
The situation deteriorated further as the release of
water from the dam coupled with the high tide in
the sea made the water level in the sea rise to its
highest levels. As a result, the sea was unable to
take any water from the river, leaving the water
stagnant in Surat and its vicinity.
The maximum discharge from the Ukai Dam was
900,000 cusecs of water. During the flood, the low
lying areas of Surat were subjected to 10-20 ft of
stagnant water for a period of 3-4 days, whereas
all the other areas got submerged under a column
of 4-8 ft. of water.
Nature of Work
The operation was directed at clearing up the
accumulated slush, waste materials (from the
households and shops) and decaying food grains
(dumped on the roads by the general public), so as
to minimise the chances of outbreak of diseases
and epidemics and bring back a semblance of order
to the city.
The nature of relief work is different from the
projects we execute, since there are no specific
guidelines or documents for execution of work. In
fact, the work was taken up against verbal
instructions from the authorities concerned on a
day-to-day and hour-to-hour basis.
Since the entire community was badly affected,
though in varying degrees, there was tremendous
pressure from all quarters on the authorities. This
sort of an operation needed to be executed with
urgency and action initiated on a war footing. In
this particular case, the plight of the people of Surat
can be understood if one considers the fact that
even the basic services like water supply, hygiene,
medical facilities, telecom, electricity and other such
services were paralysed and efforts were on by
the authorities to restore normalcy.
Like the general public, our relief operators too
faced health hazards as they were exposed to the
accumulated waste consisting of animal carcasses,
slush, decaying food grains and apart from working
under total wet conditions due to frequent
intermittent rains. Hence, the work had to be carried
out with utmost caution and we took care to provide
the right operator-kit, food and drinking water to
every member of the team.
Scope of Work
Initially L&T provided SMC and other departments
with 4 excavators and 4 dumpers for the clearing
operations in various parts of the city. The equipment
were utilized by the corporation to develop a
dumping yard at Katargam and for excavation work
and burial of animal carcasses at Ugatgam near
Palanpur village on the outskirts of Surat among
other activities. This work at various locations in
Surat continued till 21st August 2006. In these areas
also, L&T engineers assisted SMC in the supervision
of works.
However, the day after the floodwaters receded,
on a request from GoG/SMC, L&T took up the
cleaning operations with an additional fleet of
machinery under their direct supervision. The
corporation awarded the work to L&T in small
stretches, stage-wise, in the area of Randher Road,
Anand Mahal road from Palanpur patia to Prime
Surat Municipal Corporation entrusted relief
operations on a stretch of 10 km to ECC. A team of
about 35 engineers was urgently formed as per the
instructions of Mr. R. Chandrasekharan, Regional
Manger, ABRO, who set the tone for the operation
by leading the team himself to Surat. Mobilisation
was done overnight and on 13th August 2006, the
work of clearing the affected areas commenced on
the earmarked roads. Later seeing the excellent
progress made by the L&T team, SMC handed over
an entire ward for clearing operations consisting of
an additional 18 km of roads.
Scraping work in progress at Anand Mahal
14
Market totaling to about 10 km. The L&T team took
up this work with full energy and vigour and
completed the same in a matter of three days,
during which a lot of public support and goodwill
with the SMC officials was built up.
The general public was especially happy with L&T’s
work and we were told that there was a lot of
pressure on the SMC from various quarters of the
population for deployment of L&T team in more
areas. After witnessing the fast and efficient pace
of work, SMC awarded an additional scope of
approx. 18 km, covering the internal roads in Adajan
and Randher area under Palanpur Patia Ward.
At the end of the operations, L&T had executed
clearing work to the extent of 28 km, lifting about
25,000 ton of slush, garbage and debris. The lifted
material consisted of silt and clayey river slush,
mud, polythene, jute, metal and wooden articles,
household furniture, kitchen waste, rotten grocery,
animal carcass, decaying food grains, damaged
shop articles and many other assorted items.
Survey and Estimation
On being handed over the first stretch of roads, the
initial work comprised the survey of affected roads.
Along with the SMC personnel deputed for the
survey, a thorough reconnaissance was done for
assessing the quantum of work to be carried out
for clearing and making the roads serviceable. In
most cases, the roads were congested due to
accumulation of slush and also mass dumping of
waste materials from the nearby shops, lanes, bylanes and houses. Under these conditions, the
primary concern was to block the roads (one lane
in the case of roads with divider and both to & fro
traffic in all others) and divert the traffic to the
adjacent lane or provide a bypass route. For ensuring
this, we took the assistance of police, prior to
commencement of work for blocking the traffic,
which was carried out by our site engineers in
close coordination with the officials of SMC. The
survey for the roads to be cleared was carried out
a day in advance based on the priority set by SMC,
so that the next day’s work could be carried out in
full swing smoothly.
The following points were considered in the survey:
♦ Traffic direction and possible diversion plan (in
consultation with local authorities and police)
♦ Quantum of waste materials and slush to be
disposed and resources required for total
disposal
♦ Identification of utility services/obstructions
to muck removal
♦ Identification of shallow trees/utility lines which
could pose a problem to smooth scraping and
loading operations.
Another matter firmed up in advance was the
identification of suitable disposal yards for the large
quantum of waste materials collected from the
roads. Three such yards were earmarked by the
corporation in various parts of the city. Based on
proximity from the location of clearing, quantum of
waste to be handled and accessibility of the yard
(some yards were inaccessible during wet
conditions), the location of dumping yard for each
clearing location was finalized and accordingly,
instructions passed on to the Section head
concerned.
In many cases, though the yards were identified in
advance, dumping got delayed due to incessant
rains. In these cases also, SMC took prompt action
and constructed approach roads on priority to ensure
that the work progressed unhindered.
Resource Planning
Based on the quantum of work, resources were
quickly mobilized both departmentally and through
subcontractors. The resources included staff and
departmental supervisors, plant & machinery, skilled
workmen like operators, drivers and mechanics,
unskilled labour for scraping and such activities.
These resources were augmented as and when
fresh scope of work was to be taken up.
Support Services
Once staff mobilization was made, action was
initiated on the support services for enabling
unhindered flow working in the affected areas. This
included:
♦ Accommodation for staff and departmental
supervisors in hotels
♦ Work in 10-hour shifts
♦ Rented accommodation for workers in areas
close to the workspots.
It was also understood as a fact, that the skilled
workmen would be the key for successful
completion of the operation at hand. Hence, for the
operators, drivers and mechanics, rented makeshift accommodation was arranged close (about 35 km) to the work site within Surat, for the selection
of which, a great deal of effort was put in by the
team stationed at Surat to ensure that proper lodging
and clean lavatory facilities were available.
♦ Transportation arrangements for staff and
workers
♦ Catering services
♦ Mobile diesel dispensing units to meet the
requirements of site vehicles and P&M items
(Courtesy: SMC)
♦ Co-ordination between sites, Resources Dept.
and Regional Office
Micro-Planning
Based on the priorities chalked out after
discussions with the senior officials of SMC, a
macro plan was worked out, identifying the
locations of work and resources for each shift.
At the clearing location, prior to start of each
shift, the concerned engineers drew up a micro
plan for deployment of resources, blocking of
traffic, selection of dumping yards and the route
to be taken by the dumpers.
P&M Mobilised
Based on the job requirement and the deadline
fixed by the corporation for the substantial
completion of works, i.e. 21st August 2006, the
following resources were mobilised:
Hon'ble Minister Narottambhai T. Patel interacting with Mr. Senthil Raja
15
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
Backhoe
Loader cum backhoe
Loaders
Dumpers
Bus
Conveyance Vehicles
Pickup Van
Water Tanker
Tempo
Tractors
Staff
♦ Skilled Workmen
♦ Unskilled Workmen
:
:
:
:
:
:
:
:
:
:
:
2 Nos
18 Nos
2 Nos
41 Nos
1 No
10 Nos
2 Nos
1 No
1 No
2 Nos
80 (30 working
and balance on
rotation)
: 160 Nos
: 100 Nos
Work Methodology
The steps involved were as follows:
♦ At the beginning of each shift, the engineers
give all workmen pep talks on the safety and
health precautions to be taken during the
operation.
♦ Meanwhile, another team identifies the areas
to be barricaded for controlling with the help of
police.
♦ The required resources like vehicles and
equipment, already mobilized at the location,
are provided with diesel through the mobiles
dispensing units and kept ready to initiate
operations. Generally a relief operations unit
consisted of 4-5 loader-cum-backhoes and 1620 tippers. Work was taken up simultaneously
at 2-3 stretches.
♦ Dozing/ Scraping of the slush/muck was
undertaken using the loader end of the loader
cum backhoe and heaps are collected at
intervals of 50-100m.
♦ The waste material/slush so collected is lifted
with the help of excavators and loaded on the
dumpers, which then carry it to the identified
disposal yard.
♦ Once this activity is completed, the scraping
operation is taken up to remove the sticky
muck, first mechanically and then manually
with hand scrapers. The waste so collected is
again disposed of in the manner explained
above.
♦ After the end of night shift all the equipment
were parked near the location where work
was to be taken up the next day.
Safety Health and Environment
A. Safety – The following safety precautions
were taken:
♦ A safety plan was prepared identifying the
hazards, utilities and care to be exercised during
night operations.
♦ Suitable safe distances were maintained while
working in proximity to electric lines/cables
Manual scraping of Surat road in progress
etc. Each stretch was manned by safety
engineers during the operation to oversee the
safety aspects.
♦ Pep talks were given to staff and workmen in
each shift, with specific attention to the care
required for safeguarding one’s own personal
safety and health.
♦ Various personal protection devices like gloves,
gumboots, etc. were provided to the staff and
workmen.
B. Health - Clean and hygienic food and water
were provided at the messes and all work locations.
A team of doctors were identified who could treat
the relief team members in case of need.
C. Environment - The key issue in the
environment management of such operations is the
location of suitable dumping yards, which was done
by the civic authorities. It was ensured that the
waste materials were dumped only at the designated
dumping yards. The civic authorities carried out a
disinfection exercise.
Risk Mitigation Steps
The major risks in the operations were as under:
Health hazards to staff – These were neutralized
by :
♦ Reducing the number of working days per
person and operate by rotation after 3-4 days
♦ Providing hygienic living conditions
♦ Providing hygienic food and water
♦ Providing suitable gear for safe working
Health hazard to workmen – These were
neutralized by :
♦ Reducing exposure to the conditions by working
in limited hour shifts
♦ Providing hygienic accommodation and
transport
♦ Providing hygienic food through caterers
outside Surat and packaged mineral water.
♦ By giving adequate medical facility and care.
♦ By providing suitable gear for work viz.
gumboots, gloves and masks.
Mr.T.E. Senthilraja was the Project Leader of
the Flood Relief Operations. He was assisted by
a core execution team lead by Mr. E.P. Sajit,
Construction Manager-WET Bu, and well
coordinated by Mr. S.H. Vora, SPM-TI sector.
The execution team was from Mora Vapi pipeline
project, Vadodara Bharuch road project, Anand
Rajkot pipeline project and ABRO.
The execution support team which worked on
rotation basis involved sub teams from Accounts
& Administration, Plant & Machinery, Planning,
Safety etc.
Demobilisation
Immediately on acknowledgement by the
concerned officials of Surat Municipal Corporation
of the completion of the work allocated to L&T,
demobilization was set in motion.
Most of the staff and workmen were withdrawn
on August 21 itself. A skeleton team was retained
to attend to minor works that arose.
On 22nd August, the workers were called to the
office and given a pep talk acknowledging their
contribution to the successful completion of the
clearing operations. Further, each individual was
presented with a T-shirt by the management as
a memento.
S.H. Vora
SPM-TI Sector
16
s a part of L&T’s corporate social
responsibility, ECC’s Construction Division in
the Ahmedabad Region has been rendering
an yeomen service to the Society. Various CSR
activities carried out by the region under the two
broad categories of Mother and Child Health Care
and School Health.
On December 27, 2005, woolen blankets were
distributed to 50 female works at ECC’s Anand
Rajkot Pipeline project of GSPL. During 2006
programmes were orgnised at various locations
under the under the following categories:
♦
♦
♦
♦
Health Check-up camps
Swasthya Varta
Child health programmes
Donations of medical equipment
Health Check-up Camps
On January 25, 2006, Health Check-up Camp for
for Mother & Children was conducted by ECC’s
site team at RJ – 11, Road Project Kota in the
premises of Anganwadi Kendra, Banshkheda
Village, Rajasthan. Nearly 60 families from nearby
villages availed the benefit of the programme.
On May 16, 2006 another Health Check-up Camp
was organized for site-labourers at Torrent
Research Centre, Gandhinagar (Gujarat) site in coordination with Kanoriya Hospital. During this Camp
the hospital distributed free medicines and
subsidised treatment to approximately 75 male and
female workers.
Swasthya Varta
To spread awareness on health & hygiene and
identification of clinical requirements, a
programme called (SWASTHYA VARTA) was
organised at two sites.
Nearly 70 women and girl children attended the
camp held at Chacharwadi Main Depot (Sari
Village) near Ahmedabad on July 6 & 7, 2006 and
60 women and girl children attended camp
organized on July 23, 2006 at Torrent Research
Centre site in Gandhinagar.
SWASTHYA VARTA - Awareness programme
During this programme valuable tips and
information were furnished to the participants
on the following:
♦ Health – physical health, psychological health
and hygiene
♦ Physical and mental changes and ageing
♦ Age for marriage and safe pregnancy
♦ Pre & post natal care
♦ Preparation for child birth & family planning
♦ Nutrition
In addition, adequate information on child health
care, immunization, nutritious food for children,
identification of child diseases and services were
provided and an awareness on good health was
created amongst the children.
Programme for Children
In order to create and spread health awareness
amongst children, a special programme was organized on July 17, 2006 at Anganwadi Centre-Sari
Village near ECC Chacharwadi Depot, where 35 children were benefited from the programme. Topics
covered maintenance of self health & hygiene and
nutritious diet. Medical equipment worth Rs. 75,000
were donated by ECC’s site at Adani Port Mundra
to eneral Hospital, Mundra on May 24, 2006.
School Health Programme
In addition to the above ECC has been
organizing several health education
programmes for School Children and
distributing educational materials freely for
children in collaboration with the Village
Panchayat, Anganwadi Centre, Bal Mandir,
Youth Groups, Community Centres etc.
Under the above programme nearly 50
students (both boys & girls) picked up class 3
to class 7 were selected and trained as peer
educators to train other students. This
programme was assisted by two teachers
each from many school in the area. This event
took place on three different days between
June and September 2006 at the Government
Primary School, Sari Village near Chacharwadi
Main Depot & Stores and at HUDCO Primary
School, Bhat Village near Torrent Research
Centre on July 21, 2006. Out 100 student
participants about 50 students were trained
as peer educators.
Educational and stationery materials like
notebooks, compass box etc. were distributed
to needy students who are below poverty line
from 9 selected centers.
The Sarpanch of concerned village, Panchayat
Member, Media Persons, Anganwadi Workers
and villagers participated during the material
distribution programmes and around 550
students availed these benefit. The distribution
was done at the following sites:
♦
♦
♦
♦
♦
♦
♦
♦
♦
Chacharwadi Main Depot, Ahmedabad
RJ-11, Road Project, Kota (Rajasthan)
Torrent Research Centre, Gandhinagar
Mora Vapi Pipeline Job Site
Anand Rajkot Pipeline Job, Anand
HEW Hazira Site
APDRP, Tonk Site (Rajasthan)
Hindustan Zinc Ltd., Chittorgarh (Raj.)
Adani Port, Mundra
Action plans are initiated to carry these
programmes on wider and intense scale in
2007 for the benefit of the society.
V.V. Chapekar
Regional P&OD Manager
17
CC Recreation Club, Ahmedabad, formed
on 26th December 1998 is continually active,
developing vibrant outlook, healthy culture
among all its members, their siblings and
associates working in the Regional Office and at
nearby sites in Ahmedabad Region.
Under the leadership of the Regional Manager as
the President, the club provides sporting and
recreational facilities to all its members at work.
The club is monetarily self-sustained by the
members with monthly easy to pocket but vital
contribution from their salaries.
The club organizes participation in community
social gatherings, cultural events comprising of
singing and dancing, talent programs, indoor and
outdoor sports events at various places of
recreation in the Ahmedabad city which help in
strengthening the bonds among all and also boost
the morale of the members within the region.
The club also takes part in cultural and sports
competitions, debates and other recreation meets
organized among various regional offices, sites
and head quarters thereby providing the staff
and their families a broad platform to bring
Blood donation camp in progress
forward their aspiring and creative talents and
nurture the positive attitude of being together as
one large L&T family.
Widening the horizons beyond the said activities,
the club is also actively addressing social needs
for the betterment of the underprivileged,
conducts in house blood donation camps once a
year, extends welfare hands for noble causes
viz. distributing clothes, books and educational
stationeries, medical and monetary help to the
poor, etc. and is strongly committed towards
fulfilling the social responsibility towards the
society.
The club organized a blood donation camp on 11th
of August 06 with voluntary help and support
from Red Cross, Ahmedabad, which was a grand
success.
In addition voluntary contributions from
associates of ECC at Ahmedabad are welcomed
by the club for contributing to social causes.
Adding more value in return to their vital support
for the club, the club provides all its associates
an opportunity of wide exposure and introduction
of their organization/agency with L&T’s wide
spread business center offices and sites, by
placing their organization’s/agency’s
advertisements in the club SOUVENIR.
The SOUVENIR also encourages all the club
members and their families to express their
creative talents by publishing the articles, poems,
quotes and drawings submitted with great
interests and enthusiasm.
Blood donors seen with the volunteers and support staff from Red Cross
18
L&T Concrete
&T Concrete, a ready mix concrete was first
started in Bangalore in the year 1996. Since,
then it has come a long way and has emerged
as largest producer of ready mix concrete in India.
As per the policy of continuous growth and
expansion, L&T Concrete entered Ahmedabad city
in the year 2003. It started its commercial production
in November-2003 from its first plant at Changodar,
on outskirts of Ahmedabad.
Ready Mix Plant at Gota
The local market was not ready to accept the ready
mix as a better substitute to site mix concrete as
there was many negative perceptions about the
ready mix concrete. L&T’s marketing team worked
hard to educate people about advantages of L&T
Concrete over their site mix concrete.
many new players entered the Ahmedabad market
following L&T’s footsteps.
In last three years, L&T Concrete has seen a sea
change in acceptance of ready mix concrete and
The L&T Concrete in Ahmedabad region is poised
for growth with the cumulative production estimated
At present L&T has seven plants in Gujarat and
Rajasthan. Out of them 3 are in Ahmedabad, 2 in
Surat and one plant each in Vadodara and Jaipur.
to cross 4.5 lacs cum, and there are plans to expand
the base in Vadodara, Rajkot, Udaipur next year
and also to many other cities in the state of Gujarat
and Rajasthan in the coming years.
Ravi Khurana
RPM–RMC
Ready Mix Plant at Changadar
19
Torrent Research
Center (Phase-II),
Gandhinagar
orrent Pharmaceuticals Limited (TPL) is one
of the leading Indian pharmaceutical
business groups based in Ahmedabad. TPL
awarded L&T, the contract for constructing their
Research Center Building – Phase II, Animal
House and Bio Evaluation Study Center at the
existing campus located at village Bhat in
Gandhinagar.
M/s VMS Engineering & Design Services (P)
Limited, Ahmedabad, were nominated as the
project structural consultant and M/s Munjal
Bhatt, Ahmedabad were the architects. L&T’s
scope of work involved construction of RCC
famed structure with trapezoidal foundation,
tunnel works including all finishing works like
flooring, false-ceiling, Al. doors and windows,
glazing, water proofing, painting etc.
Salient Features
The Research center building structure
comprises of four stories with three different
blocks (Block A, B &C) and two core areas for
connecting the blocks, the total plinth area of
Torrent Research Center - a landmark in Gandhinagar
main building is around 3500 Sqm and floor area is
16000 Sqm. The ancillary buildings of animal house
and bio-evaluation study center has a plinth area of
1500 Sqm and floor area of 3500 Sqm.
The contract value more than doubled due to the
introduction of additional works and features such
as special sections for Al doors and windows,
louvers, vitrified tile flooring, temporary animal
house building, finishing works in ancillary building,
special roof insulation material (vermiculite) for over
deck insulation, polycarbonate roofing and
ornamental teak wood railing for all staircases and
core area of entire building.
Construction Methods
Structures have been constructed using L&T
form work materials with the guidance of
CMPC and formwork team of region, Special
steel shutters were fabricated at site for
expose finish round columns of 600mm and
900mm diameter. Flat slab of 400mm thick
was cast by using heavy duty H frame and
steel shutters. Vitrified tile flooring was done
for all office area; polished kota flooring and
skirting is provided in the utility area and
staircases.
Over-deck insulation was carried out using
lightweight material of vermiculite upon which
Brick Bat Coba (BBC) waterproofing was
carried out. Above BBC, white china mosaic
flooring was laid over the entire terrace area
to reflect the heat.
Structural glazing, special type aluminum
doors, windows and louvers, ornamental
wooden hand railings with MS tubular support
give an aesthetic look to the entire building.
The research wing where drugs are developed
20
One of the blocks of the research center
Challenges
Since the project was located in the existing
campus, space was a constraint for the construction
activity. Hence no temporary structure was made;
portable office and steel containers were availed to
accommodate the staff and materials. Ready Mix
Concrete was used for major pours and site
concrete production was kept at a minimum. Labour
colony was established outside the site premises.
All finishing activities were planned in sequence to
avoid blockage of stock yard (for example: flooring
work was started on completion of false-ceiling
work).
Being a research center, it was essential to
create a dust free environment hence all floor
and wall corners were made by epoxy coving
which gave a smooth radius and a slippage to
the dust accumulation.
Temporary animal house (@ 300 Sqm) was
constructed using aeriated cement board of
non-asbestos grade (High density light weight
cement board) with in a short span of 15 days.
Following which all animals available in the
existing house were shifted and expansion of
existing animal house was carried out within
3 months.
Commencing in February 2005, the entire project
was completed successfully by July 2006. The client
has given a good appreciation for the quality of
work executed.
The finished view of a typical room before partitioning
Saurabh Shrirup
Construction Manager
21
Akshaya Apollo
Hospital Limited
Ahmedabad
hmedabad is the largest city in the state
of Gujarat and the seventh largest urban
agglomeration in India, with a population
of almost 50 lakhs (5 millions). The city
established itself as the home of a booming
textile industry, which earned it the nickname
“Manchester of the East” . A rising centre of
education, information technology and
scientific industries, Ahmedabad is the cultural
and commercial heart of Gujarat. The need
for a quality health care facility was always
felt as the people of Gujrat had to visit
neighbouring states for medical facilities.
Apollo Hospitals, Asia’s most trusted
healthcare provider, envisioned setting up a
super specialty hospital for the people of
Gujarat. With the backing of Government of
Gujarat and the allotment of land on the
outskirts of Ahmedabad, the project
commenced in 2000. Initially the job was sublet to a local contractor who abandoned the
task leaving half built foundations.
At this critical juncture, in October 2000, L&T
was called upon to take up the project and
was awarded the construction of a worldclass hospital. When the works were on in
full swing, natural disaster struck in the form
of earthquake on January 26, 2001. It was
the worst earthquake ever in the area, which
changed the lives of the people of Gujarat.
Fortunately there were no causalities at site
and all were safe. The aftershocks of
earthquake and psychological fear among the
workers resulted in work coming to a
standstill with many personnel leaving the site.
However, within a month’s time, the
workforce was re-mobilized and the project
work was resumed. The second setback to
the project was the communal riots during
February 2002. Again L&T stood strong and
carried on with the work on hand. Finally the
hospital was inaugurated on May 13, 2003.
The Chief Minister appreciated L&T’s role in
creating a truly world class state-of-the-art
hospital for the people of Gujarat.
The hospital is strategically located between
Ahmedabad and Gandhinagar, offering
services to the residents of both Cities. This
superspecialty hospital is a multi-facility
hospital with the latest equipment and gadgets.
The hospital was designed for 350 beds with
a provision to add another 50 beds. The
Hospital has one helipad, 10 operation
theaters, 75 OPD rooms, 4 delivery rooms,
cancer unit, and many other specialized
facilities.
Scope of Work
L&T’s scope included all civil, structural,
architectural and finishing works, plumbing
and sanitary works, fire fighting system,
electrical works, internal services, internal
RCC roads, parking lot for 300 cars including
special items like space frame, curtain wall
etc.
Salient Features
♦ 350-bed hospital with total 5 blocks (3
blocks of ground + 4 storeys and 2 of
ground + 6 storeys)
♦ Service blocks
♦ Water body
♦ 825 rooms with 249 toilets
Front view of Apollo Hospital, Ahmedabad
22
♦
♦
♦
♦
♦
No of teak wood doors: 1261
Fully automatic fire fighting system
Presidential suites and deluxe rooms
Effluent treatment plants
Raw water storage and fire water storage
tanks and equipment
♦ Electrical Works
♦ Compound wall, internal RCC roads and
parking lots
♦ Separate helipad slab on top of the building
Highlights of the Project
♦
♦
♦
♦
Cost of the project
Commencement Date
Completion Date
Staff mobilized during
peak hours
♦ Workmen deployed
during peak hours
: 2192 Lacs
: Oct 20, 2000
: May31, 2003
: 26
: 600
Major Quantities
♦
♦
♦
♦
Earth work in excavation
Concrete
Shuttering
Reinforcement
:
:
:
:
65,500 Cum
13,800 Cum
65,526 Sqm
1850 t
♦ Flooring and tile
cladding
♦ Painting
♦ False ceiling works
♦ Water proofing
♦ Glazing works
♦ Aluminum cladding
♦ Polycarbonate skylight
♦ Electrification works
Fire fighting works
:
:
:
:
:
:
:
50,650 Sqm
1,20,560 Sqm
24,460 Sqm
14,200 Sqm
1,950 Sqm
1,350 Sqm
480 Sqm
: 12.50 km
Major Equipments Deployed
♦
♦
♦
♦
Tower crane
18 T cap Crane
Concrete Mixer M/C
Tough Rider
:
:
:
:
1 No
1 No
6 Nos
1 No
Sukalyan Roy
Senior Engineer, B&F
(top and bottom) Different views of the state-of-the-art Apollo Hospital, Ahmedabad
23
GK General
Hospital, Bhuj
The total contract was awarded to L&T on a turnkey
basis and was to be executed in four packages. The
architect/consultant provided the basic conceptual
drawings and the detailed shop drawings were
developed by L&T.
♦ Package one comprising civil, landscaping,
plumbing, sanitary, fire fighting and HVAC works
was awarded in October 2001 and was to be
completed by December 2002
n the devastating earthquake that hit Gujarat on
January 26, 2001, G.K. General Hospital, Bhuj
was so severely damaged that the then Prime
Minister decided to have it re-built and make it a
multidisciplinary hospital. The re-construction
contract, funded through the Prime Minister’s
National Relief Fund, was awarded to L&T on a
turnkey basis.
The Prime Minister’s Office appointed M/s EFN
Ribeiro Associates (ERA), New Delhi as architects
and principal consultants for the project. The project
management and financial management functions
were assigned to M/s National Dairy Development
Board, Anand.
ERA engaged sub-consultants for different disciplines
as listed below:
M/s. Ce-Con Engineers - Structural Consultant
M/s.M.K.G. Consultant - Public Health Engineering
M/s. Udayan Chaudhary - HVAC Services
M/s. Service Consultants - Electrical Services
M/s. Bhalla Ribeiro & Bhalla Associates - Landscaping
works
♦ Package two comprising electrical and base
Isolators works commenced on January 2002
and was to be completed by December 2002
♦ Package three comprised the construction of
ancillary building which was awarded during
May 2002 was scheduled for completion by
March 2003
♦ Package four comprised medical equipments
installation which commenced on August 2002
and had to be in place by December 2002
A/C load of the building is 617 TR. There are 2
trane chillers of 300TR capacity each which work
on vapour compression principle and 2 Thermax
machines of 300 TR capacity each which work
on vapour absorption principle. There are totally
31 air handling units located in various floors of
the building and 45 fan coil units for pay wards
and suites. Each operation theatre is provided
with a separate AHU.
Water Treatment Plant: A dual media
activated carbon filter of 40 cum flow capacity
and a softener plant of 30 cum flow capacity
takes cares of the water services of the hospital.
The main water source for the building is from
the six bore wells erected around the campus.
Boiler: There are two steam boilers each of
capacity 160 kg/hr out of which one is standby
and two hot water boilers each of 4,00,000 kcal/
hr out of which one is standby.
Electrical services: The hospital has been
provided with 3 HT panels & 75 LT panels & 8
transformers. For emergency purpose it is
provided with 3 nos 1000KVA DG sets.
Base Isolators: Since Bhuj is located in the high
seismic activity zone, construction was planned to
make the building seismic proof. There are totally
four floors including basement. Ceiling has been done
with pre-cast slabs. The ground floor and the floors
above have been isolated from the basement by
base isolation technique. There are totally 178 lead
rubber bearings installed on the columns and 101
slider bearings installed along the periphery columns.
Such type of base isolation is first of its kind in India.
Medical Package: This package includes equipments
of international repute. We have supplied and installed
1 ct scanner, 2 X-ray machines, radiology instruments,
colour Doppler’s, monitors, ophthalmology instruments.
This package also include a full fledged kitchen and
laundry equipments. Totally 300 beds, surgical
instruments were also supplied.
HVAC System: The hospital is equipped with
a centralized air conditioning system. The total
Finishing and Interior Works: The building has
been given a good finish with its front elevation having
GK General Hospital - a medical center of par excellence
24
a structural glazing and the rest of the area finished
with heritage painting in english green. The general
flooring is done with kota stones except for the ICUS
and OTS departments which is with granite. The false
ceiling is of armstrong type.
Salient features
♦ Earthquake resistant structure
♦ Base Isolation Technique adopted for
Foundation for the first time in India
♦ 300 Bed Hospital
♦ Basement + Ground + 2 Storied Structure
♦ Floor area for Main Hospital - 33800 Sqm
♦ Plinth Area for Main Hospital - 8450 Sqm
♦ Medical Equipments
♦ HVAC System
♦ Water Treatment Plants (Filtration & Softener
Plant)
♦ Steam Boilers
♦ Hot Water Generator
♦ Sewage Treatment Plant
♦ Fire Fighting (Sprinkler, Hydrant & Smoke
Detector)
♦ 10 Passenger Lifts
♦ Ancillary Building includes Nursing School,
Staff Quarters, Doctor’s Bungalow,
Commercial Center, Staff & Nurses Hostel,
Hospital Inn & DCMO Building
Major Contractual Schedules
Project awarded on Turn-Key basis
♦ Date of Issue of LOI
: 15.10.2001
♦ Date of Commencement
of Work
: 16.10.2001
♦ Contractual Completion
(Main hospital)
: 31.12.2002
♦ Date of Completion
(Main hospital)
: 31.03.2003
♦ Completion of Ancillary : 31.08.2003
buildings
Project Logistics
Land Clearance: Since the project was to be
completed in a short duration, logistics planning
was a key feature. The land allotted by
government had existing structures which had
to be demolished, after a feasible study some of
the them which were in stable condition were
utilized temporarily for office, store, QA/QC lab,
Cement Godown, site office, etc. till the basement
roof was cast.
Labour Colony: The planned labour strength at
peak period was 2500 per day. So the labour
colony was made to accommodate the strength
of 2500 within the project campus for easy access
to the work spot. Area for labour colony was
provided by client on free of cost, a Government
land near to the project site.
View from the main entrance
Precast Yard: It was decided to construct all
floors and roof as structural and pre-cast slabs
with steel frame. A precast yard of size 200m
x20m was setup just behind the main hospital
building, which was within the reach of tower
cranes for easy handling and erection of precast planks. 120 moulds made of form floor of
size 2400mmx1200mm of capacity were cast.
Two curing tanks were made for curing the precast slabs. One gantry crane of 20t capacity span 20m was engaged for shifting of precast
slabs to tank and painting area. In addition two
two manual gantry of 3t capacity electric hoist
were used for de-moulding of moulds and placing
of pre-cast slabs in cradles. A Batching plant of
25 Cum/hr capacity was installed inside project
premises near to the pre-cast yard.
Fabrication Yard: A 8 working platform
fabrication yard was constructed for fabricating all
structural beams, girders and pre-cast slab angle
frames. Around 1500 t of fabrication was completed
within 4 months. Fabricated structural steel
materials were stored in separate stack yard behind
main hospital building.
Power Supply: A 400-kVA temporary power
supply for four different locations inside project
premises was obtained from Gujarat Electricity
Board – Bhuj. One 250 kVA power generator was
used during construction. Permanent power supply
was obtained from project authorities on January
2003.
Quality Control Methods: The project
management appointed the QA engineer as
management representative for effective
administration of the quality systems during contract
review, design, document and data control, control
on customer supplied materials, material
identification and traceability, process control,
inspection and testing, calibration of equipments,
control of non confirming products, corrective and
preventive action taken, control of quality
records,internal quality audits.
Safety Measures: Safety procedures were
stringently implemented at all work zones in site.
Safety meetings were conducted at different
work areas of project to educate workmen on
safety awareness to all workmen and training
also given for working in height, Gas cutting,
Grinding, etc., Safety appliances like safety
helmets, safety belts for working in heights,
scaffolding, ladders, etc provided to all workmen
on free returnable basis.
Challenges
The earthquake and communal riots created a
sense of fear among the workmen. To overcome
the crisis, frequent pep talks were orgnaised, in
addition to this, workmen from other regions,
skills training institute, Chennai were also mobilised
to meet the huge requirement of skilled workforce.
Fabrication of huge quantity of ducting was not
possible at site due to manpower and space
constraint. Hence semi-fabricated ducts were
ordered and fabricated at Chikly, near Surat and
then transported to site.
Uniform motor thickness in AAC Blocks of 625 x 250 x
150 mm was difficult to obtain and hence it was decided
to adopt square bar of 10mm x 10mm. AAC Blocks
were not to be merged in water before use. Only the
jointing surface was to be made wet. Since it was
practically not possible to wet only the jointing surface,
a GI Tray of 10mm thick was provided so that the
blocks were placed in the tray before being used into
the masonry.
Installation of base isolators to precise line and levels
was done through templates provided at both top and
bottom portion and pockets made in RCC columns,
subsequently grouted after alignment.
S. Gunasekaran
SPM-B&F
25
Scope of works
The scope of works involved civil, structural and
finishing works including restoration works in
line with preserving heritage structures as well
as converting the building as an earthquake
resistant structure. Basically, this is a two-story
building, with a ground and first floors covered
with Mangalore tile roof above the central hall
supported on wooden trusses. This involved a
total floor area of 1200 Sqm and plinth area of
about 590 Sqm.
n January 26, 2001 a major earthquake
devastated the state of Gujarat, India. Most
of the villages in the Bhuj, Anjar and Bhachau
districts were seriously affected in the
catastrophe. Alfred Boys High School, an
heritage building in the Bhuj city that was
constructed in the year 1870 was very badly
hit by the devastating earthquake. Built with
stone masonry it is one of the monumental
buildings and has a capacity to accommodate
more than 1200 students.
Being a heritage structure as well as an
educational institution of repute, utmost
importance was given for rehabilitating and
retrofitting structure. Funds for meeting the
reconstruction cost was met from The Prime
Minister’s National Relief Fund, New Delhi. L&T
was entrusted with the responsibility for
rehabilitation and re-construction.
L&T executed the complete civil, structural and
finishing works including restoration works and
preserved the originality of this heritage building.
The Architect/Consultants provided all the basic
drawings and the detailed shop drawings were
prepared by L&T in line with the tender
specifications. The Prime Minister’s office
appointed EFN Ribeiro Associates, New Delhi
as Architects and CE-Con Engineers as Structural
Consultants.
Commencing the work in October 2003, ECC
completed the entire civil and structural works
in three months and the finishing works including
restoration operations in three months.
Project Execution
Site Clearance
The old building was strewen with a variety of
school furniture dumped haphazardly (both
usable and damaged) and covered by debris due
to the earthquake. As a result of this the school
was operating under a pre fabricated structure
and it was a hindrance for smooth operation of
site activities. Therefore, in consultation with
the school authorities the entire operations of
school was shifted to new premises.
Due to space constraints, initially, the available
pre fabricated school rooms were used for our
site office and store. Then two rooms in the ground
floor of the old damaged building were retrofitted
for our use.
Thus, site clearance and disposal of debris was
the first activity to be carried out at site. At
times walls and slabs weighing up to 500 kg used
to fall down. Hence, while removing debris from
the bottom, scaffolding was used to arrest falling
objects from top. A tractor with trolley was
used to dispose the debris.
Labour Colony
The labour strength at peak period was 150 per
day. And the area for labour colony was provided
by client, free of cost on a Government land closer
to the GKGH project site. Also, the old labour colony
of GKGH Project was availed for Alfred School.
Structural Steel Fabrication
Since there was no adequate space available in
the school area for fabrication of structural steel,
we availed the space in the GKGH area after
taking permission from the hospital authorities.
After completing 60% of fabrication, the same
was handed over to the hospital and the
remaining fabrication works were shited to the
school area, in a phased manner as per the
construction Program.
Construction Materials
Bulk materials for the construction like
aggregates and sand were sourced from a
distance of 30 to 40 km. Cement and Steel were
sourced from as far as 350 km. Temporary
power was obtained from GEB and a stand by
power generator was provided for supplying
emergency power. In addition, the site was
provided with one 10/7 Cum. Concrete mixer, three
welding generators, electric winches/builder‘s
26
hoist, curing pumps etc.apart from sufficient
number of lighting fixtures.
Dismatling and Restoration
The next in the sequence and the most critical task
was to carefully dismantle the damaged portion of
building. It was to be carried in such a way that
there is no damage to the foundations and unaffected
portions of the building structures.
Staircase
Dismantling the staircase was the most difficult
task, as it was broken from the center and there
was no access to it. Hence, the dismantling of this
was done in a sequential manner and restored its
original shape. The stone staircase waist, landing
slab and steps were then replaced with RCC.
The steps were cladded with Dholpur stone to look
like its original. The wrought iron grill
was
replaced with teak wood handrail restoring its
original design.
Ground Floor Slab
Ground floor slab was protected from falling debris
using sand bags. The existing slab was supported
using Heavy Duty Tower staging to enable it to
withstand excess load of falling objects. A special
method was used to remove only the damaged
portion of 600mm thick stone masonry slab. The
steel girders encased in the slab were supported
using steel props and dismantling was done in a
sequential manner to avoid bending of girders.
To retain the original heritage shape, size and look
of the existing ground floor slab, it was
decided to dismantle only seriously damaged
portion of it and restore the balance portion by
special repairing methods. Using 160 mm thick
M30 grade RCC, matching was done at the bottom
level and in the balance portion sand was filled to
maintain uniform thickness of 600 mm throughout.
First Floor Slab
First floor slab was repaired in the same manner
as that of the ground floor slab. L&T scaffolding
system was used for
supporting the slab
wherever required.
Moreover, the debris
of first floor slab was
directly shifted to the
tractor trolley using
chutes.
Stone Masonry
Walls
Walls were dismantled
in a special manner by
numbering individual
stones and stacking them
in order to avoid any
mismatch during refixing.
Reinforcement
Anchors
Framework of existing
building was required to
be strengthened to
convert it to an earthquake
resistant structure. RCC
footings were provided at inside of the building at
the corners and center of the room.
Then stone masonry pillars were provided with
reinforcement anchors by drilling holes, and
anchoring reinforcement rods using special sealant.
These reinforcement rods were in turn attached
to additional RCC columns, cast and extended up
to first floor roof.
These girders were extended from face of additional
RCC columns and columns were pierced through
the ground floor roof by making openings. in it.
Precast Handrails
The old handrails in the parapet portion was
damaged badly during earthquake. After retrieving
one span of the handrail, a new RCC pre-cast
handrail was constructed. Pre-cast elements were
cast in such a way, that it was assembled manually
at the desired locations.
Painting
The outside stone masonry wall was painted to its
original look without the use of any available paint
in the market. For this purpose, the original stone
was powdered and mixed with a colorless adhesive
adding adequate water to make the paint in line
with the original color of the stone. This was applied
after cleaning the surface and a silicon coat was
applied over the painting.
Top Floor Roof
Roof over the central hall at first floor was
constructed using wooden trusses and Mangalore
tiles. Special agencies were engaged by L&T for
waterproofing; recast hand railing and anti-termite
treatment works.
The job was very challenging in every respect as it
was unique and filled with several constraints. As
classes were conducted in the adjacent premises,
safety of workmen and safety of people were given
prime importance. A total 1.7 lakh man-hours were
spent to execute the project with a peak strength
of 704 workmen and the entire project was executed
without any accidents. On the whole it was a
wonderful experience to handle such unique piece
of execution.
S. Dutta
Construction Manager
27
The fabrication activities are complemented by wellequipped machine shops with sophisticated CNC
vertical and horizontal boring machines which are
capable of handling equipments as large as
12,000mm diameter and 250 to more than 1000 t in
weight.
&T has a modern, river front heavy
engineering fabrication facility situated
on a 200-acre plot at Hazira near Surat
in Gujarat. Located on the banks of the river
Tapi, this is connected by a navigation channel
to the Arabian Sea and is equipped with a
load-out quay, covered fabrication shops
extending over over 34,500 Sqm and open
fabrication yard of around 2.0 lakh Sqm to
manufacture extra-large and very heavy
equipment for power projects, chemical,
refinery, petrochemical and fertiliser
industries, oil exploration, and marine related
sectors.
With the help of the load out facility at Hazira, L&T
is capable of navigating large dimensional vessels
and other equipment for a wide variety o f
customers in India as well as abroad. For
loading out these heavy equipment, ECC has
constructed a jetty and the extension of the
same is now in progress.
In order to meet the increasing demand in
fabrication of heavy equipment, L&T is
expanding its manufacturing shops. As many
as six shops are under construction at Hazira
and Gherzi Eastern Limited, Mumbai are the
Structural Consultants for fabrication shops
HFS – V & VI, PPS & PFS – II. For the QA –
QC building Ashok Desai, Architect & Planner
are the Architects and Technocrat
Consultants, Surat are the Structural
Consultants. Recently HFS IV and the SubAssembly Shop were completed by ECC and
handed over to HEW.
Dimensional features of structures under construction
S.No
1
2.
Features
HFS IV & V
HFS VI
PPS II
PFS II
Height of structure
Rafter Top Level (in m)
Monitor Top Level(in m)
28.085
32.502
32.786
36.203
28.149
31.566
28.149
31.566
Areas in (Sqm)
6850
6850
4800
1656
Expansion in progress for Fabrication Shop at Hazira
28
Scope of works
Construction involved composite works such
precasting for pile foundations, precast elements
for roof, structural fabrication and erection for
gable ends, casting columns with slip form technique
as well as flooring with Tremix technique. This
involved innumerable activities like casting precast
piles, rafters, purlins, monitors, gantry girder for
various capacity of cranes 50, 150/200, 500 t etc.,
Pile driving, excavation, PCC / RCC for foundation,
cast–in-situ columns.
Fabrication and erection of structural steel, erection
of precast members, roof cladding with Galvalume
sheets, vertical cladding with Meta colour sheet,
rail fixing for gantry, etc,. Tremix flooring work for
heavy duty floor having capacity of 60 t per Sqm
including construction of toilet block and minor
finishing works.
Looking at the massive work involved, the height of
the structure and from our own past experience of
building HFS III we had to change our methodology
of work for certain activities as follows:
♦ As against conventional methods we have
adopted the slip-form technique of continuous
construction for concreting the columns. Three
pairs of columns were concreted
simultaneously. Apart from drastically reducing
the requirement of man power and shuttering
material this resulted in speedier construction
♦ With modification in slip form assembly, we
were able to change the height of the Yoke to
get better productivity
♦ We are managing erection activities using 150
ton crane for (PPS II, HFS V) and 225 ton
crane for (HFS VI) supported by one 75 ton
capacity crane for jacketing of the rafter ends
during rafter erection in place of the American
Hoist crane of higher capacity and tower crane
for purlins and monitor erection
Features of various structures under construction
No
1.
2
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Items of works
Precast piles
Gutter casting
and erection
Rafter casting
and erection
Monitor casting
and erection
Purlins casting
and erection
Gantry girder
Casting and erection
Excavation
Rubble Soling
Tremix Flooring work
Concrete
Formwork
Reinforcement work
Structural Fabrication
& Erection
Galvalume & FRP (500
Sqm) sheet roofing
Metacolour sheet
cladding
North Light glazing
Painting
UOM
HFS IV
HFS V HFS VI PPS &
Sub –
PFS II Assembly
Shop
Nos
360
521
401
493
225
Nos
50
50
25
25
-
Nos
52
52
52
50
-
Nos
26
26
26
25
-
Nos
550
525
550
506
-
Nos
Cum
Sqm
Sqm
Cum
Sqm
MT
80
3660
6215
6215
5660
27800
925
80
3700
6215
6215
8472
31000
1464
40
3800
6215
6215
6500
28500
1200
42
3000
4500
4500
5250
26000
975
950
5922
5450
1190
5050
84
MT
510
510
510
475
592
Sqm
7500
7500
7500
6900
5738
Sqm
Sqm
Sqm
1000
1370
12350
1000
1370
13630
1000
1370
12750
1500
1260
11500
5270
14750
♦ Ready mix concrete was procured from ECC’s
Ichhapur RMC plant, Surat, which minimized
the inventory on equipment, material and extra
labour for on-site mixing. Apart from getting
consistent quality in concrete, this helped RMC
to raise its market share in Surat during, initial
stages of its establishment
♦ During construction of HFS V and VI, we had
to face severe space constraints. However,
this has been sorted out with HED by occupying
non-priority areas and removing some of the
existing structures to create required space
S. Dutta
Construction Manager
Panoramic view of L&T’s Heavy Engineering workshops at Hazira
29
he history of Surat (known earlier as
“Suryapur”) dates back to 3000 B.C.
Though a major port during the 15th century,
the real foundation for growth of Surat City was
laid during 1960’s with the expansion of diamond
trade and its gradual shift to zari, textiles and
the intensification of the modern oil and gas
exploration activities.
However, Surat City once again shot in to
prominence with the establishment of Hazira
based industrial area, which is in proximity to
India’s major companies like ONGC, Reliance,
Kribhco, Essar, L&T, Shell, etc..
L&T Hazira, the brainchild of Mr. A M Naik,
Chairman & Managing Director, L&T is a modern
coastal heavy engineering complex, with a load
out quay on the banks of the river Tapi, close to
the Arabian Sea. It is well equipped to
manufacture extra-large and very heavy
equipment for power projects, chemical,
refinery, petrochemical and fertiliser industries,
oil exploration, and marine related sectors. And
provided with sophisticated facilities to ship these
equipment through sea to various destinations
on a global scale.
♦ Superstructure to rest on 750mm dia marine
piles, 1200mm dia contiguous piles and
400mm dia filler piles. Boring Depth varies
from CD (-)15.0 to CD (-) 22.5.m
loading / unloading purposes. When the
extension work is completed, it will help L&T
Hazira to load /unload two barges of 75m length
simultaneously.
♦ Superstructure is built up with 251 precast
pile caps, 280 precast beams covered by
850 precast deck slabs including 11 fenders
and 7 bollards. Casting of the 600 mm thick
deck slab involved pouring 1900 Cum of
concrete
Slipway
♦ Piling involved 8102 rm of drilling, 6200 Cum
of concrete, fabrication and supply 975 t of
liners, 900 t of reinforcement and 6720 rm
of liner driving
To accomplish the entire construction target in
13 months and drive piles in 10 months, 17 piling
winches and 7 gantries each weighing 20-30t
have been mobilized. In addition, three gantries
are deployed at Jetty end, three at Ro-Ro end
and one at the location of filler pile. Three cranes
of varying capacities such as 75, 45 and 11 tons
are also mobilized for this work.
We have completed around 220 piles, casting
the entire quantity of precast beams, pile caps
and 650 precast deck slabs including erection of
more than 25% of precast elements and
concreting more than 140 deck slabs till the
beginning of December 2006. This was achieved
by 15 staff and 290 workmen engaged at the
peak.
The Existing jetty which is 55m long
accommodates a barge of size 100m long for
The Construction of Slipway is one of the most
challenging assignments and also it is a dream
come true of our CMD. The slipway involves
construction of 320 numbers of 500mm dia piles,
320 precast muffs and 80 precast track girders.
The Slipway 80m long, 150m wide slopes down
from CD +7.330 to CD +0.00. Half of this
structure is on land and the other half is in water.
The slipway will facilitate large size ships and
vessels as a whole to slip down in to the water
over rails fixed on the track girder. However,
the movement of the ship in the river will be
parallel to the shore and not perpendicular to the
shore.
After a long drawn deliberation and discussion
on the type of construction method to be adopted,
it was decided by all concerned to execute the
marine piles using gantries. For this purpose
three 70 ton gantries are mobilized including
accessories. In addition, muff had to be erected
by making a localized sealed casings and carrying
out all operations through specialized diving
agencies.
The casing for precast muff was driven by
vibrohammer. After erection of muff, precast
girders were placed by using 225 ton crane and
450 ton capacity cranes from the land side.
Weight of each precast girder varied from 14
As a part of the ambitious expansion programme
at L&T Hazira and in the words of our CMD to
utilise ‘‘each and every inch of coastal area of
Tapi’’ ECC, is executing two major marine projects
under the Ports & Harbour Business Unit namely:
(a) Main jetty Extension and (b) Slipway
Construction.
Jetty Extension
In order to meet the expanding needs of the
modular fabrication facility (MFF) at L&T Hazira,
the existing main jetty is extended up to RO-RO
Jetty end. The construction programme which
involves a duration of 13 months, began in April
2006, Shirish Patel & Associates are the
Consultants. The salient features of this project
includes:
♦ Extension of the jetty to 100 m in length and
25m in width at the main Jetty side and 33m
at RO-RO Jetty side
Aerial view of Hazira jetty expansion
30
tons (6.5m to 7.5m long) to a maximum of 34
tons (10m long).
Case driving using vibrohammer (2.0m dia and 15m
long), erection of precast muff and erection of
precast track girder in the required accuracy of
line, level and slope, from the land side of marine
area is the most challenging task in this project;
both from target point of view and safety point of
view.
In L&T’s map of Gujarat, however, the pride of
place goes to the Hazira Works. In the early 1980s,
the company’s leadership took a strategic decision
to set up heavy engineering facilities near Hazira
on the banks of the river Tapi in south Gujarat. The
facility is a part of the company’s heavy engineering
division, and is engaged in the design, engineering
and manufacture of plant and equipment for core
sector industries such as cement and steel, nuclear
power, aerospace, oil and gas, petrochemicals and
fertilizers.
L&T had acquired about 200 acres (80 hectares) of
wasteland at Mora village on the northern bank of
the Tapi. Construction began in 1985, and production
commenced in November 1987. Major expansion
has been carried out since then in two phases, in
1992-93 and 1998-2000.
Today, Hazira Works has emerged as a worldclass heavy engineering facility, supplying critical
high-tech plant and equipment to its customers
located all over the world. It undertakes the
complete design, engineering and manufacture of
heavy equipment such as reactors, pressure
vessels, columns and towers. Hazira Works
specialises in nuclear power plant components such
as endshields and steam generators, aerospace
Work in progress at Hazira jetty expansion
equipment for the Indian Space Research
Organisation (ISRO), offshore platforms for oil
exploration and special project equipment for entities
such as the Bhabha Atomic Research Centre (BARC)
and the Defence Research and Development
Organisation (DRDO).
Unlike process industries, heavy engineering is a
labour-intensive industry. Hazira Works directly
employs 1,150 people. It also provides employment
to about 3,000 people through its various
contractors. The company does not believe in hiring
skilled labour from the markets but has evolved an
elaborate in-house training programme for its
employees drawn from nearby areas. The company
took special permission to train youth from Gujarat
Night view of river side work at Hazira jetty expansion
under the scheme, and has imparted training to
about 1,400 youth from different districts. Out of
635 workmen on the rolls of Hazira Works, 450 are
from this in-house training scheme.
L&T follows the credo of thinking global and acting
local. Accordingly, the company has been working
to get international recognition. Hazira Works is an
ISO 9001-2001 company. It was the first unit in the
country to get accreditation to EHS (Environment,
health and Safety) standards of ISO 14001 and
OHSAS 18001. In April 2003, Hazira Works
organised a comprehensive quality audit of its
systems by Det Norske Veritas of the Netherlands
against their quality protocol IQRS (International
Quality Rating System) and became the only
organisation in the country to be placed at Level 7.
The efforts have paid off, and 60 per cent of the
total sales of Hazira Works come from the highly
competitive export markets. Hazira Works feels it
can take on the challenges of a global market and
turn them into opportunities.
The company has represented to the State
government that the Hazira seafront should be
developed into a full-fledged port for break bulk
cargo with adequate loading facilities. At present,
Shell is developing an LNG (liquefied natural gas)
port at Hazira. L&T also feels that the Gujarat
Maritime Board should maintain adequate draught
in the river by periodic dredging of the channel so
that larger ships can dock at its jetties and at
Magdalla port. As of now, Hazira Works has to
ship its equipment by barge to Mumbai port, from
where it is transhipped to larger ships. As L&T
expands its stature as an Indian multinational, Hazira
Works will have a greater role to play in the group’s
activities.
K.S.S. Kumar
Construction Manager
31
Palanpur - Swaroopgunj
Annuity Road Project
nfrastructure is defined as the physical
framework of facilities through which goods
and services are provided to the public. Its
linkages to the economy are multiple and complex,
because it affects production and consumption
directly and creates both positive and negative spill
over effects apart from involving large inflow of
expenditure. Good transportation systems serve
as a lifeline to the development of a Nation. A good
road network helps in the movement of people and
goods apart from developing agriculture, trade and
commerce, education, health, social welfare,
cultural diversification and maintenance of law and
order and security.
The design, engineering, construction, development,
finance, operation and maintenance of 76 km long
Palanpur-Swaroopgunj highway on NH -14 passing
through the states of Rajasthan and Gujarat is under
execution by L&T.
Construction of this road corridor commences at
Palanpur on km 340.000 and ends at km 264.000
on NH -14. The initial 34 km stretch of the project
from Palanpur (km 340.000) to Amirgarh (km
306.600) falls within the state of Gujarat and the
remaining stretch of 42 km spreads in to Rajasthan.
The highway passes through some of the important
districts like Banaskantha in Gujarat and Sirohi,
Udaipur in Rajasthan.
also an important highway. This apart, there are
several other places of tourist attraction like the
Delwara Temple, Mount Abu and Sun Temple on the
surrounding areas, which makes this highway, all
the more significant.
It was found during the survey that traffic originating
from Kandla/Gandidham destined to Uttar Pradesh/
Northern states are using NH-14 up to Abu Road and
from there, they use SH-27. This is to avoid ghat
sections between Sirohi and Pindwara. It is also to be
noted that the section of SH–27 between Deesa and
Sirohi is a toll road. From the survey it is inferred that
for goods traffic originating from Kandla and destined
to Uttar Pradesh / North Eastern states, alternative
route 3 i.e. via NH-14 and NH-76 is the shortest route.
Also for the traffic originating from Kandla and destined
to Udaipur, the distance travelled via Palanpur (i.e.
NH-14 & NH-76) and via Mehsana, Himmatnagar (SH55) is about 550 km and 586 km respectively. Hence,
there is a savings of 36 km.
Due to this savings in distance and by the willingness
survey conducted it is clear that about 9% of traffic on
SH-27 whose origin/destination is either Kandla &
Uttar Pradesh/North Eastern states and about 11%
of traffic on SH-55 whose origin/destination is either
Kandla/Udaipur/Uttar Pradesh/North Eastern states
are willing to divert via Palanpur if the same is upgraded
as a four lane divided carriageway. From this survey
it is clear that this indicated increase of 20% growth in
the traffic volume, making it highly viable for NHAI to
award this as an Annuity Project.
Thus, upgrading this highway will not only fuel economic
growth but also provides for speedy and safe travel
apart from reduction in accidents, diesel consumption
and wear and tear of the vehicles. Moreover, it will
ensure increase in comfort of the user and safety of
the user.
As this highway passes through very
economically challenged areas of Rajasthan
and Gujarat; right from its construction stage,
till expiry of its operation and maintenance
contract, this will act as a growth engine for
local employment.
There are many cement industries in the
vicinity of this road project, such as RIICO,
J.K. Cement, Laxmi Cement and Binani
Cement etc, who have influenced this
corridor. These industries will also be
benefited to a great extent by virtue of faster
movement of the commodity.
Special Purpose Vehicle
This is L&T’s first annuity based road project
and this was bagged against international
competitive bidding. L&T will design, engineer,
finance, construct this 76 km long highway and
maintain it for a period of 17 years and six months
through a special purpose company L&T
Interstate Road Corridor Limited.
National Highway Authority of India are the
promoters. There are two consultants involved
in this project. ARRVEE Associates is assigned
the role of Independent Consultant reporting to
NHAI and Scott Wilson Kirk Patrric is the
Supervision Consultant. Since the design is
provided by L&T’s in-house team, the design is
entrusted to M/s SECON.
Highlights
♦ Contract value
♦ Contractual
commencement
♦ Project duration
: Rs. 550 Crores
: September 2006
: 30 Months
Some of the national and state highways substantially
affect travel characteristics of this road project.
Among the National Highways, NH-8 and NH-15
are most significant. NH -8 passes through Udaipur
and intersects a section of NH -76 known as Udaipur
bypass within the city of Udaipur. This stretch also
carries heavy traffic from Mumbai and Ahmedabad,
bound for Jaipur and other northern areas via
Udaipur.
NH-15 carries traffic from Kandla Port and leads
to Jaisalmer, Bikaner in Rajasthan and many
other northern parts of India. State Highway SH27 carries traffic from Kandla, Deesa etc. and
passes through Sirohi. Palanpur is like a
confluence or a hub city, which meets SH-41,
NH-14, and SH-55. SH-55 passes through
Mehsana, Himmatnagar, and joins NH-8. Thus,
SH-55 carries Udaipur bound traffic and this is
Preparation of subgrade in progress
32
A compactor in action
♦ Reinforced earth wall
construction of more than
64000 Sqm
♦ Construction of road
drainage system for 76km
♦ Construction
of
medians, intersections and
access arrangements
♦ Construction of Toll
Plazas
♦ Provision of road
signs, markings and
furniture
Kerb casting in progress
Scope of work
♦ Site clearance including maintenance of
existing road
♦ Traffic management and diversions
♦ Widening of existing 2 lanes to 4 lane
highway with service road construction
on either side for 40km
♦ Construction of new flyovers, ROBs, bridges
and culverts
♦ Construction of under passes (14Nos)
Logistics of the
Project
As this road project spans over two states,
proper care will be taken and due diligence is
being applied for the efficient operation of the
entire system to ensure that every road user
is highly benefited by utilizing the resources
to the fullest capacity.
Innovative Techniques to be used
♦ Modified bitumen for the top layer of the
pavement
♦ Precasting elements for the box culverts
and drains
Major P&M mobilized for the
project
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
Hot Mix Plant
Batching Plant
Pug Mills
Lime Kilns & Hydrated
Lime Plant
Motor Grader
Vibratory Roller
Tandem Roller
Asphalt Sensor Paver
WMM Plant
WMM Sensor Paver
Pneumatic Tyre Roller
Kerb Casting Machine
Screening Plant
Crushing Plant
:
:
:
2
2
3
:
:
:
:
:
:
:
:
:
:
:
6
9
16
6
2
2
2
2
2
1
3
Mohit Verma
Project Manager
B.S. Rathore
Planning Manager
33
Six Laning of
Vadodara-Bharuch
BOT Road Project
ational Highways Authority of India
(NHAI), under Ministry of Road Transport & Highways (MoRTH), is implementing the construction of six laning of Vadodara
-Bharuch road project on NH-8. This is a
part of the ambitious National highway development programme (NHDP) of Government
of India, connecting four metros of the country. Considered as one of the major high-density traffic highways in India, NH 8 connects
national capital of Delhi and the financial hub
Mumbai.
Construction of this 84 km long project of
national importance has been awarded to L&T
Vadodara-Bharuch Tollway Limited, a Special
Purpose Vehicle promoted by L&T
Infrastructure Development Projects Limited,
with a negative grant of about Rs.450 crore
(Rs.4500 million). The total construction cost
of the project is around Rs.750crore (Rs.7500
million) and construction period is 30 months.
The concession period including construction
period is 15 years.
The agreement was signed on July 12, 2006
and the construction commenced from
January 2007 and is expected to be completed
by March 2009 and the commercial operations
would commence thereafter.
Construction of this highway commences at
108/700 km and ends at 192/000km, on NH8 in the state of Gujarat. The highway while
connecting the two cities of Vadodara and
Bharuch, passes through many semi urban
centers and intersects a number of state
highways, MDR (Major District Roads) and
ODR (Other District Roads) in these two
districts. As a part of the continuous stretch
of Ahmedabad-Vadodara expressway, this
serves as the main arterial road for the traffic
emerging from eastern and western sides of
the highway.
Moreover, it is one of the busiest highways
of India and it has immense potential to attract
increasing traffic as it serves various industrial
estates especially in Mumbai, Surat and
Ahmedabad and nearby areas. Upgrading
this section to 6 lanes will not only develop
the main industrial and commercial hubs
enroute but this will also give a direct boost
to the economy and business as well as people
in its neighbourhood. Apart from widening of
the existing 83.3 km of 4 lane carriageway to 6
lanes, the scope of work includes rehabilitation
of the existing carriageway, widening and
renovation of 10 major bridges, 36 minor
bridges and 70 culverts. Construction of 11
new flyovers, 20 new pedestrian
underpasses, 2 railway over bridges, 8 cattle
crossings, 1 vehicular underpass,
improvements to 44 minor intersections. In
addition, the scope also includes construction
of 8 m wide service roads 22 km (11 km on
each side) along with 11 bus bays, 21 bus
shelters, 2 truck lay byes, 2 rest areas, one
toll plaza and one base camp.
ECC, L&T’s Construction Division is executing
this project to the design of SAI, Ahmedabad,
the Design consultants - Artifect Projects
Private Limited are the independent
consultants appointed by NHAI for
supervision.
As a part of the contract L&T will also provide
Highway Traffic Management System (HTMS),
which consists of emergency communication
system, mobile communication system,
variable message sign system, meteorological
data system, automatic traffic counter–cumclassifier system, CCTV surveillance system,
power supply system to collect/disseminate
information about the traffic and incident
management and for the safety of the highway
users.
For execution and logistic purpose, the project
is divided into four sections of 20 km each.
Carrying out the entire construction activity
amidst continuous and uninterrupted flow of
traffic is a major challenge in this project.
For this purpose, an elaborate traffic
management plan has been prepared
envisaging the complete risks and problems
involved in traffic movements. The traffic
management plan prepared is expected to take
Grading and watering in progress
34
Grading work in progress
care of total safety of all staff and workmen
and minimize the accident rate to zero in spite
of the heavy traffic flow of speeding vehicles
plying along the work site. The safety plan
includes providing proper barricades using
concrete safety barriers along the road,
installation of sufficient numbers of warning
signs and signals at entry and exit locations,
bifurcation of the existing road traffic to
service roads and diversions etc. apart from
many other elaborate traffic management
systems to take care of the safety of every
road user and as well construction crews.
quarry sites with crushing plants of different
capacity with state of the art crushing technologies.
The next challenge during construction is mobilizing
approximately 60000 tons of lime stone which is
needed for the construction of the stabilized subgrade.
In order to meet the enormous quantum of
aggregates required for executing the project
(27 lakh tons of aggregates and 13 lakh tons of
Granular Sub base), L&T has established three
The massive scope of structural work demands
efficient and cost effective shuttering solutions,
which is expected to be around 2.5lakh Sqm.
L&T Formwork, with in house design and
Major Plant and machinery required for the
construction includes 3-Hot Mix Plants, 4 -Pugmills,
3 -Batching plants, 1-Hume pipe Manufacturing Unit,
2-Pre cast yards, two 35m long trailers for shifting
of the girders, two 100t Hydraulic Cranes, 20 Earth
Compactors, 14-Motor Graders.
system components would meet this
requirement.
During the course of construction special
attention will be devoted for safety and quality
assurance. In order to achieve this a
separate quality plan has been prepared,
giving details of work procedures, guidelines
to be followed for material management, site
quality control tests, etc.
This will ensure full-fledged compliance of
specification and reduce the cost of re-works.
To achieve highest standards in quality of
work, a site lab is established with well
equipped testing machinery, instruments and
test procedures to meet the quality
requirement.
In order to achieve various other objectives
of the company, diverse cost saving devices,
techniques and methodology are proposed and
they will be implemented at the site. Some of
these techniques include execution of Risk
Management, Contracts Management,
Quantity Survey/Mark Number Concept, WBS
based integrated planning execution strategy,
Earned Value Methodology, Execution
Planning, Modified JCR, Productivity Norms/
Measurement,
Wastage
Norms/
Measurement, Cost Sheet Based Negotiations
etc.The construction of the entire project is
expected to be completed well ahead of June
2009.
Ravi Prakash
Project Manager
Compaction in progress
K.V. Mahadev
Planning Manager
35
Construction of
Container Terminal
#2 at Mundra Port
fenders, CR 120 rails, etc. The projected is to be
completed in 19 months from 19th September, 2005
and has one of the shortest duration considering its
long berthing face. However, the client has added
to ECC’s scope by extending the length of the
terminal by 13 metres and revised the completion
date as 30th June, 2007.
♦ The berth deck is to be designed for an udl of
3t/Sqm
♦ The back up area is to be designed for stacking
of 5 loaded containers high and 6 empty
container high.
♦ The design life of berth is 50 years.
♦ The total berth area is 29,530 Sqm
The broad scope involved in this project
includes:
The client’s design proposal was for diaphragm
wall construction for retaining weak soil mass behind
the berth. As the diaphragm proposal was found to
be expensive, ECC considered several options and
proposed as follows:
♦
undra Port is located in Navinal Island in the
Gulf of Kutch, Gujarat, on the west coast of
India. Currently the port has one multi-purpose
berth and a container terminal. Initially Mundra
Port proposed to develop a Dry Bulk Terminal but
with a view to meet the anticipated rise in traffic of
container vessels, they decided to go in for Container
Terminal #2 (CT 2) measuring 618 m long and and
48.5 m wide.
M/s. Mundra Port and SEZ Ltd. awarded the design
and construction of CT 2 to ECC amidst competition
from Simplex, AFCONS, Skanska, HCC, etc. The
existing multi-purpose berth at this port was
constructed by ECC in 1997.
The terminal is designed to facilitate berthing of
bulk carrier vessels varying from 150,000 dwt to
10,000 dwt as well as container carriers of 8,000
TEUs to 100 TEUs. The clients chose M/s. Stup
Consultants Ltd. as their consultants while ECC
chose M/s, L&T Ramboll Consulting Engineers
Limited.
The contract value of the project is Rs.46.25 cr.
excluding cement, steel and berth fixtures like
♦
♦
♦
♦
♦
Construction of 475 bored-in-situ piles of dia
varying from 1300mm to 1000mm to be driven
in marine mode method using piling gantries
95 nos. of 50m long transverse in-situ beams
integrated with 6.5m long crane and rear end
deep beams
2,000 nos. of precast planks to be placed
over in-situ beams
50,500 Cum of concrete
Placing rock in rock bund at rear of the berth
to a tune of 600,000 t
Placing of geo-textiles and sand filling to a
tune of 150,000 Cum behind rock bund for
development of back-up area
Salient features of the project
Design
♦ The berth needed to be designed to following
berthing requirements:
a) Bulk carrier vessels varying from
150,000 dwt to 10,000 dwt
b) Container carriers ranging from
8,000 TEUs to 100 TEUs.
♦ The draft required at berth face is -18.50 m for
which dredging is done by others.
♦ Strengthen the weak soil mass behind berth by
way of dredging
♦ Protect the slopes with rock bund behind berth
♦ Sand filling behind berth for back-up area
development
♦ Tie the berth in transverse direction with SAIL
MA tie rods of 100mm dia between rear pile
and dead-man anchor wall in sand filling area.
Construction Methodology
The job has been a challenging task as the
construction is on marine waters having spring
tidal variation of 5m.
♦ Two fronts were opened for operations – one
from middle of the berth and another from far
end.
♦ The five grid piles were executed using one
three-pile gantry and one two pile gantry from
each front.
♦ The in-situ cross beams trail the piling gantries.
♦ Rock bund behind the berth will be placed by
end-on method using long excavators in pace
with the two-pile gantry’s speed
Deck slab and marine piling works in progress
36
♦ Balance rock placement and profiling
underneath the berth was done by 75 t cranes
fitted with 1 Cum orange peel rock grabs from
completed deck slab
♦ Once the above rock placement was completed
the pre-cast slab placement was done using
the same crane, followed by 250mm thick insitu deck slab
♦ Further marching of crane on the completed
deck slab was done after the in-situ slab
concrete attains M-20 strength which is
achieved after 72 hours
♦ To avoid idling of work for 72 hours, the berth
width was taken up in two halves
♦ Once rock bund was completed for substantial
length, geo-textile laying and sand filling was
taken up
♦ The dead-man anchor wall was done in part
pre-cast and part in-situ mode. The pre-cast
part was placed in the trenches followed by insitu portion and tie rod fixed
Major Equipments Deployed
♦ Three-pile gantry with
7.5 T winches
♦ Two-pile gantry with
7.5 T winches
♦ 75 t crawler cranes
♦ 40 t hydraulic crane
♦ Concrete batching
plant 30 Cum/hr
♦ Concrete batching
plant 15 Cum/hr
: 2 Nos
Deck slab work in progress
: 2 Nos
: 2 Nos
: 1 No
♦ Transit mixers
6 cum/4 Cum
♦ Concrete pump
♦ Long stick excavators
♦ 1 Cum Orange peel
rock grabs
♦ 6 cylinder boat
: 1 No
: 1 No
: 4 Nos
: 2 Nos
: 2 Nos
: 2 Nos
: 1 No
Troubleshooting
♦ Initially the winches broke down at frequent
intervals as they had not been in use for quite
some time. These were replaced with new
ones, after which the piling cycles stabilized at
6-7days per bent
♦ Material feeding to gantries/fronts was
centralized by synchronizing/networking all
resources, thus avoiding delays
♦ The height of the goosenecks was increased
by 1m resulting in a big ease in reinforcement
cage handling, which gave rise to considerable
time reduction in cage lowering
Staff
The project team is led by Mr. A.K. Jayaprakash
with three section-in-charges, viz., piling, in-situ,
and rock bund, and supporting staff. The total staff
including accounts and administration is 33.
Awards
Client has awarded ECC a certificate for achieving
1 million safe man hours.
Project Monitoring
The project is monitored on fortnightly basis using
MS Project and variance statements.
Central part of Jetty piling works in progress
A. K. Jayaprakash
Project Manager
37
high currents in the Gulf of Khambatt (rated as second
highest in the world for tidal currents).
The basic infrastructure facility under construction
involved:
♦ Pumping Station of 25 MLD capacity at Vilayat,
solely to cater to new industries, with four
Effluent Transfer Pumps (2W+2S) powered with
135 KW induction motors for a discharge of 525
Cum/hr
CC executed a unique infrastructure project for
Gujarat Industrial Development Corporation at
Dahej to cater to the safe disposal of treated
effluent collected from various industries in Dahej &
Vilayat Industrial Estates into the Gulf of Khambatt
Valued at Rs. 176 crores, this is the first project of
its kind and perhaps the longest effluent disposal
pipeline in the country.
Moreover, this involved several challenges like laying
large diameter HDPE onshore pipeline ( 710mm &
1000mm dia) and hydro testing the same in long
stretches of 3-5 km length as well as laying 4.5km
long marine pipeline, under huge tidal variations with
♦ 40 km of 710 mm dia HDPE pipeline for conveying
the treated effluent from Vilayat to Dahej
♦ Pumping Station of 90MLD capacity at Dahej
(including 25 MLD for future requirement), with
four Effluent Transfer Pumps (2W+2S) powered
with 415 KW induction motors for a discharge
of 1875 Cum/hr
♦ 9 km of 1000mm dia HDPE pipeline for conveying
the treated effluent from Dahej to landfall point
(Starting point of the Long Sea Outfall)
♦ 4.5 km of marine pipeline for conveying the
treated effluent from landfall point to diffuser
point in the Gulf of Khambatt
Salient Features
♦ Supply & installation of 40 km onshore HDPE
pipeline with 641mm ID, 710mm OD - PE
100.SDR21 PN 8, at 20° C, conforming to DIN
8074:1999. Testing of the pipeline was done in
stretches exceeding 5.00 km in length
♦ Supply & installation of 9 km onshore HDPE
pipeline with 922mm ID, 1000mm OD PE 100,
SDR 26, PN 6.3 at 20° C, conforming to DIN
8074: 1999. Testing of the pipeline was done in
stretches of 3.00 km length
♦ Laying of the critical 4.5 km ‘Long Sea Outfall’
CS pipes of grade API 5L X60 comprising:
♦
2700m of 1000mm ID CS pipe, 17.6mm
thick with 12mm thick cement mortar
lining, 2mm outside bitumen wrap and
65mm thick concrete weight coating
♦
1800 m of 1000mm ID CS pipe, 11.7mm
thick with 12mm thick cement mortar
lining, 2mm outside bitumen wrap and
90mm thick concrete weight coating
Offshore pipeline laying in progress for the disposal of treated effluents from Vilayat to Gulf of Khambatt
38
Methodology for Long Sea Outfall
execution
Execution of the 4.5 km Long Sea Outfall was the most
critical activity, especially due to the extraordinarily
high tidal variations and the enormous length of
the Inter-tidal zone (2.0 km). The pipe for conveying
treated effluent weighed 1.25 t/m in air against its
submerged weight of approximately 135 kg/ m. The
pipeline was to be installed using the “Bottom Pull”
method using pull force generated from a barge in the
deep sea.
However, the major problem was to take the pipeline
through the inter-tidal zone, where the weight of the
pipe increased 10 folds during the low tide, making the
‘Bottom Pull’ process next to impossible since
continuous pulling was a necessity for countering the
high currents.
To overcome this problem, an innovative scheme was
developed, by which a 2. 70 km long railway track
from land, extending 1.75 km into the sea was specially
laid for conveying the pipeline in the inter-tidal zone.
Structural system for the rail track involved driving
640 marine piles and 2750 tons of structural fabrication
and erection. This was made ready within a short time
of 4 months.
Specially designed saddles for carrying the pipe,
mounted on bogies to run on the rail track, were shop
fabricated, supplied and installed at site for use in the
inter-tidal zone. The co-efficient of friction using this
system was found to be within 1.5%.
The entire strings were kept ready in lengths of 500m800m, at the stringing yard near the Landfall Point for
sequential launching and pulling.
Pipes entering deep sea
Using this pipe conveyance system, the pipeline was
sequentially launched, with the pull generated using
10t capacity winches and the pipeline taken to
Ch.1650m, from where our Offshore Partner, SMIT
International, Singapore took over the pipe pulling
activities using a 750t pull force capacity barge.
The main pipeline pull was completed as scheduled on
March 3, 2004, to the entire satisfaction of the client
and consultants - Frischmann Prabhu, India Pvt. Ltd.
The system designed was so efficient that the ultimate
pull experienced was only 250t against the anticipated
600t. Probably, this is a breakthrough for systems
being used all over the world for marine pipeline
installation, doing away with the requirement of high
cost barges, with measured investments in the
infrastructure for pipe conveyance.
E.P. Sajit
Construction Manager
A Pumping station
G. Balasubramanian
Designs Manager (Civil)
39
of 20 MLD Capacity) was constructed and
commissioned for its full capacity of 40 MLD.
The plant’s common facilities were designed for 60
MLD capacity, providing for future expansion. The
final treatment consists of three levels - primary,
secondary and tertiary. The effluents from three
industrial estates are pumped into the inlet chamber
of the plant. All interconnecting and pumping lines
are of HDPE up to 900 mm diameter while all the
equipment are of stainless steel to withstand
corrosive effect of the effluent.
nkleshwar is a major industrial town of
Gujarat, situated on the bank of river Narmada.
Many chemical, pharmaceutical and pigments
industries are located in nearby industrial zones of
Ankleshwar, Jhagadia and Panoli. All these
industries were discahging their effluents into the
nearby open drain (Amala khadi). To comply with
the orders of the Hon’ble Gujarat High court, it
was considered necessary to construct a Final
Effluent Treatment Plant (FETP) and pipeline through
which the effluents can be discharged into the sea
about 40 km away. This will protect the surrounding
agricultural land and the open drain from pollution.
The site selected was near the Amala khadi where
effluents from all the three industrial estates are
deposited. Raw effluents, once lifted, would pass
through different units by gravity flow before being
pumped into the sea. This is one of the biggest
plants of its kind in India. A common Final Effluent
Treatment Plant of 60MLD with two batteries (each
The primary treatment system consists of units
like equalization tanks for mixing effluent from the
three industrials estates to ensure homogenization.
For mixing, 24 mixers (imported from Italy) are
installed. Effluents are treated further for
neutralization by lime slacker unit and its dosing
system. Removal of solids is to be done in the
clarifier, in preparation for secondary treatment.
The sludge generated from clarifiers is thickened
through thickener and converted into sludge cake
by two centrifuges of 15 Cum per hour capacity
each, procured from Germany. The sludge cake
storage platform is provided for further drying and
dispatch to a hazardous landfill area 15 km from
the site.
The secondary treatment is an aerobic process
that entails an activated sludge system with extended
aeration and de-nitrification by anoxic process. The
aeration tank is divided into two batteries of 20MLD
flow, each consisting of three ponds in series having
two days retention time for aeration. A dedicated
intermediate tank with a retention time of 12hours
is provided for denitrification process. The air is
supplied through eight 180HP twin lobe blowers to
the fine bubble diffusers in aeration tank. There are
about 9,000 silicon membrane diffusers imported
from USA. The diffusers are fine bubble type for
good oxygen transfer efficiency of 35%. For online
maintenance, the diffusers are of retrieval type
which can be removed from the tank without
resorting to shutdown. For anoxic tanks there are
eight aspirators (each of 22KW+3KW) provided
for the blower imported from Australia. The process
of extended aeration is followed by biomass
separation in two secondary clarifiers, each of 55
m dia. The sludge is re-circulated in the aeration
tank and the excess to sludge thickener through
re-circulation pumps.
The tertiary treatment is a chemical coagulation
and flocculation process to remove residual
pollutants in conformity with the marine disposal
standards. Facilities are available to doze and store
alum and lime. The tertiary clarifier for removal of
chemical sludge and thickener as well as two
centrifuges (20 Cum/hour capacity) are provided
for disposal of sludge. The final supernatant from
tertiary clarifier is discharged into guard pond of
one-day storage to check the marine standards
and provision for reprocessing of the effluent. The
treated effluent is pumped through a 40-km-long
onshore rising mains and 10 km inside the sea for
View of tertiary clarifier, thickener, guard pond, final sump and pump house for disposal to sea
40
final disposal as recommended by
the Gujarat Pollution Control
Board.
The plant is equipped with an online SCADA system to monitor
treatment parameters. A fullfledged laboratory is installed with
atomic spectrophotometer
(AAS203)
and
visible
spectrophotometer (UV2100)
besides other analytical laboratory
instruments. To check the
incoming effluent parameter
online, TOC (Total Organic Carbon)
analyzers along with a composite
sampler are installed for all the
three streams. CCTV cameras are
provided at inlet chamber to
monitor the incoming effluents
right from the control room. For
uninterrupted operation of the
plant two DG sets of 1275 kva
capacity are provided.
Mr. Anupkumar V. Patel, Project Manager, L&T (second from left), briefing
Mr. Narendra Modi Hon’ble Chief Minister of Gujarat on the effluent treatment
process during the inauguration of the plant
The clients for the project are
Bharuch Eco-Aqua Infrastructure
Limited (BEAIL), a public limited company floated
jointly by industrial units in the Ankleshwar, Jhagadia
and Panoli along with GIDC. Multi Mantech
International Pvt Limited, Ahmedabad are the master
consultants.
Total contract duration was 27 Months including 12
months for operation and maintenance (O&M). The
final contract value stood at Rs.38.76 cr. The Plant
has been commissioned and the O&M part of the
contract will be in force up to November 30, 2007.
Mr. Anupkumar V. Patel (Project Manger) took the
lead role since beginning of the project for approval
of design and drawings, procurement of various
equipment, construction and commissioning of the
plant. Mr. Sunil Kumar Singh (Planning Engineer)
and Mr. S. Sarvanan (Acct & Admin) along with 12
technical staff contributed to the successful
completion of the project. The major items of work
involved in the construction of this plant are given
below:
♦ Earth work excavation
: 4,00,000 Cum
♦ Disposal of surplus earth
up to 20 km radius
: 1,75,000 Cum
♦ Plain cement concrete
: 6,000 Cum
♦ Reinforced cement
concrete
: 21,000 Cum
♦ Corrosion resistant steel : 1,809 t
♦ 3 mm thick FRP lining
: 7,200 Sqm
♦ Brick work
: 3,200 Cum
♦ Plaster
: 27,000 Sqm
♦ Piping network
(HDPE/PVC)
: 11,500 Rmt
Construction of the Biological Reactor in the plant
was completed in December 2004 and taken up for
hydro testing. During hydro testing, some leakages
were observed through the bottom slab from one
compartment to another.
Despite consultations with some experts, no
solution could be found for this problem. However,
at the request of a Director of BEAIL, ECC took up
rectification work as a challenge and successfully
completed the job.
The Client appreciated ECC’s efforts for timely
completion of Biological Reactor modification job
with good quality and safety standards and awarded
an incentive payment of Rs.15 lakh.
Primary Treatment Units showing clarifier, thickner, neutralization tank, lime
slaker unit, equalization pump house and chemical storage room
Anupkumar V. Patel
Project Manager
41
nder the ambitious Sujalam Sufalam Yojna
visualized by the Hon’ble Chief Minister of
Gujarat, L&T bagged contracts worth Rs. 495
crores for laying 149 kms of bulk lines and 600 kms
of distribution lines. This scheme seeks to address
the water problem in North Gujarat with a
concentration on drought-prone areas and also aims
to double the farmers’ income and improve the
rural economy of the Gujarat.
As a part of this project, L&T is executing about
115 km of bulk lines of 2150 mm dia MS pipes to
connect Narmada Main Canal with Dharoi Dam,
Hathmati and Guhai reservoirs. The scope also
includes 34 km of distribution pipelines of MS Pipe
1600 mm-1750mm dia as extension work of canals.
L&T’s scope comprises works with
♦ Gujarat Water Resources Development
Corporation Limited,
♦ Narmada Water Resources, Water Supply
and Kalpasar Department (NWRWSKD)
Dharoi dam
♦ Gujarat Water Supply & Sewerage Board for
the Mehsana District Water Supply Scheme,
which provides potable water to 239 villages
Modhera–Dharoi Pipeline
(MDPL)
The Dharoi dam, constructed on river Sabarmati in
Mehsana District from 1972-78, caters to irrigation
and potable water requirements of villages under
Mehsana and Sabarkantha districts of Gujarat. In
the early days there was sufficient water in the
dam to meet the total demand. Subsequent
construction of water harvesting structures and
storage points limited the water supply to Dharoi
dam from the upstream catchment areas. Further,
scanty and erratic rainfall ensured that the average
storage of Dharoi Dam from 1993 to 2003 was a
meager 345.23 MCM against the total storage of
capacity of 735.05 MCM (less than 45%).
The reduced availability of surface water resulted
in alarming depletion of groundwater levels and
deterioration of water quality resulting in increase
of salinity, fluoride and nitrate levels. To augment
inflow of water to Dharoi dam, the Government of
Gujarat decided to supply water from Narmada
Main Canal (NMC) for which it sanctioned 0.55 MAFT
of water from Narmada. In North Gujarat, water
from the Narmada river flows through the NMC,
which is a contour canal; hence flow/gravity
irrigation is only possible to the left side of the
canal, whereas on the right side, the contour/
elevations are higher than the NMC water level,
Trenching work under progress
42
making it unsuitable to be fed through gravity flow.
To achieve this, three lift irrigation schemes are
earmarked at different chainages of NMC. MDPL
is one of these.
This project, valued at about Rs. 260 Crores,
comprised supply and installation of pipes, valves
and allied civil works. Gujarat Water Resources
Development Corporation Limited (GWRDCL)
monitored the execution of the project and the role
of the third party inspecting agency (TPI) was
entrusted by client with M/s SGS, Ahmedabad.
L&T’s scope involved manufacture, supply and laying
of the 2150mm dia MS pipeline from Narmada Water
Canal to Dharoi dam through 88 Km of agricultural
land, strata varying from soft murrum to sandy via
the pumping stations located at Modhera, Motidau
and Rasulpur. With the pumping stations scheduled
for completion by February 2007, the project is
expected to go on stream during March 2007.
Scope of Work
♦ Total Length of Pipeline
♦ Diameter
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
: 88.75 km
: 2150 mm x 12
thick
: 60000 t
: 6.07 lakh Sqm
: 5.99 lakh Sqm
: 10-lakh Cum
: 0. 8 lakh Cum
: 6 lakhs Cum
Total Weight of Pipes
Outside Tape Coating
Inside Epoxy Painting
Excavation
Sand Bedding
Backfilling
12mm thick HR coil
conforming to IS 10748 :
Manufacturing and supply
of 2150mm dia ID pipe
with inside epoxy painting
and outside coal tar taping:
Supplying and Fixing of
1800mm dia Butterfly Valve:
Supplying and Fixing of
300mm dia Scour Valve :
Supplying and Fixing of
200mm dia Air Valve
:
Fixing of 2150mm dia Zero
Velocity Valve
:
Fixing of 300mm dia Air
Cushion Valves
:
58000 t
88750 Rmt
18 Nos
Hathmati reservoirs and caters to the
requirement of Guhai Dam. The project is located
in the Sabarkantha district of North Gujarat and
is being executed by the Narmada Water
Resources, Water Supply & Kalpsar Department.
M/s. Harmony Associates, Baroda, is the design
consultant, M/s. SGS India Pvt Ltd., is the
nominated third party inspection agency.
L&T’s scope of work involved laying 64.45 km of
various diameters pipes (2174mm OD/1920mm,
OD/1770mm OD/1614mm, OD/1214mm, OD/
1164mm) from Talod pumping station from where
the canal water is lifted and pumped after filling
various reservoirs enroute.
The pipeline is externally coated with coal tar
wrapping of 2.5mm thick and internally lined with
110 micron Epoxy comprising of spirally welded
SAW pipes.
The pipeline traverses through different terrains
like rocky, marshy, water logged, loose soil etc.
Around 12 Km of the pipeline is laid under heavy
ground water conditions, 2 Km of the pipeline is
laid across the Fatherpur reservior in water
stagnant conditions.
The pipeline crosses the Chiloda Udaipur National
Highway no – 8, for which 2150mm of ID casing
pipe is done beneath the highway. In addition
there is a railway crossing and Hatmathi main
canal crossing at two locations.The complexities
involved arrangement of Right Of Works for the
transportation of huge pipes, pipe laying in water
logged areas, executing the 19 major road
crossings including one railway and NH. Meeting
the challenges head-on, the project team
completed the entire job with right planning and
supports from the departments and the regional
office. The site clocked 908779 safe man-hours.
Project Highlights
♦ Section - 2 : S S S Canal To Fathepur 14.867Km
♦ Section - 3 : Fathepur To Khed-20.773 Km
Fathepur To Bhujwa-8.750Km
♦ Section - 4 : Khed To Hathmati - 3.172 Km
Khed To Guhai - 16.890 Km
♦ Total length : 64.452 Km
Quantum of work
MS Pipeline
♦
♦
♦
♦
♦
♦
♦
Length
2174mm OD x 12mm
1920mm OD x 10mm
1770mm OD x 10mm
1720mm OD x 10mm
1616mm OD x 8mm
1214mm OD x 7mm
1164mm OD x 7mm
:
:
:
:
:
:
:
♦ Butter Fly Valves
(1800/1500/1200)mm Dia
♦ Scour Valves
(300mm Dia)
♦ Air Valves with
Isolation Valves
♦ Construction Of RCC
Valve Chambers
26027 Rmt
7440 Rmt
7953 Rmt
1660 Rmt
16890 Rmt
1310 Rmt
3172 Rmt
: 10 Nos
: 23 Nos
: 212 Nos
: 54 Nos
Productivity
♦ Hard Rock Excavation
(Average)
:
♦ Excavation (capacity) :
♦ Crane
:
♦ Pipe Laying per day :
1500 Cum/day
84 Cum per Hour
4.2 Pipes per day
62 Pipes (756 Rmt)
M.K. Mishra
Construction Manager
29 Nos
299 Nos
9 Nos
29 Nos
E.P. Sajit
Project Manager
Narmada Main Canal
pipeline to Guhai - Hathmati
Reservoirs
Narmada Water Resources Development
Scheme (NWRDS) contributes to Bhujwa and
Pipe installation work in progress
43
View of Clariflocculator for Water Treatment Plant
Mehsana District Water
Supply Scheme on Design
Build Operate basis
The people of North Gujarat are dependent on deep
bore wells for drinking and irrigation water supply.
Due to extensive use of such bore wells coupled
with poor rain fall, the water table has gone down
drastically, in addition to high concentration of
Fluoride in these areas.
To put an end this problem, the Government of
Gujarat came out with the plan for the construction
of Narmada Main Canal Based Regional Water
Supply Scheme to provide potable water to 12 sub
groups of Mehsana and Patan districts of Gujarat
covering 239 villages/habitations of Mehsana,
Becharaji and Chanasma taluks. Under this scheme
water is drawn from the Narmada Canal at village
Modhera in Chanasama taluka and after filtration
and treatment, it is supplied to various towns and
villages by pumping main, gravity main and
intermediate head works with sumps, ESRs and
Pump Houses.
The 12 areas covered under this scheme include
Mehsana, Nanidau, Sametra, Jotana, Kherwa,
Ambliyasan, Modhera, Kalari, Pimpal, Lanva,
Dharmodoa and Islampura. For this purpose, two
filtration plants are constructed – (a) at Modhera
(45 mld capacity) located two km away and (b) at
Dediyasan (91 mld capacity) located about 25 km
away from the tapping source.
♦ 490 km of PVC pipeline, dia ranging from 90
mm to 315 mm
♦ 10 elevated storage Reservoirs of 5 lakh litre
to 20 lakh litre capacity
♦ 58 sumps of 5 lakh litre to 20 lakh litre capacity
♦ 4 intermediate pump houses
ECC, L&T’s Construction Division executed this
project for Gujarat Water Supply & Sewerage Board
and the work involved construction of pipelines,
ESRs, underground RCC storage reservoirs/
sumps, pump houses, water treatment plants etc..
Certification Engineers International Limited,
Mumbai were the Consultants for the project.
This also involved installation of pumps, valves,
water hammers, water meters, pressure gauges
and associated civil works including supply,
erection, testing and commissioning of electromechancial equipments for various services.
The work on the project began in March 2004 and
the entire work was completed in December 2006
and it is now under Operation and Maintenance by
ECC for the next two years.
Apart from building two water treatment plants,
the work involved construction of:
♦ 160 km of MS pipeline in dia ranging from
322mm to 914 mm
♦ 40 km of DI pipeline in dia ranging from 300
mm to 450 mm
At peak of works ECC deployed 28 staff, 43 skilled
and 280 unskilled workmen including five 8t cap
Hydra cranes, one crawler type and three tyre
mounted excavators, two 40 kVA DG sets, eighteen
10/7 Cum mixer machines and three 40 feet trailors.
The entire work was completed in December 2006
and 200 out of 239 villages have been supplied with
treated water. Moreover, ECC has been entrusted
with the O&M contract for 24 months from January
2007.
E.P. Sajit
Construction Manager
44
ECC, L&T’s Construction Division takes pride in
having been associated with GSPL in laying and
commissioning more than 430 km of gas
transmission pipelines at various sections in the
State from Bhadbhut – Paguthan, Petronet Dahej,
Paguthan – Baroda, Mora – Sajod operating in the
Hazira-Vadodara-Ahmedabad-Kalol area. And these
pipelines transports more than 13 MMSCMD of gas
currently, including more than 5 MMSCMD of RLNG.
ujarat is the leading onshore producer of crude
oil and natural gas in India contributing 17.9
per cent of the total oil production and 10.4
per cent share in total gas production in the country.
The major players in the upstream oil & gas sector
in the state include ONGC, GSPC, Niko Resources,
Cairn and GAIL.
Currently, crude oil is transported from domestic
oil fields and ports/jetties (for imported crude) to
the refineries, and oil products are transported
from refineries to the marketing networks, by rail,
road and transmission pipelines. Understandably,
pipelines are far more advantageous considering
the fact that transportation cost accounts for
roughly 25 per cent of the product cost.
Extensive network of gas pipelines
Gujarat State has an extensive network of gas
pipelines. Gujarat State Petroleum Corporation
Limited (GSPC) a vertically integrated energy
company set up in 1979 is a force to reckon with in
the sector with its wide range of hydrocarbon
activities. Gujarat State Petronet Limited (GSPL), a
subsidiary of GSPC is a pioneer in developing energy
transportation infrastructure and connecting natural
gas supply basins and LNG terminals to growing
markets. In order to meet the increasing demand
for gas supply, GSPL is continuously expanding its
pipeline network in Gujarat, connecting the demand
centers with various gas grids.
Out of the 742-km gas pipeline expansion plan of
GSPL, ECC has already constructed and
commissioned 542 km comprising of major sections
of gas transmission pipelines from Anand-Rajkot,
Mora-Vapi, on EPC basis.
Project Highlights
Following are some of the major pipeline projects
executed by ECC for GSPL
Anand-Rajkot
Engineering, procurement and construction of 123km
long 24" dia x 11.1/14.3 mm thick API 5LX65 pipeline
system from Anand to Rajkot, including HDD for 1
river crossing, cathodic protection work, fiber optic
cable network, sectionalizing valve stations including
associated civil, mechanical, electrical and
instrumentation works and commissioning of the
entire system on EPC basis.
Mora-Vapi
Engineering, Procurement and construction of 128
km long 30" dia x 14.3/17.5/20.6 mm thick API 5L
X65 pipeline system from Mora to Vapi, including
HDD for 12 river crossings, cathodic protection
work, fiber optic cable network, sectioning valve
stations including associated civil, mechanical,
electrical and instrumentations works and
commissioning of the entire system on EPC basis.
Mora-Sajod
Laying of 24" dia pipeline to a distance of 15 km for
Mora – Sajod section.
Paguthan-Baroda
EPC contract of residual process design, detailed
engineering, procurement, construction,
commissioning and mechanical guarantee including
temporary/permanent cathodic protection system
& OFC work for Paguthan – Baroda Gas Pipeline
project (24" dia x 80 km) including construction of
sectionalized valve station and river crossing by
HDD works.
Petronet Dahej
Turnkey contract including residual engineering,
procurement, laying of 24" dia 8.5 km long gas
pipeline including TCP/PCP and OFC works along
with metering station form Petronet Dahej to Gujarat
Alkali Limited of Gujarat State Petronet Limited.
Bhagbhut-Paguthan
Residual process design, detailed engineering,
procurement, construction, commissioning of 24"
dia pipeline x 24.88 km long and 12" dia pipeline x 5
km long including installation of OFC and temporary/
permanent cathodic production.
GAIL (India) Ltd
GAIL India Ltd. (earlier Gas Authority of India Ltd),
India’s principal gas transmission and marketing
company, was set up by the Government of India
in August 1984 to create gas sector infrastructure
The gas grid project promoted by GSPL, envisages
transporting indigenously produced natural gas from
production centres and LNG terminals to demand
centres all over Gujarat through a high-pressure
trunk pipeline transmission project to deliver gas
to end users and for local distribution.
Gujarat State Petronet Ltd, which owns the second
largest gas transmission network in India after
GAIL India Ltd, is expanding its pipeline network in
Gujarat from 433 km at present to 742 km. Gujarat
is the largest consumer of gas in the country,
accounting for one-third of the national gas
consumption.
Anand-Rajkot Gas terminal
45
for sustained development of gas market in the
country comprising of Jamnagar-Loni, Kalol-Ramol
Pipeline Projects constructed and commissioned
by ECC. Highlights of these projects include:
Kalol-Ramol
Laying of 40 km long 12" pipeline and composite
works along with optic fiber cables and complete
design, engineering, supply, installation testing and
commissioning of receipt terminals, SV station for
Kalol–Ramol Pipeline project including civil,
mechanical and associated works for the terminal
stations at Kalol and Ramol terminals.
Jamnagar-Loni
Laying of LPG pipelines for a distance of 755 km
using 16"/14"/12" dia pipes including optic fiber
cables and complete design, engineering, supply,
installation testing and commissioning of receipt
terminals, SV station for Jamnagar–Loni Pipeline
(JLPL) project of Gas Authority of India Limited
(GAIL). This also involved construction of terminal/
intermediate pumping station at Jamnagar
Samakhiali, Abu Road, Ajmer and Loni including civil,
mechanical and associated works for the terminal
stations at Ajmer.
ECC Division undertakes turnkey & EPC
construction of Oil & Gas, Refinery & Petro –
chemical, Cross country pipelines projects covering
civil, structural, piping, equipment, heavy lifts,
electrical & instrumentation works. ECC has Inhouse design engineering capabilities for cross –
country pipelines, terminals, offsite facilities,
floating/fixed roof tanks, cooling towers/cooling
water system, electrical & instrumentation system,
fire protection system, etc.
Pipe laying work in progress
Control panel installed at the Anand-Rajkot gas terminal
Oil & Gas Terminals and Crosscountry Pipelines
♦ Execution of cross-country pipeline projects
involving laying including OFC, Horizontal
Directional Drilling, testing, pre-commissioning
and commissioning of pipelines. Expertise
includes design, engineering, procuremeant
and construction of civil, mechanical, electrical
and instrumentation for composite station
works, cathodic protection system for
pipelines/stations
♦ Construction of LNG terminals and LPG storage
facilities
♦ Design, procurement & construction and
commissioning of facilities for underground
cavern storage system for LPG
♦ Erection of high capacity gas compressors and
associated facilities
Refineries and Petrochemicals
♦ Design and Construction of civil works, viz.
cooling tower, equipment/pipe racks
foundation, sub station/control buildings
including geo technical studies
♦ Design, procurement & construction of the civil
structure for the plant
♦ Design, procurement & construction of storage
tanks
♦ Design, procurement & construction of
electrical systems, project electrification,
control and automation systems
♦ Procurement & construction of fired heaters,
structural and process plant piping including
inconel, hastalloy, titanium, etc.
♦ Procurement & construction of mounded bullets
and Horton-spheres
♦ Erection of static and rotary equipment
including heavy lifts of reactors, re-generators,
columns, etc.
♦ Shutdown maintenance and revamping works
Rajiv Kumar
SPM – HCP
46
Petroleum Product
Pipelines for IOCL
ndian Oil and its subsidiaries account for 47%
petroleum products market share among public
sector oil companies, 41% national refining
capacity and 74% petroleum products pipeline
capacity.
The Company’s cross-country crude oil and product
pipelines network spanning over 9,000 km meets
the vital energy needs of the country. L&T has
played a vital role in developing major projects of
IOCL across the country and Gujarat in particular.
Following are some projects executed by L&T for
IOCL.
Koyali-Viramgam-SidhpurSanganer Pipeline (KVSSPL)
The 249 km long Koyali-Viramgam-Sidhpur
petroleum product pipeline was extended with a
518 km long pipeline of 18" dia from Sidhpur to
Sanganer connecting it with the Kot-Salawas branch
pipeline at Kot and delivery facilities at Sanganer
terminal. Apart from laying the pipeline, this involved
cathodic protection and civil, mechanical, electrical
Reactor erection for FCCU shutdown work
and instrumentation works at stations en route. This
was commissioned by ECC in 2004.
electrical and instrumentation works for Petronet
V. K. Limited/IOCL.
Vadinar Kandla Pipeline Project
Crude Oil Pipelines
Installation, testing and pre-commissioning of 60 km
24" dia on-shore product pipeline (API-5L Gr X-60)
from Vadinar to Kandla, including composite works of
inter-mediate works involving civil, mechanical,
Kandla-Bhatinda Pipeline (KBPL)
Commissioned in 1996, the 1443 km long KandlaBhatinda Pipeline, with a capacity of 8.8 MMTPA, pumps
crude oil from Mundra Port to the 12 MMTPA Panipat
Refinery. It has recently been converted to crude
service. It was a Petroleum Products Pipeline earlier,
pumping petroleum products from Gujarat coast to
the heartland of Punjab.
Pertronet LNG, Dahej
Petronet LNG Ltd is a company promoted by four
hydrocarbon majors in India viz. IOCL, GAIL, ONGC,
BPCL, Gaz de France, Ras Gas, GOG, and the rest
from banks and financial institutions to develop the
infrastructure required for imports to bridge the
demand-supply gap primarily through imports of LNG.
Petronet LNG Ltd constructed and commissioned in
2004 India’s first LNG Terminal at Dahej, Gujarat of
5MMTPA capacity. ECC executed construction and
testing of trestle & jetty area piping; terminal area
piping (30" cryogenic lines – 5.631 km & 56 km utility
and process pipelines of various diameters) and
equipment erection for LNG Regassification Plant for
Petronet LNG Limited at Dahej in 14 months.
A section of the FCCU
Dhiraj Gidwani
BU Co-ordinator, HCP
47
The Anand - Rajkot
Pipeline
ujarat State Petronet Ltd. (GSPL) is currently
implementing a high-pressure pipeline project
covering various industrial belts and cities of
Gujarat. Considering the importance of such a
pipeline network and realizing Gujarat's aim of
emerging as the 'Petro Capital' of the Country, the
State Government has accorded 'Infrastructure
Project' status to GSPL's project.
In a bid to establish a systematic, integrated and
seamless infrastructure for gas transmission from
supply points to various demand centers in the
state, GSPL has been laying underground gas
transmission network across Gujarat.
At present around 742 Km of gas pipeline is under
construction. The EPC contract for the 123
Km long 24” Natural Gas Pipeline from
Anand (Gana) to Chuda, awarded to L&T, is
the first section (Section A)of the AnandRajkot pipeline laying programme of GSPL.
Project overview
The project envisages setting up of a high-pressure
natural gas pipeline system. The pipeline system
broadly consists of the following:
Trenching and laying of pipes
♦ ARPL is originating from the existing
Sectionalizing Valve Station No. 2 of BarodaAhmedabad-Kalol Pipeline (BAKPL) situated at
Gana Village of Anand District in Gujarat.
of intermediate sectionalized valve stations and an
intermediate pigging station at Chuda.
♦ The Pipeline will transport natural gas from
Anand to Rajkot for domestic, automobile,
commercial and industrial consumers.
The Anand Rajkot Gas Pipeline Project Section A
(ARPL-A) was awarded on 7th July 2005 with a
tight completion target of 13 months including
commissioning and one-month operational
acceptance. This being a full-fledged high-pressure
pipeline, all parameters right from procurement of
all specialized materials and equipment to delivery,
execution including pipeline laying and HDD at
Sabarmati river, testing and commissioning of the
pipeline needed to be meticulously planned and
executed. With excellent coordination between site
management, HCP BU at HQ, North Zonal and
Ahmedabad Regional Office, the project has seen
smooth and steady progress till date, which has
earned profound appreciation of the client.
L&T's scope as an EPC contractor in this project
includes design and detailed Engineering, supply
and laying of 123 Km pipeline, construction and
installation of launching facilities at Gana, six nos.
Peep hole
This project had set tough challenges for the Site
Management which rose to the occasion by evolving
effective strategies and implementing the same.
Following are some of the strategies the site
adopted. This not only yielded the desired result
but also resulted in achieving the targets as per
schedule.
Strategies adopted
The contract required approved work procedures
for almost all activities. Hence the first thing the
site did was to draw up procedures and submit
them to client for approval. This helped in obtaining
Welding in progress
48
approved procedures much before the actual start
of job, which gave the frontline engineers
enough time to study and understand the
procedures. This in turn guaranteed execution
with absolute conformity with contract
specifications and saved time and cost of
rework and repairs.
The approved procedures required 'procedure
qualification'. This meant the sequence of
activities for pre-and post-welding are
performed on actual mainline pipes and tested
for viability of the procedure.
However, the pipes were to reach site three
months later. So, waiting till then meant a
delay of at least one week in start of
production because actual job could be started
only after Procedure Qualification.
immediately and the site was ready with welders
before the mainline pipes arrived.
Similarly it was ensured that welding machines
and other equipment were received, inspected
and made ready before the mainline pipes
were received at site. All efforts were made
for early import of electrodes. Electrode
qualification tests were also successfully
completed before the mainline pipes arrived.
Unloading and stringing of pipes
It was decided that pipes be directly unloaded
at site and stringing be done simultaneously
during unloading. Keeping in view the hundreds
of trailer loads of pipes to be received, this
task needed close and meticuolous
coordination between pipe manufacturer and
the frontline team.
To overcome this situation, the clients were
persuaded to arrange for a small quantity of
pipes immediately, on which we could carry
out procedure qualification and return them
at a later stage. Thus a lot of time was saved
and procedure qualification obtained much
before arrival of mainline pipes.
To ensure accurate delivery at desired
locations, it was decided to depute one of our
senior personnel at the manufacturer's works
to coordinate with site and the transporter,
to monitor progress and expedite third party
inspection.
The third and most important achievement was
welder selection and their qualification at site.
The sub-contractors were called and instructed
to mobilize welders immediately. On arrival of
welders, they were interviewed and screened.
The welder qualification activity followed
As part of this effort, a meeting was held between
the manufacturer, the front line team and pipe
delivery coordinator. This helped everyone
concerned to clearly understand their role in the
activity and facilitated smooth delivery of pipes
at site. The whole exercise was so well-planned
that the actual mainline welding started the very
next morning on receipt of the first pipe with
zero loss of time.
Effective resource management
A project of this magnitude with an asking
rate of 120 joints per day would generally
require mobilisation of ample resources.
Keeping in view the limited resources allocated
to this project, a detailed and effective
resource allocation was worked out at site.
Low-priced and easily available alternatives
(12t Hydras) to unavailable resources
(Pipelayers/Tata320) were mobilised at site
for stringing activities.
Similarly resources in other activities were
allocated in such a manner that the availability
of equipment would help and complement the
smooth progress of work. This resulted in
achieving 120 to 150 welded joints per day.
Quality assurance
The site management made it a policy to keep
weld joint repair percentage below 2%. To
achieve this target, a strategy was established
to analyse and find out the root causes of
repair.
Once the root cause was found out, the
frontline engineers, sub-contractor
supervisors and welders were given feedback
and advised of the preventive action to be
taken to stop further recurrence of repair.
This was quite educative for the front line
team and helped them achieve a repair
percentage of as low as 1.2%, which is one
of the most commendable achievements of
the project.
ECC's success in the project proves that a
strategy can work only when it is worked out
with a vision at the back of everyone's mind.
The site team worked with diligence in turning
the strategies into concrete results.
The relentless efforts of the whole team with
firm commitment to achieve targets both
quantitatively and qualitatively have been
commendable.
V. Thirumalaisamy
Project Manager
Composite civil, mechanical, electrical and instrumentation works done at the gas
terminal
Dev Nandan Das
Planning Engineer
49
No Man’s Land
our Indian states, namely Jammu & Kashmir,
Punjab, Rajasthan and Gujarat lie on India’s
border with Pakistan. Recently India started
fencing large sections of its border with Pakistan
which is vulnerable to infiltrators and terrorists.
The total length of India’s border with Pakistan is
3310 km. Gujarat’s share in this is 512 km.
In view of reports of misuse of Gujarat border by
anti-national elements, top priority was accorded
to the work of erection of fencing on India-Pakistan
borders with a view to contain infiltration, smuggling
and other anti-India activities from across the
border. Border Security Force (BSF) is controlling
and managing the entire operation of this fencing
and flood lighting works.
In this no man’s land, L&T is entrusted with
installation and stringing of 11kV HT Lines for
Gujarat Electricity Board (GEB). The work
involves supply, erection, testing &
commissioning of 281 km of HT Lines consisting
of 55 nos. of 100kVA distribution transformers,
2300 tons of galvanized RSJ girders, 450 km of
ACSR Panther Conductor, 400 km of ACSR Dog
conductor, 3920 nos. stay sets and 28000 nos.
of Disc insulators. Though this project is located
in the Rann of Kutch along the sea shore, it
remains dry for nearly six to seven months in a
year and there is no habitation for almost 50 to
100 km along the border.
Executing the project in this no man’s land is a
real challenge in view of the adverse weather
conditions and restriction on free movement of
men, materials and vehicles, in addition to
following reasons:
♦ Entire work is coordinated from the main site
office located at Khavada, 120-200 km away
from the work-site
♦ While staff used to commute in jeeps to and fro
from office to site, workers are allowed to
stay in tents near the existing BSF camps and
food materials are transported from Khavada
♦ Entry permits to be obtained on daily basis for
all workmen and vehicles. Without a valid
permit, no one can move beyond BSF check
posts
♦ Workmen are transported in trucks to various
operation points along the border.
♦ Because of the restricted working hours, BSF
doesn’t permit workmen to move around after
sunset and overnight stay is not allowed. During
working hours in the day, workmen have to
commute almost 200km, resulting in loss of
effective man hours.
♦ During summer, no work can be done due to
heavy sand storms
♦ Moreover, there is threat of scorpions bite
mostly in the Rann area
Gujarat Electricity Board awarded this contract to
ECC in February 2005 and the work commenced in
April 2005. It is scheduled for completion by March
2008.
This is an interesting project from the point of view
of safeguarding and building the Nation.
Ramchandra Yadav
Asst. Construction Manager
50
enpact is the largest business services and
technology solutions company in India with
a global presence operating out of 10 sites
in Gurgaon, Delhi, Hyderabad, Bangalore, and
Kolkata. The latest addition to list of their
operating offices in India is the IT processing
facility at JLN Marg, Jaipur. A green field project
and the first IT/ITES project in the state of
Rajasthan, Genpact awarded the contract to L&T
during February 2005 with a stringent schedule
of 12 months to build a state of the art IT
processing facility. The contract period was later
extended to September 2006 after an increase in
the scope of civil and service works.
M/s Design Plus, New Delhi, was nominated as
the main consultants assisted by specialised
services consultants - M/s. MKG Consultant,
Pioneer consulting engineers Pvt Ltd, Gupta
consultants, Electrical consulting engineers,
Khote landscape and horticulture services.
L&T’s major scope of work comprised civil,
structural, architectural and finishing works of the
entire area which included the IT building, service
blocks, compound wall, Sewage Treatment Plant,
Water Treatment Plant, plumbing and sanitary
works, external development with internal RCC
road, landscaping and horticulture, fixed and loose
interiors and PMC for services package such as
HVAC and VRV system, fire fighting, electrical
system, DG sets, fire alarm system, PA system,
CCTV, Access control system, BMS, Elevators, STP,
WTP, modular furniture, sinages, chairs, carpets,
blinds, kitchen equipments.
Salient Features
The building 28 m tall and 80 m x 35 m wide, is a
ground plus four floors structure with two
basements with an overall built up area of around 3
lakhs Sqft. L&T’s scope of work involved
construction of RCC framed structure with brick
masonry walls and involved architectural and
sophisticated finishing works such as false ceiling
made of gypsum and metal tiles with acoustic layer
of high NRC value, high ACP canopy, semi unitized
curtain glazing, Al. door/window , special white
beach wood doors, fire proof doors, tiling works,
marble and granite design flooring, false flooring,
red sand stone cladding, external texture paints
finishes, and all services related to IT building.
The amphitheatre is designed traditionally with sand
stone cladding, wood Pergola and wall paintings
surrounded by attractive landscaping. The recreation
facilities included a 312 seater state of the art
cafeteria at two floors, 2 break out areas with
refreshment facilities and house phones in each
floors, a full fledged Gym, lawn of more than 27000
Sqft area, party terrace adjacent to lawn.
Employee services like ATMs, departmental store,
Information and reservation booth, phone paying
machine and a hospital are available inside the
campus.
Green building
Being a green field project, the latest energy
conservation systems are adopted to economize
the cost of operation and conserve the energy. The
HVAC systems (Variable refrigerant volume,
variable frequency drive, Thermo fusers, energy
efficient chillers), Electrical system (Compact
fluorescent lamps and dimmer systems) monitor
and control the power usages at various areas.
Other special features included hot water generation
through solar panels, hydro pneumatic pumping
system, RO water system and 3X synchronization
for elevators.
Power and Utility features incorporated are in line
with the latest technology with highest efficiency
plus 100 percent redundancy. A 33-kVA electrical
sub station with 2000 kVA transformer through
exclusive cables is installed. Special CFL lamps are
used for power savings. Technology for earthing is
GENPACT Jaipur - A green field IT/ITES processing facility in Rajasthan
51
maintenance free and has life span for 25 years.
Advanced technology is used for lightening arrestor.
Silent power generators with Euro III engine designed
for zero noise level, 4 DG sets in N+1 redundancy
(2x750 + 2X500 KVA) and fueled through 30KL UGDST
which is monitored by ultrasonic level sensor, PLC
panel for auto power management, UPS N+1
redundancy (2x200 + 5X120 KVA) are installed. All
services are automatically controlled through Building
Management System.
Security System
A foolproof intelligent security system with closed circuit
television monitoring, intelligent perimeter protection,
and access control with biometric/keypad readers
monitors the man movement in critical areas such as
data centre, hub rooms and all entry/exit doors. Cages
are provided in the server room for external customer
racks for privacy and high security. A guard tour
system ensures effectiveness of security guards and
a full-fledged badging station is established for ID card
printing.
Fire & Safety System
The fire alarm system provided is an addressable type
for smoke detection all over the building. An automatic
fire extinguishing system (Inergen) is installed to reduce
down time in server and all UPS rooms. The overall
building is protected with fire sprinkler, internal and
external hydrant systems as per NFPA Standard.
Environment Protection – Bearing in mind the
green field objectives, the project is equipped with rain
water harvesting, a sewage treatment plant that
ensures that there is no disposal let into the city sewage.
A full-fledged laboratory, water treatment and softening
plant ensure on the quality of water used.
East side elevation of GENPACT
Telecommunication - A full range of voice, data
and internet services are provided via CAT 5 wiring,
multi-mode and single-mode fiber for connectivity
with all sites.
Features of GENPACT
♦ Plot area
♦ Permissible Ground
coverage
♦ Ground Coverage
♦ Super Built up area
♦ Landscaped Area
♦ Area under road and
Car park
♦ Basement Car parks
♦ External car Parks
♦ Two level Cafeteria
: 11487 Sqm
:
:
:
:
3967 Sqm
2597 Sqm
17339 Sqm
8600 Sqm
:
:
:
:
3985 Sqm
165 PCU
167 PCU
312 seater
Major items of work include:
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
Excavation
Concreting
Shuttering
Reinforcement
Brick work
Plastering
Painting
Stone cladding
Flooring
Al. glazing
False ceiling
Water proofing
Structural steel
Doors/ window
Expansion joint treatment
Vacuum dewatering
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
45665 Cum
17290 Cum
51395 Sqm
1500 t
4516 Cum
40629 Sqm
55615 Sqm
3257 Sqm
20895 Sqm
2287 Sqm
20600 Sqm
15460 Sqm
82 t
2280 Sqm
2889 RM
8245 Sqm
Design Complexities
Services such as wiring, conduiting, duct, piping,
cable tray etc had to laid above false ceiling and in
external development area by following a complex
design pattern.
Initially Sewage treatment plant design had 2 tiers
in 11 m depth which was modified to single tier in
7 m depth where the space between the inter
compartment is limited and tedious to build.
30 m high DG exhaust structure was designed for
erection in close proximity to the temple wall, which
was later relocated and redesigned with reduced
height.
Construction Challenges
Beautiful view of the landscaped garden
Considering the open office environment in IT
process, installation of glass partition with
52
EHS (Environment Health and safety) Standard.
Getting acetylene and O2 gas was one of the
constraints.
Fabrication of tubular steel structure was done in
truss form to suit the desired shape of ACP canopy.
Erection
Erection of shop fabricated diesel oil tank was a
critical activity due to space constraint near the
temple and surrounding filled soil. This was
successfully executed using heavy crane.
Lifting of chillers to 30 m high terrace was another
major challenge as the lifting crane had limited
space within boundary. This was negotiated with
80 tones capacity tyre mounted crane with long
boom.
Two level cafeteria
accommodation of data cabling and other wiring
was a challenge.
As per client requirement, second floor including
server room was to handed over first and hence
the finishing works from top could not be started.
Executing the second phase works in the
operational building was a highly sensitive and
critical activity.
Deep excavations done during the construction
of UG diesel oil storage tank and STP required
precise planning and continuous monitoring since
the area was very close to adjacent temple wall
and service road.
Since there was a constraint in getting brown
gravels (as per specification) of uniform colour
and quality, it was decided to make use of factory
made round shaped white marble pebbles for filling
at entrance which has greatly enhanced the
aesthetic appearance of the outdoor landscape.
Fabrication & Welding
Fabricating the chiller steel structural foundations
at heights and huge ducting for HVAC was a major
concern. Hence shop fabricated ducts were used
and fabricated the chiller structural foundations
in small segments at positions. Using LPG for
welding or cutting was strictly prohibited as per
Erection of structural beams for chillers
foundation at terrace level was done by certified
chain pulley block system with utmost care.
Lifting of UPS panel through window at third floor
level was complicated task executed skillfully as
the building structure and external finishes was
already completed.
Safety
To meet the tight construction schedule and
ensure a safe working environment the project
team had taken the following safety measures:
♦ Issue of personal protection equipment
for all labourers, vendors, supervisors
and staff working in the project
The labour colony had to be relocated during
execution of the project since the existing place
was sold to private party. The relocation was
established without affecting the progress of the
job.
Innovations
Instead of the conventional chemical mixed
concrete for RCC road work, Tremix flooring
technique was used which was of higher
durability and gave a smoother aesthetic finish
and facilitated speedy execution.
The RCC road was cast in one go and grooves
were cut in set concrete instead of providing
construction joints in panels. This helped in speedy
construction without affecting the technical
requirement.
Deep excavation slopes were cut in steps instead
of one slope with more clearance, which made
execution easy and safe.
Inside view of the workstations in the BPO
53
♦ Induction and screening of workmen
working at site
♦ Security system at all corners of
construction premises
♦ Work permit system before start of any
work
♦ Checking of staging, working platform,
hand rails and issuing the green tag for
use
♦ Checking and issuing ‘safe for use’
certificate to all construction eqipments,
tools and tackles, vehicle etc.
♦ Keeping centralized house keeping crew
on daily basis
♦ Keeping an emergency vehicle 24x7 hrs
♦ 100%hard barricading of the construction
zone from surrounding public prone zone
The stringent safety measures adopted paid rich
dividends when the project was awarded a safety
appreciation certificate for achieving one million
man-hours of incident and injury free work by the
client.
Formwork
L&T formwork was used for the entire structural
work of the building. Concreting work was done
using 2 nos RM-800, 5 nos 10/7 mixer machines
and builder hoist.
Logistics
The project is located in the heart of city and comes
under no entry zone during day for goods vehicle.
A section of the basement showing the utility services
Hence an alternative route was found for goods
received during day and planning had to be done
accordingly during night.
Workspace constraint was a major challenge,
which was effectively handled through meticulous
material management on daily basis. Coordination
among different services vendors, respective
consultants and establishing their work sequence
was brainstorming exercise through out the project.
Due to transporters strike the flow of cement and
other long lead materials were delayed. Procuring
from the local market and rearranging the sequence
of activities according to the materials availability
negotiated the problem. Since the supply of
reinforcement steel from Kolkatta was time
consuming, a delivery schedule was prepared and
physical reconciliation was done on weekly basis
and suggestion was given to transport in truck
instead of trailers. Also coordination with vendor
and monitoring the vehicle from loading point to site
helped in materials reaching site at the earliest.
Quality of Works
Only client/consultant approved materials was used
for the project. Method statement for all major and
important activities was made and followed.
Approved and reputed manufacturers were
deployed for materials supply. Besides quality of
civil and structural works was monitored by testing
and inspection procedures as per Project Quality
plan requirement. Samples, mock-ups were
presented to clients for approval and thereafter
works were carried out. Quality checks were
prepared and corrective action taken for the
shortcomings if any.
Being Rajsthan’s first IT building, the project has
drawn the special attention of the government and
during its inauguration, the client as well as the
Hon’ able chief minister of Rajsthan appreciated
L&T for creating a landmark building in Jaipur in a
very short duration.
A part of the control systems for the water treatment
Ashok Kumar
Resident Engineer
54
Four Laning
of Road Project on
NH-76 in Rajasthan
he North South - East West Corridor (NS-EW)
being implemented by the National Highways
Authority of India (NHAI) under the Ministry
of Road, Transport and Highways (MoRTH) is the
largest ongoing expressway project in India. It is
the second phase of the National Highways
Development Project (NHDP), and consists of
building 7300 km of four/six lane expressways
connecting Srinagar, Kanyakumari, Porbandar and
Silchar, at a cost of US$ 12.317 billion and the
entire project is expected to be completed by
December 2009.
As a part of this East- West Corridor Project, ECC
is executing the rehabilitation and upgradation by
four laning of 70 km road (from 509.000 to km.
579.000 km Package RJ-11) on NH-76 in the state
of Rajasthan. ECC bagged this contract in the
teeth of stiff domestic competition.
Funded by the Asian Development Bank (ADB), the
Package begins approximately 109 km from Kota
city and ends in the Rajasthan - MP border and
connects Porbandar in the West with Silchar in the
East. The Project has a great importance as it forms
a part of the East-west corridor, which when
completed will significantly improve the connectivity
between the Western India with the East in terms
of reducing distance, improving the riding quality,
saving time and fuel cost thereby directly benefiting
all road users. This apart, it will benefit the local
people through new business opportunities, better
marketability of local agricultural produce,
appreciation of immovable properties through better
connectivity.
The Project is being executed by L&T for NHAI
under the supervision of Wilbur Smith and Associates
who have been appointed by the client as Supervision
Consultants.
The Architectural and structural design are provided
by Span Consultants Pvt. Ltd., New Delhi.
Commencing the project in September 2005 L&T is
expected to complete the same in 30 months (March
2008).
The Scope of work involves:
♦ Construction of new flexible 2 lane carriageway
on one side of existing single lane pavement
♦ Widening and strengthening/ reconstruction of
the existing road
♦ Construction of New 4-lane dual carriageway
in bypasses, detours
♦ Construction of service roads
♦ Construction of junctions, intersections
including grade separators
♦ Construction of bus stops, truck lay byes
♦ Construction of new bridges, underpasses and
box culverts
♦ Providing road markings, road signs, protective
works, metallic crash barriers, guard rails,
etc.
♦ Construction of reinforced earth retaining
structures in underpass approaches
♦ Maintenance of existing road and traffic
management during construction period
Salient features of the contract
♦ Contract Length
♦ Date of Acceptance
♦ Contract Agreement
Signed on
♦ Commencement Date
♦ Completion date
♦ Original Contract Period
♦ Major Bridge(4-Lane)
♦ Minor Bridge(4-Lane)
♦ Underpass(4-Lane)
♦ Box culverts(4-Lane)
: 67.225 km
: 31.05.2005
:
:
:
:
:
:
:
:
20.07.2005
30.09.2005
29.03.2008
30 months
4 Nos
9 Nos
24 Nos
69 Nos
Major items of work:
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
Roadway excavation
Earthwork in filling
Granular Sub Base
Wet Mix Macadam
Primer and Tack Coat
Bituminous Courses
Concrete -All grades
Steel reinforcement
Prestressing strands
Turfing
Road Marking
Metal crash barrier
Crushed Aggregates
Crushed GSB
River Sand
Cement
Bitumen (60/70and
PMB for BC)
Expansion joint
RE Facia Panel
Spherical Bearings
Elastomeric Bearings
High Tension Strand
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
339300 Cum
3648300 Cum
375900 Cum
355800 Cum
3933450 Sqm
187300 Cum
118770 Cum
4370 t
925 t
592200 Sqm
51000 Sqm
25600 RM
1620214 t
808185 t
61052 Cum
50000 t
:
:
:
:
:
:
23500 t
770 RM
7350 Sqm
72 Nos
336 Nos
925 t
Preparation of subgrade layer in progress with grader
55
Strategies for Project Execution
The project office, P&M workshop, site store,
weigh bridges, time office, carpentry
workshop, bar bending yard, batching plant,
wet mix plant, hot mix plant, quarry and
crusher for the project including the bachelor
accommodation and guest house and labour
camp have been set up at a strategic location
on km 532 spread over on a 80 acre land
taken on rental basis. This has resulted in
better usage of resources through instant
communication, immediate co-ordination and
sharing of common resources in the event of
break-downs. Moreover, we could get rid of
additional burden of aggregate transportation,
double handling of aggregates, etc., resulting
in substantial cost savings.
Quarry & Crushers
Road projects generally require huge
quantities of different grades of aggregates
and GSB. For this purpose, we mobilized and
erected four crushers to meet the entire
aggregate requirement of the project and
timely supply of the same. In fact we are
contemplating to make all supplies in time and
the total crushing is completed three months
ahead of completion date.
♦ 2 x 150 tph Aggregate Crusher @ km. 532
♦ 1 x 50 tphGSB Crusher @ km. 532
♦ 1 x 50 tph GSB Crusher @ km. 548
The mining operations/maintenance of the above
crushers are sub-contracted to the same agency
to avoid under utilization of crushing plants. The
crushing plants are installed 500m away from quarry
to reduce the cost of quarrying and feeding to
crusher keeping in view the minimum safe distance.
View of shahbad Ghati
With these arrangements, till end of November 2006,
we have been able to achieve an average monthly
production of 66000 t aggregates with an highest
Monthly production of 94500 t in March 2006.
Survey
Soon after the site was handed over for carrying
out the road construction work, site survey, the
most critical pre-construction activity was taken
up before the commencement of all other works.
One after the other all other works are carried
out in a sequence as follows:
Excavation
This project involves a quantum of 339300 cum
of excavation in soil and hard rock, on tough
terrains in the ghat area, close to the forest
land. Hence the excavation in hard rock is being
carried out by controlled blasting, to minimize
the impact on the wildlife, in the forest.
Earthwork
Around 3648300 cum of earthwork is to be done
including embankment and sub grade filling. Of
this nearly 133000 cum of embankment filling is
to be done with selected materials for the
construction of reinforced earth wall at underpass
locations. 1228785 cum of earthwork have been
executed till date using 10 earthwork teams. Each
team made use of one excavator, 4-5 dumpers
of 20 t, one vibratory roller, one water tanker
and one motor grader for two teams. Using these
resources, we were able to achieve a maximum
quantity of 270000 cum of embankment filling in
just one month.
Granular Sub base
Crusher GSB is used for construction of sub
base course. The total scope involved in this
project is around 375900 Cum. Transportation
contractors are engaged for transporting GSB
material and a total of 10 dumpers of 20 t
capacity have been used for this purpose. Till
date 81500 Cum of GSB has been laid with 2
GSB teams each making use of one grader,
one roller and one water tanker.
Wet Mix Macadeam (WMM)
Two pug mills of 60 tph (L&T) and 200 tph (Sub
contracted) have been commissioned to produce
355800 Cum of WMM. Laying of WMM is being
done by sensor pavers for maintaining the profile
and cross fall as required. As of date 83636 Cum
Crusher in operation
56
Asphalt paving in progress
of WMM have been laid with a maximum quantity
of 1100 Cum laid in one day. We have deployed 2
WMM teams for laying. Each of this team is
provided with one vibratory roller, one water tanker
and adequate lighting facility for laying at night.
Asphalt works
One Hot mix plant of 160 t/hr has been
commissioned for executing asphalt works to the
tune of 187300 Cum. 15 km of two lane carriageway
has been covered with asphalt layers till date with
one asphalt team comprising one paver, one
pneumatic tyre roller, two tandem rollers and one
water tanker. As the project is located in a semi
arid zone, where the maximum pavement
temperature touches as high as 68 degree Celsius,
we have been able to convince the Engineer for
permitting us to use polymer modified bitumen for
the wearing course, in order to avoid bleeding and
rutting in the pavement.
Kerbs
One kerb casting team is being engaged for laying
of kerbs. Kerb laying is done before the paving of
asphalt, as it confines to one end of the pavement
layer thereby reducing wastage due to confinement.
Finishing Items
Specialised agencies for construction of reinforced
earth structure, post tensioning mastic asphalt,
supplying of road signages, thermoplastic pavement
marking machines have been identified/mobilized
for carrying out the specialized works.
Bridges, Underpasses, Culverts
and Retaining Walls
A separate team is formed for the construction
of cross drainage works and bridges, as it is
more important to complete these works to avoid
gaps during paving during construction of the
road.
A total of 19834 cum of concrete have been laid
till date against the scope of 118770 Cum. In
addition, we have till date completed around 37
box culverts against 69 and 15 underpasses
against 24. Sub structure works for almost all
bridges have been completed with a few in their
final stages of completion.
Retaining wall to contain the embankment with
its right of way is progressing in full swing so
that earthwork activity in these areas can start
at the earliest.
L&T Formwork is being utilized for all structural
works and a maximum quantity of 312 cum of
concrete is poured in a single day with an average
of 190 Cum/per day for the month of November
2006.
Plant & Machinery
A well equipped P&M department at site undertakes
repairs and maintenance of all plant & machinery
items at regular intervals as per schedule in order
to avoid major breakdowns.
The following are the major machinery and
equipment being used in this project.
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
Excavators
Wheel Loaders
10 t Vibratory Rollers
Wheel loader
200 tph Wet Mix Plant
60 tph Wet Mix Plant
Paver Finisher
160 TPH Hot Mix Plant
Pneumatic Tyre Roller
Tandem Vibratory Roller
Bitumen Sprayer
30 Cum/Hr Concrete
Batching Plant
15 Cum/Hr Concrete
Batching Plant
Excavator With Rock Breaker
Transit Mixers
Concrete Pump
Cranes
40 T Trailors
DG 62.5 kVA/125 kVA/
750 kVA (2 each)
:
:
:
:
:
:
:
:
:
:
:
10
8
15
4
1
1
4
1
1
2
2
:1
:
:
:
:
:
:
1
2
11
2
1
2
:6
57
View of completed dense bituminous macadam work
Human Resource
Around 90 technical/non-technical staff have been
mobilized to execute the works with 350 department
workmen for carrying out various tasks. In addition,
around 850 workmen have been engaged from the
subcontractors to execute the works under our
supervision. Some of the major sub contractors
are involved in crusher and quarry operation,
earthwork filling, transportation of GSB, WMM and
asphalt materials, paving of WMM layers, concreting
works, reinforcement cutting and bending works
and other special items of work. The field execution
staff have been grouped under five major groups,
such as: structure works, earthwork and GSB,
base courses (WMM), asphalt works and finishing
works for better execution, control and
accountability.
Challenges Faced
Poor availability of river sand
As the source for lifting the river sand (for all
concrete works) is located at a distance of 200 km
away from site, we were not able to get sand at
estimated prices on regular basis. Moreover, the
local agencies were paying better prices when
compared to us and hence, no agency was willing
to supply the same to L&T on a regular basis.
However, this problem was sorted by by convincing
the Engineer to use crushed sand produced by our
crushers in partial replacement of natural sand,
without sacrificing quality.
Conveyance
As the site is located 65 km away from the nearest
township (Baran), which has basic facilities for
education and healthcare, staff families chose to
stay at Baran. Since the journey takes 4 hours
to and fro site, it was decided to put up the
bachelor staff accommodation closer to site to
take care of the early morning and late evening
works. In addition, this is provided with complete
recreation, sports & games facilities including
communication gadgets, vehicles for respite of
employees and to meet any emergency that may
arise.
Ghat section
Since the excavation in the ghat section involves
a massive quantity of 339300 Cum of excavation
(both in soil/hard rock), a detailed work plan
has been prepared by the site think tank
committee. Accordingly, the entire ghat stretch
has been divided into 3 sections.
To begin with access roads are being made so
as to commence the retaining wall activity.
Initially concreting will be done with concrete
pumps, as transit mixers can’t access all locations
due to the very steep terrain. Once the retaining
wall is built-up, in the initial approaches, filling
will be taken up in the valley side and this will
serve as the approach for transit mixers to reach
the subsequent sections for concreting of
retaining walls.
Though the site team is continuously facing
several such odds, kudos to our team who have
been braving every such impediment and
progressing our way, achieving every milestone
in the right earnest.
D.K. Nanda
Project Manager
T.R. Patnaik
Construction Manager
58
Hindustan Zinc Limited
Poised to become the
leader in Zinc & Lead
edanta Resources plc, a London Stock
Exchange listed and FTSE 100 metals and
mining global major has interests in
aluminum, copper, Zinc, gold, silver and lead
with operations in India, Australia, Armenia and
Africa. Recently, Hindustan Zinc Limited (HZL)
part of Vedanta Group, successfully completed
the phase I project of HZL at Chanderiya Unit,
Rajasthan, where Larsen & Toubro Limited (ECC
Division) was associated with execution of this
prestigious project, in a record time of 24 months.
HZL has an installed capacity of 2,30,000 TPA Zinc
ingots and 35,000 TAP Lead ingots across the country.
In pursuit of its vision of becoming a World Class
Global Company, HZL has presently undertaken another
expansion for a 170,000 TPA Zinc Smelter at its
Chanderiya Unit. L&T is once again proud to be
associated with this major project and inked the contract
for undertaking the construction of this project with
Sterlite Group, a flagship company of Vedanta
Resources Plc., UK.
L&T successfully executed the following works in
a record time for the Phase-I Project of HZL at
Chanderiya.
completion of Cell House, apart from eliminating
the use of huge quantity of formwork system
components.
Detailed engineering, procurement, erection,
commissioning of leaching purification & cadmium
plant (EPC-4). This involved supply and erection of
mechanical equipment, civil and structural works
for the construction of tanks, silos, launders, utilities,
process piping including complete electrical &
instrumentation works.
The Casting and Melting furnace building is
a 83m long and 45m wide structure. This
accommodates two zinc melting induction
furnaces, one ingot casting machine, one jumbo
casting machine all for melting zinc cathodes
and casting zinc slabs.
Detailed engineering, procurement, erection,
commissioning of tank house, zinc melting & casting
plant and zinc dust plant (EPC-5), which involved
supply and erection of mechanical equipment, civil
& structural works for molten metal launders,
utilities, process piping, including complete project
electrification & instrumentation works.
Some of the salient features of structures executed
under phase-I includes:
The Cell House which has a length of 167m and
width of 52m with a structural steel roof and covered
by 9600 Sqm of FRP sheet, accommodates 124
RCC cells, two cathode stripping machines and one
anode washing machine.
A unique feature includes casting 124 RCC cells insitu, as against pre-casting them in the yard,
transporting and erecting them in position. Yet
another innovation included converting the concrete
portal using structural steel, which resulted in timely
Erection of two fully automatic cathode stripping
machines with PLC, each having a rated capacity
of 300 cathodes per hour and weighing 55 t was
successfully erected for removing zinc deposition
on the cathode plates during the electrolytic
process. Erection of the 22t per hour capacity
zinc slab casting machine (65m long and 75 t
heavy) which can cast 880 ingots each of 25kg
weight in one hour including erection of the 30 t
capacity anode washing & flattening machine
having a rated capacity of 100 anodes per hour
was a challenge.
The Leaching and Magnesium Removal
area has a dimension of 77m x 52m with
structural steel trusses covered by 4394 Sqm of
roof sheet. This houses five calcine feed hoppers,
24 tanks made of MS/SS associated with related
pumps and thickners for leaching.
The Purification process area which has a
dimension of 45.75m x 60m, houses 15 tanks of
MS/SS along with associated pumps and piping.
View of Casting and Melting area
59
EPC 5 - Cell House, Melting and
Casting Plant
This package involves design, detailed engineering,
project management, procurement, supply,
fabrication, inspection, transportation, unloading
including free issue items, storage, construction,
installation, testing, pre-commissioning, assistance
in commissioning and handing over the plant.
EPC 10 – Civil and structural works
for the above plants including raw material storage
and handling, roaster and waste heat recovery
section, gas cleaning section and sulphuric acid
plants.
EPC 12 – Tanks and Silos Package
involves construction of MS tanks including supply,
fabrication and erection in the leaching and
purification area as well as calcine silos.
Over view of Cell house
In addition, two MCC buildings one for Roaster
and the other for Leaching and purification houses
the motor control centers with connected
electrical and instrumentation works. This also
involved finishing items/specialized items of
works like, floor tile fixing, aluminium doors &
windows, acid resistant brick lining, PVC lining,
mastic lining, FRP sheet roofing & grating, epoxy
painting on RCC structures including painting of
buildings.
More than 150 staff and approximately 3000
workmen were employed round the clock to
complete the project in a world record time of 24
months. Fixing the 16 paraliners in 10 hours is
yet another world record (previous record -14
hours in Australia). In addition, ECC completed
the refractory lining works in the induction
furnace and commissioned two fully automatic
EOT cranes for handling of anodes and cathodes
in the Cell House in a record time. And achieved
11 million accident free man-hours by maintaining
high standards of safety throughout the project
construction period.
grass-root level plant except sharing of certain
utilities with the existing production plant.
ECC’s scope of works in this project involves
four major packages as follows and this includes
civil and structural works, fabrication of tanks
and silos, mechanical erection and process piping
works as per details below:
EPC 4 - Leaching and Purification Package
This involves design, detailed engineering, project
management, procurement, supply, fabrication,
inspection, transportation, unloading including
free issue items, storage, construction,
installation, testing, pre-commissioning,
assistance in commissioning and handing over
the plant.
UHDE India Limited (UIL) have been appointed by
HZL as Detail Engineering and Project Management
Consultant (PMC) for Civil and Structural Package.
The detail civil engineering and PMC for tank
package is also done by UIL.
ECC is executing the EPC 12, EPC 4 & EPC 5
packages as lump-sum turnkey contracts, hence
the detailed engineering are provided by ECC.
However, the PMC for the entire package rests
with UIL. As Project Management Consultants,
UIL are responsible for the project execution
and to ensure the handing over of plant as per
contractual terms to the complete satisfaction
of HZL.
Process technology for both Phase I and II are
sourced from Outokumpu, USA by Hydrometallurgical route.
In recognition of its speedier completion of the
Phase-I project and in appreciation of its team
leadership, HZL awarded ECC Project
management a bonus of Rs.3.0 crore.
Phase-II
Currently, ECC is actively involved in the PhaseII expansion plant which will have a capacity of
1,70,000 TPA Zinc Smelter Plant. This is coming
up close to the existing production unit (Phase I
built by ECC) at Chanderiya near Chittorgarh in
the state of Rajasthan.
Though Phase-II is a separate capacity
expansion, it has practically all elements of a
Over view of Leaching area
60
Construction schedule
Approximately Rs.430 crore worth of orders are
under execution by ECC for phase-II expansion
of HZL and the completion schedule for these
projects are as follows:
EPC-10 which began in February 2006 is expected
to be completed by May 2007
EPC-12 which began in May 2006 is expected to
be completed by January 2007
EPC-4 & 5, which began in August 2006 are expected
to be completed by June 2007
The major items of work involved in the Civil and
structural Package (EPC 10) are given below:
Major quantities of work
Structural erection of acid plant
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
♦
Excavation
Backfilling / Disposal
Concrete
Formwork
Brickwork
Plaster
Reinforcement
Miscellaneous Flooring
Doors & Windows
Structural Fabrication
Structural Erection
Grating
Sheeting
Sand blasting &
Painting
Water Proofing
Sanitary & Plumbing
Mastic Lining
PVC Lining
AR Brick Lining
Cell Casting &
Alignment
:
:
:
:
:
:
:
:
:
:
:
:
:
172862 Cum
250150 Cum
92341 Cum
139512 Sqm
4456 Cum
36600 Sqm
4967 t
27609 Sqm
1055 Sqm
6272 t
6272 t
8390 Sqm
40248 Sqm
:
:
:
:
:
:
6155 t
4432 Sqm
72 Nos
21040 Sqm
25750 Sqm
26250 Sqm
: 132 Nos
ECC’s work in this project involves civil and
structural, mechanical equipment erection and
piping, testing and commissioning of equipment
including electrical installation and instrumentation
work as well as testing and ommissioning of the
same.
Tanks and Silos Package (EPC 12)
The tanks and silo package for Phase II involved
fabrication and erection of two silos for the calcine
storage apart from 42 tanks in the leaching and
purification area. This is estimated to consume a
total quantity of 1035. 42 t of steel for fabrication 367.42 tonne for the two silos and 668 tonne for
fabrication of 42 tanks.
Fabrication challenges
The structural fabrication and erection was a real
challenge as it involved plate bending of each
segments of shell in the yard, transporting these
segments to the actual site incluting erection and
welding of the same.
This involves a whopping quantity of 6272 t. Out of
this total quantiy, fabrication and erection of tank
and silo package alone touches a quantity of 1035.42
t. Moreover, the two silos fabricated here are one
of the tallest structures having a height of 19m and
internal dia of 13m. 20mm thick MS plates were
used for the fabrication of the silos and this involved
a total quantity of 183.71 t for each silo. In all there
were 8 shells – 7 of 2.5m height and the top one of
1.5m height.
Leaching and Purification Package (EPC 4)
This EPC package which covered the leaching,
purification and jarofix areas involved mechanical
equipment erection including erection of free issue
items, piping, SS tank fabrication and erection, acid
resistant brick lining etc. The detailed scope of the
package is as follows:
♦ Equipment erection
♦ Plates and structural
steel (MS)
♦ Plates (SS)
♦ Piping (CS,SS & PPH)
♦ Fittings (CS, SS & PPH)
♦ Valves (diaphragm, plug,
butterfly, gate, globe,
ball and check valves)
♦ Steam traps
♦ Grating (MS & FRP)
♦ SS904L – Coils and
Injectors
♦ Rubber lining
♦ A R Brick lining
: 1280 t
:
:
:
:
900 t
400 t
24700 m
23565 Nos
: 2219 Nos
: 71 Nos
: 29 t
: 130 Nos
: 1655 Sqm
: 14984 Sqm
View of control room
61
The EPC 5 package covers the gypsum removal
area, cell house, melting and casting areas and the
major items of work are given below:
♦ Equipment Erection
♦ Piping (including
CS, SS & PPH)
♦ Fittings (including
CS, SS & PPH)
♦ Valves (Including diaphragm,
plug, butterfly, gate, globe,
ball and knife gate valves)
♦ SS Plates
♦ CS Plates & sections
♦ Grating (MS & FRP)
♦ Rubber ling
♦ A R Brick lining
: 6362 t
: 14080 m
: 13492 Nos
:
:
:
:
:
:
808 Nos
27 t
371 t
6.9 t
6986 Sqm
5483 Sqm
The electrical and instrumentation packages form
a major part of the project as most of the mechanical
equipments are fully automated. The major items
of E&I work involved:
♦ Motor control panels
(15x3 m)
♦ Marshalling junction
box (5x3 m)
♦ Emergency power distribution
board (10x3 m)
♦ VFD panels (1x3 m)
♦ Cables (Power control
& Signal)
♦ FRP cable trays
♦ Illumination system
♦ FIM – E&I related (For
Anode washing/ cathode
stripping, filter press, slab
cast, furnace etc)
♦ Analyzers ( pH, conductivity
& density)
♦ DB/SLDB/ESLDB
: 11 Nos
: 8 Nos
: 12 Nos
: 98 Nos
: 648 km
: 22 km
: 2378 Nos
: 36 Nos
: 28 Nos
: 65 Nos
In addition, ECC’s scope of work also involves
finishing items, such as:
View of thickener formwork
♦ Tiles
♦ Aluminium doors and
windows
♦ FRP Sheet
♦ Epoxy paint (RCC)
♦ A R Brick lining
♦ PVC Lining
♦ Mastic lining
♦ FRP grating
♦ Painting of buildings
: 1348 Sqm
:
:
:
:
:
:
:
:
873 Sqm
9150 Sqm
20000 Sqm
26250 Sqm
25750 Sqm
21040 Sqm
6860 Sqm
50900 Sqm
With an exponential growth rate of Indian market
the scope for infrastructure and construction work
is increasing. The use of galvanized steel in
construction field is increasing which leads to a
significant demand for Zinc in India. Though the
requirement of Zinc is increasing in other fields
also, including export, the present expansion will
bridge the gap between demand and supply. The
employment opportunities generated by the plant
requires no mention, as it will definitely help to
increase the job openings for large number of people
in and around the place.
The Zinc Smelter complex consists of the following
process units:
♦
♦
♦
♦
♦
♦
♦
Raw Material Storage and Handling
Roaster & Waste Heat recovery section
Gas cleaning section
Sulphuric acid plant
Leaching, purification and Cadmium section
Cell House, Melting & casting section
Off sites & Utilities section
The Zinc concentrate is received on road trucks
and directly unloaded into raw material storage
shed. The concentrate is reclaimed by pay-loaders
and transferred to roaster section through
crushers, screens, and conveyors. The concentrate
is roasted in the fluidized bed roaster at high
temperature to yield calcine (Zinc oxide) and Sulphur
dioxide gas.
The sulphur dioxide gas is cooled by passing through
waste-heat boiler. The gas undergoes further
cleaning in the Hot gas precipitators scrubbers and
wet gas precipitators. The cooled gases are then
sent to the Sulphuric acid plant.
The calcined material from the roaster is cooled
and sent to the leaching and purification section
wherein further processing takes place to produce
Zinc Sulphate electrolyte with various impurities.
The impurities are precipitated and pure electrolyte
is produced. The purified zinc sulphate is sent to
the Electrolytic cell house. In the cell house the zinc
is deposited on the cathode.
The zinc sheets are removed from the cathode and
melted in Induction furnace. The molten metal is
cast in to ingots by casting machines. Lumpy dross
generated in the induction furnace is ground in dross
treatment plant. The fine dross is recycled to
roaster by mixing with concentrate.
J. Suresh
Construction manager
Cell house cooling tower
A.K. Mallik
SPM – IPU Sector
62
Bisalpur Water
Supply Project
aipur, the Pink city of India, is located in
northwest part of Rajasthan surrounded
by the Aravalli mountains. The population
of Jaipur, which is close to around 2,50,000,
depends almost entirely (97%) on ground
water resources for its potable water supply,
as a result of which over the years the water
table has fallen dramatically and continues to
decline at an alarming rate. Four consecutive
years of drought conditions have exacerbated
the problems, and it is felt that the ground
water resources within many parts of the city
may not be adequate in the future.
Bisalpur dam is the only nearby water source,
which is located over the river Banas near
Devoli. It has the potential to cater to the
city’s
requirement
and
includes
complementary provisions for supplying water
to other areas. The long-term strategy is to
develop the Bisalpur water source to provide
treated surface water to Jaipur City.
The government of Rajasthan conceived the
Bisalpur Water Supply Project and requested
the Asian Development Bank (ADB) to take up
the first Phase of the project as a part of the
ongoing Rajasthan Urban Infrastructure
Development Project (RUIDP).
protection to increase the longevity of the
pipes .It consists of both above ground and
below ground portions with all auxiliary works.
The contract valued at Rs 481 crore was
awarded to L&T during July 2006 and involves
design, procurement and construction of the
transmission system for phase I works. The
scope of work comprises water supply,
treatment and transmission system from the
Bisalpur dam to the Balawala reservoir site
on the outer edge of Jaipur City and includes
operation and maintenance for a five-year
period. The project is scheduled for
commissioning by December 31, 2008.
Water treatment plant: The plant is of the
pulsator type with technology from M/s
Degremont, France and is being designed for
a capacity of 400 mld (360 mld for Jaipur plus
40 mld for the rural towns). It will be located
at the village of Surajpura, 3.5 km from the
Tehsil town of Todaraisingh in the Tonk District
of Rajasthan and will be connected to clear
water pumping station-having reservoir of
capacity of 25 ml. 10 nos. of HSC Pumps will
pump the treated water to Balawala reservoir
near Jaipur.
The project is divided in 6 units
Intake Pump House: The scope of work
involves supply and installation of 9 vertical
turbine pumps in the existing intake pumping
station at the Bisalpur dam, renovation and
strengthening of the existing structures,
construction of new hostel building and a 33/
3.3 kV substation.
Pipeline: The pipeline works comprise laying
of the 2400 mm diameter mild steel raw water
pipeline of 8400 m length from Bisalpur intake
to water treatment plant at Surajpura and 2300
mm diameter mild steel clear water pipeline
of 97400 m from clear water reservoir at
Surajpura to Balawala reservoir. The pipelines
are externally coated with cold applied
polyolefin to be imported from USA and
internally lined with cement mortar. It will
comprise of spirally welded SAW pipes and
has to be provided with adequate cathodic
Existing
Reservoir
Banas River
WTP - 400MLD
Existing Intake
Roadwork: A four metre wide all weather
service road will be constructed along the
pipeline from Balawala to Bisalpur.
Renovation Work: The project also includes
renovation of 21 quarters and campus
development for housing the operating
personnel in 5 locations at Todaraisingh,
Tordisagar, Diggi, Phagi and Balawala. Office
space and accommodation for line staff will
be provided by renovation of existing railway
station buildings.
Electrical Works: Comprise construction
of a 33/3.3 kV substation at intake point and
WTP sites and connecting the 33 KV power
transmissions. The 33kV existing line from
Thadoli to Bisalpur will be upgraded to Wolf
ACSR conductor from the existing Dog ACSR
conductor.
The scope also includes construction of a new
33kV overhead lattice tower single circuit line
from Thadoli to Bisalpur. Similarly, two
separate 33kV overhead single circuit lattice
tower lines are to be executed from Thadoli
to Surajpura (WTP/CWPS).
Project execution is in the initial phase with
planning, design and mobilization underway.
Survey and soil investigations have been
completed. Location for setting of pipe mill
has been finalized and the manufacture of
pipes will commence shortly.
HR Coil for the project is likely to be sourced
from China. The project execution task is being
mobilized along with other supporting
resources. Construction is likely to commence
from January 2007.
Ajoy Bhattacharya
Project Manager
63
the state electricity board, Rajasthan Rajya Vidhyut
Prasaran Nigam Limited (RRVPNL):
♦ Design, detailed engineering, supply,
erection, testing and commissioning of 132/
33 kV switchyard at Gorera village in
Jaisalmer.
ajasthan, one of the power starved states,
in India is endowed with enormous wind
power at its disposal. In order to harness
the wind power available in the state, Govt. of
Rajasthan formulated a policy for promoting
generation of power through Non-conventional
Energy Sources and offered incentives to
companies, putting up Wind Farms and supplying
power to state’s power grid.
In response to this welcome move by the
government, Enercon (India) Limited, one of the
major wind power producer, made a feasibility study
of the wind speed, wind profile, wind power potential
and selected “Jaisalmer” in Rajasthan for putting
up its green field 2x50MW Wind Farm.
Enercon entrusted this EPC project to L&T-ECC for
executing the complete Power Evacuation System.
This involved two sections as follows, apart from
getting ROW clearance and statutory approvals from
♦ Design, detailed engineering, supply,
installation, testing and commissioning of a
33km long 132 kV double circuit transmission
line of ACSR Panther conductor from Gorera
to Amarsagar at Jaisalmer including bay
extension at receiving end of grid substation.
Major items of work for the substation involved
supply and installation of one 132 / 33 kV, 75
MVA transformer, 5 Nos. 145 kV SF-6 circuit
breakers, 5 Nos. 36 kV vacuum circuit breakers,
12 Nos. 132 kV isolators, 16 Nos. 33 kV isolators,
15 Nos. 132 kV current transformers, 6 Nos.
132 kV potential transformers, 15 Nos. 33 kV
current transformers, 3 Nos. 33 kV potential
transformers, 12 Nos. 30 kV lightning arrestors,
6 Nos. 120 kV lightning arrestors, 1 set of 132/
33 kV control & relay panels, 1 No. ACDB, 1 No.
33 kV/440 V auxiliary transformer, 1 set of
110V, 150 AH battery & charger including laying
of LT/Control cables, civil works for equipment
foundation and cable trench, control room as
well as erection of gantry structure and
equipment.
Construction of transmission line work involved
supply and installation of 88 A type tower
including extensions, excavation and concreting
at 108 locations, supply and installation of 20
angle towers and stringing of ACSR Panther
conductor for a distance of 33 km including
insulators, fixtures and other hardware
accessories.
L&T commenced the work in August 2003 and
completed the same by January 2004, taking
precisely 145 days, which is a record breaking
achievement. Thus the switchyard was
successfully commissioned on February 27, 2004.
In a certificate received by L&T, Mr. T.R. Melroy,
Assistant General Manager - Projects, Enercon
(India) Limited mentioned that “ L&T maintained
good standards of quality and safety
requirements. We are satisfied with their ability
to complete the project in the shortest possible
duration in difficult terrain and adverse weather
conditions”
Challenges
Since the site is located on a difficult terrain with
hard rock, we found it very difficult carryout
excavation for every foundation. Hence, it was
decided to blast the entire switchyard area up to
a depth of 1.5m. Thereafter, all foundations were
cast in one go and then the entire area was
backfilled.
The procurement of 50/63.5/75 MVA Power
Transformer was delayed due to frequent
breakdown of transport vehicle and finally when
it reached the site, we had just 3 days for the
final testing and commissioning.
However, with excellent planning of all parallel
activities, transformer unloading, erection,
assembly, oil filling, oil filteration and testing were
carried out successfully to the complete
satisfaction of our clients.
Growing concern for the environmental
degradation has led to the world’s interest in
renewable energy resources. Wind is
commercially and operationally the most viable
renewable energy resource and accordingly,
emerging as one of the largest source in terms
of the renewable energy sector.
Wind Energy will witness abundant opportunities
in the developing economies, such as India,
where the power supply situation and
infrastructure development efforts provide a huge
market for active investment.
Power Evacuation System for Enercon’s Wind Farm at Jaisalmer, Rajasthan
Samir Gupta
Construction Manager - E&I
64
Manipal Academy of Higher Education (MAHE) Inaugurated
A part of the University and Library
building at MAHE
Manipal Academy of Higher Education (MAHE)
located at Manipal, in Udupi District of Karnataka is
the Educational hub of South India. Situated on a
500 acre plot on a hilly terrain, MAHE is home to
several institutions in Medicine, Engineering,
Business Management, Hotel Management,
Nursing, Bio-technology and Allied Health Services.
ECC was associated with this prestigious
The plan showing the punctuation mark “,” (comma)
educational institution for the
construction of their University
and Library Building including a
Lecture Hall. Having 2.50 lakh
sft built up area, the University
and Library Building presents a
beautiful look with its strikingly
rich structural glazing. Moreover,
this is the largest building with
structural glazing in the whole of
Udupi district. Sundaram
Architects were the Structural and
Architectural Consultants.
A section of the building with its rich structural glazing
Shaped in the form of the
punctuation mark “,” (comma),
the University and Library
building is divided into three
sections as University, Central
Hall and Library. The University
blocks are located in the
basement, ground plus four
floors. This houses the university
administrative offices. The office
of the President, Vice President and Directors are
located in the fourth floor with a terrace garden.
The Central hall is meant for evaluation of answer
papers and the Board Room is located at the terrace
level.
The library is a six-storied structure with a car
park at the basement. The Library building, largest
in Asia can accommodate more than 650 Students
at a time. In addition to above, the University and
Library accommodates Banks, ATMs, Food Courts/
Coffee Shops, Creche, etc.
Hon’ble Sri P Chidambaram, Union Minister for
Finance inaugurated the administrative block of the
university building on September 6, 2006 at Manipal.
Dr Ramdas M Pai, Chancellor, Dr Ranjan R Pai,
CEO, MEMG, Bangalore, Dr HS Ballal, Pro
Chancellor, Brig (Dr) SS Pabla, Pro Vice-Chancellor
and Dr H Vinod Bhat, Registrar of MAHE were
present on the occasion. Sri Chidambaram also
launched the digital campus initiative of MAHE on
this occasion.
65
Wadi-Abdoun Bridge, Jordan, Opened to Traffic
The 425m long cable-stayed bridge built by ECC,
L&T’s Construction Division, at Amman, the capital
city of Jordan was opened to traffic at 11.00 a.m.
on December 14, 2006. H.E. Dr. Ma’Rouf Al Bakhit,
the Prime Minister of the Hashemite Kingdom of
Jordan, inaugurated this in the presence of Eng.
Omar Al Mani, the Mayor of Greater Amman, H.E.
Rachakondu Dayakar, the Indian Ambassador, and
Senior Executives of L&T.
Leaping across valleys and meandering with a
complex “S” curve horizontal alignment, this unique
and seismically designed, dual two lane bridge is
the first of its kind in the world. This is the first
cable-stayed bridge built by L&T and also the first
one in Jordan.
The bridge has dual two lane carriageways, each
7.28 m wide, and is supported on three towering
pylons rising to a maximum height of 71 m from the
bottom of the valley bed (pile cap). It has become
an engineering marvel, a new landmark in the capital
of Jordan and a cynosure of all eyes. Gliding across
the Abdoun valley, the bridge presents a panoramic
and strikingly beautiful view of Abdoun Township
with its beautiful residential and commercial
buildings.
Project Highlights
Client
: The Municipality
of Greater Amman,
Jordan
A view of the bridge supported on “Y” shaped pylons
Consultant
: Dar-Al-Handasah
Consultants, Amman
Commencement : December 2002
Completion
: December 2006
Type of Bridge : Curved Cable Stayed
Bridge
Length of Bridge : 425m (1x63m+2x 32m+
1x63m+1x27m+2x4m)
Number of Lanes
Carriageway
Total width
Superstructure
Deck construction
Max radius
in the alignment
: Dual two lanes
: 7.28 m per lane
: 22.5m to 29.39m
: Built on 3 ‘Y’ shaped
pylons
: Precast Segmental
: 180m
Night view of Wadi-Abdoun cable stayed bridge, Jordan
66
L&T Concrete Launched in Dubai
(from left to right) Mr. V.B. Gadgil, EVP & Head - B&UI and PT&D Sector Business (GCC Countries),
Mr. K. Venkataraman, Senior Vice President (Hydrocarbon & Power Sector), Mr. K.V. Rangaswami, Member of the Board &
Head-Construction, Mr. Shukri Saleh Yahya Al Braik, Member of the Board, Larsen & Toubro Readymix Concrete Industries
LLC and Mr. S.R. Kumar, Vice President (Ready Mix Concrete) during the inauguration of L&T Concrete Plant in Dubai
L&T unveiled a Dh48 million ready mix concrete
(RMC) plant with a capacity of 240 cubic metres
per hour in Jebel Ali, in Dubai on January 24, 2007.
This plant will meet the growing demand for readymix concrete in the UAE.
In India L&T manufactures and supplies about three
million cubic metres of L&T Concrete per annum
through 60 plants spread across the country and
commands 28 percent market share.
These plant operations are supported by a fleet of
500 transit mixers, six mobile concrete pumps and
100 static concrete pumps.
L&T plans to expand the total number of plants in
India to 150 by the year 2009-10. In the Middle East
the company proposes to expand in other Emirates,
specifically in Abu Dhabi and Ras Al Khaimah, and
also in Sohar and Muscat in Oman.
Mr. K.V. Rangaswami, Member of the Board and
Head - Construction, L&T, said: “I am confident
that L&T will establish itself as a major force in this
segment in Dubai and soon spread its wings to
other parts of UAE as well as other countries in the
Gulf Region. With its increasing focus on the Gulf
construction market, the company can leverage
the many advantages that L&T concrete offers and
supply this product for its own projects as well as
to other contractors.”
Copyright Obtained for Hollow I-160 Aluminium Beam
Formwork is playing a major role in civil
construction. Timber products also play a vital role
in construction of Concrete structures. Every
construction site needs thousands of running meters
of Timber H-Beams.
This is basically aluminum extrusion of closed
section and carries high load carrying capacity for
short span. L&T obtained the copyright of the
profile from the Copyright Office of Govt. of India
bearing Registration nos L-27038/2006.
In order to reduce the exploitation of timber and
timber products and maintain environmental
harmony, the Formwork Competency Cell of ECC
Construction Division has come up with a solution,
an alternative to its own H-16 Timber Beam with I160 Aluminum Beam.
This beam will be used as flextural member to
support sheathing element for application of slab &
Beam Formwork as well as Wall & Column
Formwork. Polyethyl infill locked in the serration
of profile will also gives the comfort of nailing.
67
CSTI Launches Training in Welding Trade
L&T’s Construction Skills Training Institute
(CSTI) has added the welding trade to the
courses it has been offering over the past
ten years. The new course was launched at
Chennai on December 16, 2006 by Mr. K.V.
Rangaswami, Member of the Board & HeadConstruction, L&T. Mr. K. Venkataraman, Sr.
Vice President, L&T, released the course
curriculum and skills standards for the welding
t r a d e . T h e f irst b a tc h in c lu d e d tw elv e
trainees.
The training programmes already in place are
civil- and electrical-oriented and cater mainly
to the requirements of building projects. With
the introduction of welding trade, CSTI meets
the mechanical-related needs of the
construction industry for industrial projects
like steel plants, petrochemical complexes and
Mr. K.V.Rangaswami inaugurating the welding trade at CSTI, Chennai
process plants. The eligibility criteria for
admission to the course are 18 to 24 vears of
age, tenth standard pass, experience of two
years or ITI pass (desirable) together with a
normal physique. The course duration is two
months.
CSTI is situated on a 5-acre plot of land in
Manapakkam on the outskirts of Chennai in a
setting conducive to vocational training.
A trainee undergoing the welding
training
The Institute, established by L&T in 1995, has
permanent infrastructure and training facilities
to provide structured training in the following
trades: 1) Formwork Carpentry 2) Masonry
(Brick work) 3) Bar Bending and Steel Fixing
4) Plumbing & Sanitary 5) Electrical Wireman
and 6) Trade Assistant.
The structured training will enable both new
entrants and workers with some experience
in the industry to progressively improve their
skills level and knowledge competency in the
respective trades. The Institute has branches
in Ahmedabad, Bangalore, Delhi, Kolkata and
Mumbai.
L&T Lays Foundation for Gujarat’s First Knowledge City
On January 24, 2007, the state of Gujarat took its
first major step on the technology super-highway
with the proposed L&T Knowledge City in Baroda.
Mr. A. M. Naik, Chairman & Managing Director,
L&T, Performed the ground breaking and foundation
stone laying ceremony for this new facility.
In his address, Mr. A. M. Naik urged the employees
to leverage L&T Knowledge City to create value
for the country and build a strong nation with a
vibrant economy.
This new facility, the only one of its kind in Gujarat,
is to be set up in an area of 112 acres between the
Ajwa and Waghodia crossings on AhmedabadMumbai Highway (NH-8). It will entail an investment
of Rs.500 crores in infrastructure and building alone
from L&T, spread over a period of 5 years.
Eleven buildings will be constructed in the first
phase which will house offices of L&T’s
e-Engineering Solutions, EPC Businesses,
L&T-Sargent & Lundy and L&T Chiyoda. Other
facilities planned are Project Management
Institute, Convention Centre, Employees
Hostel, Residential Colony, Food Courts and
Entertainment Facilities.
68
New Orders
Delhi International Airport
L&T has won a contract valued over Rs 5400
crores from the GMR-led Delhi International
Airport Private Limited for the expansion and
modernization of the Delhi International Airport.
The order, secured against international
competitive bidding, is an end-to-end contract
that involves design and construction of a state
of the art passenger terminal, and one of Asia’s
longest runways. L&T will also carry out
associated work for the airport, scheduled to be
commissioned in time for the prestigious
Commonwealth Games in 2010.
Commenting on the order, L&T’s Chairman and
Managing Director, Mr A.M. Naik, said “L&T is
happy to participate in providing a world class
airport for the country’s capital. We have an
excellent professional relationship with the
project developers led by the GMR Group, and
look forward to building a magnificent gateway
for international visitors to India.
As the country’s leading company engaged in
building infrastructure for India, L&T’s strategic
plan involves focusing increasingly on large
magnitude projects in critical sectors like
airports, ports, power and upstream oil and
gas.”
The new terminal (Terminal 3) will come up
adjacent to the existing international terminal,
and will have a number of advanced features.
Over 130 check-in counters and 70 emigration
desks will cater to both domestic and international
traffic and will handle 37 million passengers per
annum. This is more than twice the present traffic.
The new terminal building will have a total built
area of 4.8 million sq ft, and will include 74 aero
bridges, 56 passenger travelators, IT and
security systems, E&M systems, etc. A new
4.43 km runway will be one of the longest in
Asia, and equipped with CAT III B – a landing
system that enables landing with a visibility of
only 50 meters - will be operational in 2008. The
contract also involves connecting taxiways,
satellite fire fighting facilities, etc.
The ‘airside’ work to be executed by L&T includes
aprons, remainder taxiways, cargo terminals,
aircraft maintenance facilities, utility services and
other primary infrastructure support facilities. The
‘landside’ works includes a six lane road connecting
the terminal and national highway NH-8, a new
multi-storey car park to accommodate 4300 cars,
and a forecourt for the new terminal.
Tapovan Vishnugad
Hydropower Project
L&T in joint venture with Alpine Mayreder Bau
GmbH, Austria, has bagged an order valued at
Rs. 456 crores from NTPC Limited (a Government
of India enterprise) for the execution of 4 x 130
MW Tapovan Vishnugad hydropower project in
Uttaranchal.
The package includes construction of a concrete
lined head race tunnel of approx. 11.3 km length
and 5.6 m finished diameter, using, partly by,
tunnel boring machine and partly by roadheader/
drill and blast. The project is located in district
Chamoli on the Dhauliganga river, a major
tributary of Alaknanda.
This is the second hydropower project L&T will
execute in Uttaranchal. The earlier project, Singoli
Bhatwari project being implemented through BOT
route, is located 125 km from Tapovan Vishnugad.
Substations in UAE
L&T has secured an order valued at Rs. 418
crore (USD 94.33 million and AED 346. 68 million)
from the Abu Dhabi Water & Electricity Authority
for the construction of six major electrical
substations in the Al Ain sector of Abu Dhabi.
According to the terms of the contract, L&T will
supply and install 33/11kV primary substations
to the specifications of the international consultant
Mott MacDonald. The project, which includes
design and construction of civil building and over
120 km of 33 kV cabling, will be completed within
18 months.
The L&T-built substations will come up at Al
Mutaredh, Al Mezyad South, Al Dhaher South,
New Al Qua’a, Al Qattara and Civic Centre to
reinforce the region’s power distribution network
and help meet the increased demands for power
in the region.
Each substation consists of 33 kV gas insulated
switchgear, 11 kV air insulated switchgear, 15
MVA 33/11 kV transformers, substation control
and monitoring system, protection and
telecommunication system, DC system and
auxiliaries.
The contract also encompasses design and
installation of utilities such as air conditioning
and lighting systems.
Software Park for CTS
Cognizant Technology Solutions, Chennai has
awarded a contract to ECC for the design and
construction of Phase-1 works for SDB 1& 2,
Canteen Building, External Works and Utilities at
their MEPZ campus, Tambaram, Chennai. The
contract valued at 270.10 crores is to be
completed within a period of 550 days. The major
scope of work includes 73000 Cum of excavation,
47954 Cum of concrete, 2,25000 Sqm of
shuttering, 6268 t of reinforcement and 68000
Sqm of flooring works.
JIPMER, Pondicherry
ECC has bagged a contract valued at 169.90
crores from Hindustan Latex Limited, Noida. UP,
for the design, construction, procurement,
installation and commissioning for super
speciality block, trauma care center, nursing
college at Jawaharlal Nehru Institute of Post
Medical Education & Research (JIPMER),
Pondicherry. The contract duration is for 20
months from October 2006.The major quantum
of work includes 55000 Cum of excavation, 61300
Sqm of filling, 23150 Cum of concrete, 1,10,000
Sqm of shuttering, 2610 t of reinforcement,
35970 Sqm of flooring, 38400 Sqm of water
proofing and other medical equipments in general.
Orders from Oman
L&T (Oman) LLC, has secured orders valued at
US$ 120 million (Rs. 550 crore) for the
construction of multi-storied apartments and
villas at Sohar in the Sultanate of Oman.
A prominent business group in the Sultanate is
implementing a greenfield township project at
Sohar, 300 km from Muscat, to meet the
increasing demand for residential properties. L&T
Oman has successfully bid for and secured
contracts for two packages in the township.
The packages are worth US$ 56.5 million (Rs.
259 crore) and US$ 63.5 million (Rs. 291 crore)
and are to be completed in 18 months from
October 2006.
Larsen & Toubro (Oman), a joint venture of
Larsen & Toubro Limited-India and the Zubair
Corporation, has established a strong presence
in Oman over the last ten years and is well set to
consolidate its position in the years to come.
69
Build Expo 2006 at Kochi
L&T participated in the Build Expo 2006-the largest
construction expo organized by BAI (Kochi Chapter) in
Kochi. This took place at at Jawaharlal Nehru Stadium
at Kaloor, Kochi, during December 2-6, 2006. Nearly
100 companies from construction equipment; building
materials; and real estate participated in the event.
L&T took part in a 100 Sqm pavilion and depicted L&T
Formwork components, L&T Concrete and major
projects of ECC across all business units.
Mr. Raghava Reddy, National President, CII and Mr.
Mani Sankar, Deputy Mayor of Kochi inaugurated the
show and visited L&T’s stall. Numerous visitors mainly
from builders fraternity appreciated L&T’s stall design,
which was done up using formwork components. A
model of Tejomaya IT Park - the state-of-the-art IT
Park in Kochi promoted by L&T Tech Park was also
displayed. Salient features of L&T Formwork System
and Tejomaya were briefed to visitors by marketing
managers of L&T Formwork and L&T Tech Park .
A view of L&T’s stall at Build Expo 2006, Kochi
Build Con Expo 2006, Ahmedabad
Build Con Expo 2006 – the first of its kind in Ahmedabad
– was organized by CII (Gujarat Chapter) and held at
University Grounds, Ahmedabad, during December
15 – 17, 2006. This major construction expo of
Ahmedabad had nearly 75 companies participating from
different segments of the industry (construction
equipment; building materials; facilities and service
providers) in three halls.
ECC participated in the region for the first time and
displayed its expertise in building materials (L&T
Formwork and L&T Concrete) and turnkey construction
capability in an area of 54 sqm through photo panels.
Landmark projects executed in Ahmedabad region
across all BUs were highlighted in our display.
Mr. Chetan Tamboli, Chariman-CII, Gujarat and Mr.
Amol Sanghi, M.D, Sanghi Industries, inaugurated the
exhibition. Other Indian Companies, who participated
in the exhibition include Kirloskar, Schwing Stetter,
Ultratech, Essar, Godrej, Universal, SREI
Infrastructure and few overseas companies.
The unique design and the attractive posters of ECC’s
stall was cynosure of all eyes.
A view of L&T’s stall depicting building materials and turnkey construction
capabilities at Build Con Expo 2006, Ahmedabad
The response for the exhibition was very good and
many prospective clients thronged ECC’s stall The
local MLA Mr. Patel said that whatever projects L&T
has undertaken in Gujarat is a hallmark of high-class
quality and wished that L&T should undertake more
A team of 18 members from ABRO and RMC plants
manned ECC’s stall. From planning to conduct of the
exhibition the team displayed excellent involvement.
70
Construction Expo, Thimphu - Bhutan
To create awareness and provide a wide range of
exposure to stakeholders on the latest developments
in the construction sector, the Construction Expo
2006 was conducted in the Land of Thunder Dragon
(Bhutan). Jointly organised by Standard and Quality
Control Authority, Ministry of Works and Human
Settlement, Royal government of Bhutan and New
Wave Display Services Pvt. Ltd., Kolkata, this four
day event was held at the Changlimithang ground,
Thimphu, the capital of the Royal Kingdom of Bhutan
during October 14 –17, 2006.
The exhibition was formally declared open by the
Hon’ble Prime Minister of Bhutan Lyonpo Khandu
Wangchuk and Hon’ble Health Minister Lyonpo
Jigme Singye in the presence of Dr.Ketan Shukla,
Deputy Chief of Mission, Embassy of India, Thimpu.
This is the third such expo to be held in Bhutan and
the first one was held in December 2003.
More than 30 Indian companies including 5
Bhutanese companies both from the government
and private sector participated in the Expo. L&T,
JP, HCC, and many other manufacturers, suppliers
and dealers of construction related products and
services from India took part and set up their stalls
at the expo demonstrating their capabilities and
modern technologies available in the field of
construction. Concurrent technical seminars were
also held during the expo for the benefit of the local
engineers, builders and other young participants
from Bhutan.
During the closing ceremony, Hon’ble Secretary,
Ministry of Works & Human Settlement, Dasho
Tshering Doprji thanked all participants and
emphasised the need for organising such events
periodically to expose Bhutanese construction
companies to the latest technologies available in
the world.
During the course of the expo, the Royal Government
of Bhutan invited L&T representatives to the
Secretariat and made enquiries about its interest in
Hon’ble Prime Minister of Bhutan,
Lyonpo Khandu Wangchuk (middle)
along with the Health Minister (left) at
L&T’s stall
undertaking construction of certain important
projects in the offing, such as:
♦
♦
♦
Construction of Stadiums at Thimphu
Expansion of Runway at Paro airport
New major hydel projects
In addition, Mr. Sangay Dorjee, Director of the
Department of Occupational Standards, Ministry of
Labour & Human Resources, Thimphu, Bhutan,
showed interest in knowing more about our CSTI
operations and construction trade certifications. A
delegation also visited L&T Chennai, in this context.
L&T’s stall attracted huge crowds for its unique
display as well as high pitched audio-visual films
and videos. Thus, L&T has left an indelible mark in
the minds of the people and government of Bhutan
through this four day event at Thimphu.
Top and bottom: Two views of L&T’s stall
71
Construction Aggregates, Importance to Mankind
Mr. P.K. Govindaswamy, Head-Quarry &
Crushing and Mr. A. Ravikumar, ManagerQuarry & Construction Blasting, ECC HQ,
Chennai, presented a technical paper titled “
Construction Aggregates, Importance to Mankind”
at a colloquium on “Mineral Potentialities of Tamil
Nadu Nadu and Kerala-A macro level review with
a thrust on XI five year plan” in Chennai on October
13, 2006.
The presentation highlighted the amazing use of
aggregates in diverse areas such as construction,
paints, glass, medicine etc. Drawing a parallel
between the global and Indian aggregate scenario,
the paper highlighted that countries like USA have
established super quarries producing over 5 million
tons of aggregates per annum with at least 150
million tons of reserve and the industry as such
was more organised with corporate players
whereas the Indian sector is fragmented with mini
quarries.
The presentation urged the need to organize and
meet the global demand of aggregates, which is
likely to exceed 21.7 million metric tones in 2007
with an estimated annual rise
of 4.7%. The total size of the
Indian aggregates market is
estimated at Rs 9000 – 10000
crores. The high aggregate
consumption in the western
countries and the diminishing
availability has resulted in the
development and use of
aggregate substitutes whereas
in India it is still in its infant
stage. The paper highlighted the
scope for large-scale
investment and scientific quarry
operations by major players.
Mr. A. Ravikumar, delivering the presentation on
“Construction Aggregates, Importance to Mankind”
co-authored by Mr. P.K. Govindaswamy (extreme right)
Being a state controlled industry in India, issues
such as short term policy decisions, unscientific
exploitation of scarce resources are some of the
fundamental problems faced by the Indian
aggregate industry. The paper called for a strategic
approach with focus on forecast, demand and
consumption of aggregates, develop and understand
resource constraints, government assistance in
planning of aggregate supply and demand to match
Planning, Designing & Construction
of Healthcare Facilities
with urban development. Suggestive means of
approach such as identification of major geological
sources, location of quality aggregate resources,
mandatory EIA for establishing new units, technical
expertise, single window regulation of the sector,
training facilities, safety procedures, change over
from minor mineral to major mineral status were
highlighted in the presentation which was well
received among the participating industry experts.
Innovative Structural Steel
Design Award for L&T
Mr. V.Sukumar Hebbar – Principal Architect, EDRC-HQ,
Chennai, presented a technical paper on “Planning, Designing &
Construction of Healthcare Facilities – L&T Experience” at the
International Conference on Planning & Designing of Healthcare facilities
organised by AIIMS – New Delhi along with Ministry of Health &
Family Welfare in Goa during September 15-17, 2006. More than 350
dignitaries including architects and doctors of national and nternational
repute attended the conference.
At the National Award Competition for Professionals on
Structural Steel Design and Construction –2005 organised by
INSDAG, L&T was awarded the third prize for team work in
the project “ HITEX at Hyderabad” for innovative structural
steel design of exhibition hall roof during the workshop on
“Steel in construction” held at Mumbai on November 24,
2006. Mrs. M.F. Febin, Engineering Manager, Civil, EDRCB&F and her team guided by Mr. S. Kanappan – Head, EDRCB&F carried out the design.
Mr. V.Sukumar Hebbar presenting the technical
paper on “Planning, Designing & Construction of
Healthcare Facilities”
Mr. S. Kanappan, receiving the award from Mr. Tanaji
Satre, Joint CEO, MIDC. Mrs. M.F. Febin is at the
extreme right.
72
FOCALPS ’06
Ms. M.F. Febin,
Engineering
Manager, EDRCHQ, B&F, made a
presentation
on
“Recent Trends in
Civil Engineering”
in the National level
technical symposium,
M.F. Febin
FOCALPS’06
organised by the Civil Engineering Association
and the department of Civil Engineering of
Periyar Maniammai College of Technology
for Women, Thanjavur on 21st September,
2006. The presentation focused on latest trends
in civil Engineering, buildings & factories
constructed by L&T - ECC including case studies
of HITEX and Convention Centre – Mauritius.
Membrane Bioreactor in Sewage Treatment Plants
Conference On Cleaner Technologies and
Environment Management” in Pondicherry
Engineering College campus.
Their paper was adjudged the best among the
selected eight papers out of the 120
presentations made at the conference.
S. Virapan
M. Lavanaya
M r. S . V i r a p a n , E n g i n e e r i n g
M a n g e r,
Building
Utilities
Competency Cell and Ms. M.
Lavanaya, Design Engineer – EDRC,
HQ, Chennai, presented a technical paper
“Membrane Bioreactor (MBR) in Sewage
Treatment Plants” at the “International
Their paper highlighted the advantages MBR
had over the conventional wastewater
treatment systems and the potentialities for
membrane application in treating industrial
effluents.
Experts and delegates from different
institutions from India and abroad participated
in the program and shared their experience.
International Technical Meet on Steel Industry at Ranchi
L&T and its technology partner Paul Wurth,
Luxembourg jointly sponsored an International Meet
on Steel Industry at Ranchi during 18-20 January
2007. The meet was organized by the Ranchi
Chapter of IIM; Centre for Engineering &
Technololgy, SAIL; Research & Development Centre
for Iron & Steel, SAIL; and Mecon Limited and was
attended by over 200 delegates from across the
world.
The aim of the meet was to understand the full
implications of the projected growth of the Indian
Steel Industry from the present level of 42 MTPA to
120 MTPA by 2020 and tackle the challenges in
equipment manufacture and plant construction as
well as finding the right manpower to shoulder this
responsibility in the face of the attraction that the
IT sector holds for engineers.
At the first Technical Session L&T and Paul Wurth
presented papers on Steel Plant Construction and
on the latest developments in BF BLT equipment.
L&T’s paper was presented by Mr. R.P. Das, Sr.
DGM (Business Development), Minerals & Metals
BU, and was well received, judging by the response
it evoked in the question & answer session. The
questions touched upon L&T’s limited engagement
in manufacture of steel plant equipment, the
company’s strategy in not taking up projects below
a certain value and the scope for procurement of
equipment from China.
Mr. R. P. Das (right) receiving a memento from Mr. Rajesh Singh, General Manager,
CET, SAIL
Mr. Peter Zoneveld, CEO, Danieli Corus, in his
presentation made a plea to SAIL and other buyers
for a tendering process that would give a fair
opportunity to even those companies whose prices
are somewhat higher but who offer more advanced
technologies. Stopinc, Switzerland made a point
that technologists and end users should lead project
and technology selection and that purchase and
commercial departments should play more of a
complementary role. SSIT China said that Indian
buyers should study the quality grading system of
Chinese manufacturers and take their advice to
source the best and economical products from China.
Some major organizations, which were represented
at the meet, include Messrs. Bosch Rexroth, UCAR,
Siemens VAI, IMS Maco, ZAO VTf, Mckeown and
ABB.
73
Performance for the Quarter Ended December 31, 2006
Sales
Gross sales from operations of Larsen &
Toubro Limited for October–December 2006
stood at Rs. 4200 crore as against Rs.
3742 crore for the corresponding quarter
of the previous year. The share of revenues
from international operations constituted 19%
of the gross revenues reported for the
quarter.
For the period April–December 2006, the
order booking was higher at Rs. 22944
crore, registering 41% increase over the
corresponding period of the previous year.
Profit after tax (PAT)
P r o f i t a f t e r t a x [ PAT ] f o r t h e q u a r t e r
October–December 2006 at Rs.344 crore is
higher by 33% , when compared to the
corresponding period of the previous year.
Excluding extra ordinary and non-recurring
items, the PAT grew by a healthy 84% over
the corresponding quarter of the previous
year.
PAT for the nine-month period April–
December 2006 at Rs. 702 crore is higher by
29%, when compared to the corresponding
period of the previous year. Excluding
extra ordinary and non-recurring items, the
PAT rose smartly by 69% over the
corresponding previous period.
Group Financials
Group PAT for the quarter OctoberDecember 2006 at Rs 604 crore is
higher by 80% when compared to the
corresponding period of the previous
year. Excluding extra ordinary and nonrecurring items, the PAT increased by 90%
over the corresponding previous period.
Group PAT for the nine-month period AprilDecember 2006 at Rs 1529 crore is higher by
82% when compared to the corresponding
previous period. Excluding extra ordinary
and non- recurring items, the increase in
PAT is 89% over the corresponding previous
period.
The total income of the Group for the ninemonth period April-December 2006
increased to Rs. 14121 crore from Rs.
11743 crore achieved in the corresponding
period of the previous year. Most of the
businesses of Subsidiary and Associate
companies have performed exceedingly well
during the period, thereby boosting the Group
revenue & profitability.
Engineering & Construction
Segment (E&C)
The Company’s E&C segment reported
significant growth in order booking during the
quarter, in line with the increased activity
in the domestic & international markets
particularly in the Infrastructure & Hydrocarbon sectors.
The E&C order booking at Rs.8172 crore for
the quarter ended December 31, 2006 posted
an increase of 26% when compared to the
corresponding quarter of the previous year.
The share of International orders booked
during the quarter was around 12% of the
total orders booked.
For the nine-month period, the E&C order
booking was higher by 43% at Rs. 19127
crore, over the corresponding previous
period, which reflects the Company’s
superior competitive strength in the E&C
segment. The Company expects this growth
trend to continue in the last quarter of the
current fiscal year.
E&C segment revenue for the quarter ended
December 31, 2006 was at Rs.3160 crore as
against Rs. 2951 crore for the corresponding
quarter of the previous year. The share of
export revenue for the quarter at Rs.614 crore
represents 19% of the segment revenue.
Segment profits [PBIT] at Rs. 325 crore for
the current quarter recorded a smart growth
of 56% over the corresponding quarter of
the previous year, largely due to better
selection of jobs, close monitoring and
control of contract execution costs through
appropriate risk management framework
and economies of scale achieved through
larger size of orders.
The segment order backlog as at December
31, 2006 is robust at Rs.34142 crore.
Electrical & Electronics
Segment
Electrical & Electronics segment reported a
robust growth in sales, reflecting the
superiority of the Company’s products and
its contemporary applications in a rapidly
growing market. The segment revenue at
Rs.483 crore for the quarter ended December
31, 2006 was significantly higher when
compared to Rs. 383 crore for the
corresponding quarter of the previous year.
The increase reflects a sustained growth in
the Electrical Standard Products, Electrical
Systems & Equipment, Control &
Automation and Metering & Protection
Systems businesses.
The Company continues to be a market leader
in Low Tension Switchgear products through
its cost efficient manufacturing, widespread
distribution network, product innovation and
quality.
Machinery & Industrial
Products Segment
The segment revenue at Rs. 407 crore for
the quarter ended December 31, 2006 was
higher when compared to Rs. 349 crore for
the corresponding quarter of the previous
year.
The growth in revenue was witnessed in most
of its product lines, both manufactured and
traded. Increased volumes, higher price
differentials and improved manufacturing
efficiency contributed to better margins and
profitability over the corresponding quarter
of the previous year.
Outlook
Indian economy is poised to sustain its
accelerated growth momentum led by an
impressive performance of the manufacturing
and infrastructure sectors. The Company’s
leadership position in these sectors holds
good potential in terms of continued upsurge
in order booking and sales.
The current economic buoyancy seen in the
Middle-East region, where the Company is
building up a significant presence, also offers
several promising business opportunities for
all business segments of the Company.
The revenue growth, which was modest in
the first nine months, is expected to be at a
higher level in the last quarter. The smart
improvement in margin is expected to be
maintained in the short and medium term.
74
“Engineering Without Frontiers”
The Sixth Brunel International Lecture was
organized on October 25, 2006 jointly by the
Institution of Civil Engineers UK (ICE) and Larsen
& Toubro Limited, ECC Division. The venue was
Mortensen Block, Convention Centre, in ECC’s
Manapakkam Complex.
Prof. Paul W Jowitt, Vice President, ICE, delivered
his International Lecture on ‘Engineering Civilisation
from the Shadows’ as part of the Sixth Brunel
International Lecture that is being taken across
the Globe. The Chennai lecture was the first of two
series in India. Similar events were held earlier in
England and other countries such as Tanzania, South
Africa and Sri Lanka.
Profiling great engineers and 19th Century heroes,
Prof Jowitt highlighted the connection between
Engineering, Technology and Economics. “Works
of great engineers have had great significance to
the extent that it did add over 2 decades to human
life span. There are innumerable projects that could
testify this,” he said.
He provided a ‘big picture and urged the engineers
to view this in everything they do. Prof Paul said
the climate change people talk of is real and that
natural calamities such as hurricane, earthquake
and tsunami threaten the civil infrastructure. He
also reiterated that in the global context poverty
was real and said that the creation of infrastructure
will be the key to sustainable development.
He also called for a change in human behaviour and
advocated a shift to appropriate technology,
embarking on change in fuel and energy source be it wind, wave, hydel, hydrogen, hydropower or
even nuclear. In effectively creating the requisite
infrastructure, he stressed the need for good
governance and transparency.
Mr. K. V. Rangaswami, Head Construction, L&T, & Member of the Board, delivering
his presidential address
ICE is a body, which facilitates ‘Engineering without
Frontiers’ and shares knowledge across frontiers,
beyond communities and nations. Prof. Jowitt called
upon engineers to evaluate their own work - as to
what it meant to them, their profession, their
organization, and its consequences action and
ultimately, one’s own will to execute the work. He
urged the engineering community to ‘make poverty
history’.
Mr. K.V Rangaswami, Member of the Board &
Head-Construction, Larsen & Toubro Limited, was
bestowed the ICE Fellowship Certificate for his
notable contribution to civil engineering.
In his presidential address, Mr. Rangaswami
expressed that with the establishment of ICE
Chennai Chapter, there would be enormous impetus
to Civil Engineering in India, particularly with the
younger generation who would gain by virtue of
participation and knowledge sharing with global
engineers.
Mr. G.D. Sharma, VP & Head-HR, L&T ECC Division
received the certificate recognising L&T ECC Division
as “Approved Employer” for training young
engineers preparing for professional review for the
Chartered Membership of ICE-UK. This is the first
time in India that an organization has been accorded
such status.
As many as 13 L&T Engineers were awarded the
Membership of ICE-UK after a Professional Review
conducted for the first time in India a few months
ago.
Mr. S. Ganguly, GM - Personnel & HRD, emphasised
the need for association with such international
professional _ bodies in view of L&T’s growing
operations internationally.
Mr. P.A.K. Murthy, Country Representative of ICE,
Chennai introduced the Prof Jowitt and the Chennai
Chapter of ICE.
Chartered Members of ICE-UK from L&T seen with Prof. Jowitt and Mr. K. V. Rangaswami
75
AIDS Awareness Campaign at BIAL Project
Bangalore International Airport Ltd. (BIAL)
project site in association with the Family
Planing Association of India (FPAI), a leading
national NGO working in the area of sexual
and health care, organised an AIDS
awareness campaign on December 1, 2006
on the occasion of World AIDS Day.
Mr. G.D. Sharma, Vice President & Head HR, L&T-ECC, and Mr. A.K. Monnappa, IAS
and Director, Dept. of Women’s and Child
Development, Govt.of Karnataka, inaugurated
the function.
Others present on the occasion were Mr.
G.V. Narasimha, SPM PT&D Sector, Mr. S.
Srinivasan, Regional Accts. & Admin.
Manager, Mr. Javeed Shakil, Project
Manager, BIAL, staff members, employees
from BLRO and BIAL site and more than 300
workmen.
The campaign aimed at generating awareness
among the workmen and staff of BIAL project
site on HIV/AIDS, risks involved and
preventive measures.
In his welcome address GDS emphasized the
importance of healthy and active individuals
in the process of nation-building. He pointed
out that it is not just structures but the quality
of human resources which is vital for national
development. He re-affirmed L&T’s
Mr. G. D. Sharma, Vice President & Head - HR, L&T - ECC, inaugurating the AIDS
Awareness Campaign at Bangalore International Airport Ltd. (BIAL)
commitment towards the society as part of
its corporate social responsibility.
people needs to be addressed by changing
people’s attitudes.
Mr. Monnappa in his address said that it is
time to intensify action to generate awareness
and work on the infected people. He also said
that social ostracization of HIV/AIDS-affected
Mrs. Raj Mathur, President of FPAI’s
Bangalore branch, appreciated the initiatives
taken up by L&T and the promptness of their
workforce. She asserted that the spread of
HIV can be prevented by more aggressive
information sharing and appealed to the
audience to take a pledge to eradicate the
devastating disease.
Dr. Sheela Mane, Executive Member, FPAI,
explained the difference between HIV and
AIDS, and factors causing the disease, modes
of transmission, indicators and preventive
methods.
A street play on AIDS was performed by
artists from CARDS, Mangalore, which was
very moving and had a profound impact on
the audience. Participants took a candlelight
pledge to spread awareness of HIV/AIDS
among the people. An exhibition of posters,
pamphlets and audio visual presntation on HIV
/AIDS was organised.
Mr. Javeed Shakil proposed the vote of thanks
and attributed the success of the campaign to
the dedicated team work of staff from project
site, volunteers from NGOs and BLRO.
Participants taking a candle light pledge
76
Medical Camp at Konaseema Power Project
A free medical camp was conducted by Konaseema Power project site at Deveapalli
village under East Godavari district, A.P. on January 7, 2007. Dr. Somasundra
Reddy, Ex-MLA inaugurated the camp. This was attended by more than 800 residents
from nearby villages. A team of doctors rendered the service. Free diagnosis and
medicines were distributed to the patients. A blood donation camp was also
organized on the same day and 30 persons donated blood. M/s Chiranjeevi Charity
Trust extended all support and doctors/nurses from KIMS, Amalapuram came to
site for extending necessary assistance.
CFO Award for YMD
Mr. Y.M. Deosthalee,
CFO, L&T, has been
conferred
the
prestigious CFO Award
in the Engineering &
Capital Goods sector by
India’s
leading
business TV channel,
CNBC-TV18. The awards ceremony was held in
Ras-al-Khaimah, the UAE, on November 26,
2006.
Instituted by CNBCTV18 in 2006, the CFO
Awards recognize the efforts of CFOs in
creating wealth for the organizations,
stakeholders and customers.
This is the second such honour won by Mr.
Deosthalee. Earlier, he had won the CFO of the
Year Award instituted by the Economic Times,
Economic Intelligence Unit and American
Express.
Medical camp in progress
Best Corporate Social Responsibility Award for L&T
Appreciating the efforts of L&T as a good
corporate citizen, and the yeoman service
rendered by ECC’s Construction Skills Training
Institute (CSTI), the Bombay Stock Exchange
(BSE) awarded L&T the Best Corporate Social
Responsibility Award.
The award was received by Mr. S. Natarajan,
Head-CSTI, ECC, Mr. G.D. Sharma, Vice
President-HR, ECC, and Ms. Sanyogta Raina,
Manager-Corporate Social Initiatives, L&T, at a
ceremony held in Mumbai on December 15, 2006.
Mr. Natarajan made a passionate presentation
to the contest jury on L&T and the role of CSTI in
creating employment opportunities, skills
ugradation and social upliftment.
BSE in association with Times Now (a Times
Group and Reuters Service Company) presented
the ‘Business for Social Responsibility’ (BSR)
Awards for Corporate Governance. The
competition hosted by ITM Business School,
Mumbai had the theme: ‘Questioning Assumptions
- Changing Framework’.
The panel of jury was headed by Mr. Harit
Nagpal, Operations Director, Hutchison Essar
Ltd., and Mr. Rajnikant Patel, MD & CEO, BSE,
and comprised 14 heads of companies. The
Mr. S. Natarajan, Head - CSTI, ECC, Mr. G.D. Sharma, Vice-President - HR, ECC,
and Ms. Sanyogta Raina, Manager-Corporate Social Initiatives, L&T, are seen at
right with the Best Corporate Social Responsibility Award
award is part of a wide-ranging initiative to
promote Business for Social Responsibility in
India. This involves developing responsible
business policies and practices and making them
an integral part of organisations’ mission, values,
strategy and operations.
77
Quality Rolling Trophy 2005-06
Continuing the tradition of honouring excellence
in Quality in our projects, the Quality Rolling
Trophy for the year 2005-‘06 was presented to
the winners on January 2, 2007 at the Convention
Centre, ECC-HQ, Chennai. This year the Trophy
presentation ceremony was held in conjunction
with the customary New Year address by Head
of ECC Mr. K.V. Rangaswami.
As in the earlier years there was enthusiastic
participation in the competition, with thirty-seven
sites getting short listed for the final rounds. The
entries were assessed on the basis of various
parameters such as product quality,
housekeeping, customer satisfaction, project
schedule, project cost management, safety and
adherence to the Company’s quality management
system. They were assessed in stages by the
Site Quality team, Quality Management Committee
of the Region (QMC [R]), a board of examiners
consisting of QMC (R), internal auditors, and the
Quality Management Committee-HQ.
The awards were presented by Mr. K.V.
Rangaswami, Member of the Board & HeadConstruction, Mr. K. Venkataraman, Sr. V.P.
Hydrocarbon & Power, Mr. K.G. Hariharan, Sr.
V.P. & Head-Industrial Projects & Utilities, Mr.
V.B. Gadgil, EVP & Head-B&UI and PT&D Sector
BU (GCC Countries), Mr. J. Ganguly, EVP &
Head-Resources Support & Supply Chain, and
Mr. K. Venkatesh, EVP & Head-Developmental
Projects. The winners are :
Quality Trophy Winners - 2005-06
Site
Region
Project/Construction
Manager
Anand Rajkot Pipeline
ABRO
V. Thirumalaisamy
GWRDC - Ahmedabad
ABRO
E.P. Sajit
Wockhardt Hospital
BLRO
K. Nataraj
Kudankulam Nuclear Power Plant
CNRO
P. Paulraj
Kuttiyadi Hydel Power Project
CNRO
M.V. Ramachandran
Allahabad Bridge across River Ganga
DLRO
G. Vinod
DMRC Cut & Cover Tunnel
DLRO
Dharmendra KR Sharma
ASAHI Glass Factory
DLRO
B.M. Verma
SALPG-Underground LPG Storage Cavern
HYRO
K.S.R.K. Verma
O&M Anantpur
HYRO
P.R. Harikrishna
Coal Handling Package for Bakreswar TPP
KKRO
S. Raja
Tankage, Vessel and Piping Job at Lanjigarh
KKRO
P.K. Bandyopadhyay
Jharkand Road Project
KKRO
Chunduru Rajendra Prasad
Sri Satya Sai Water Supply Project -
400 kv D/C Maithon-Ranchi Transmission Line
KKRO
V. Mohana Sundaram
Durgapur Project Limited-Durgapur
KKRO
B. Paul
AWTF & SFSF BARC Tarapur
MBRO
B. Sundaramoorthy
G-1296 Project
Al Ain
V.V.V. Satyanarayana
Winners of the Quality Rolling Trophy seen with Mr. K.V. Rangaswami and other Senior Executives
78
KV Elected President of Indian Institute of Chemical Engineers
Mr. K. Venkataramanan (KV), Member of the
Board and President (E&C Projects), was elected
President of the Indian Institute of Chemical
Engineers (IIChE). He will hold office in the 60th
(diamond jubilee) year of the institute.
Established in 1947, the IIChE is the apex
professional society of chemical engineers in
India, with over 18,000 members on its rolls. It
has emerged as a national platform overseeing
the interests of the academia as well as industry
in the field of chemical engineering and allied
sciences.
KV said he would direct his efforts to build on
the historical traditions of the institute to expand
its role and relevance in contemporary industry
and society.
Making particular mention of the youth, he said
the institute would enhance its engagements with
young chemical engineers and provide avenues
to help them enhance their capabilities and
expertise.
K. Venkataramanan (left) receiving a memento from the outgoing President of
IIChE, Prof. S. Venkateshwar, Principal, University College of Technology,
Osmania University, Hyderabad.
ECC Wins its Fifth RoSPA Award
ECC’s PTA Project Site - IOCL Panipat, has won
the prestigious Silver Award of the Royal Society
for the Prevention of Accidents (RoSPA), UK. The
award is in apt recognition of ECC’s excellence in
occupational health and safety performance
achieved at site during a period of three years from
2003 to 2005. This is the fifth RoSPA award won by
ECC.
Instituted in 1956, the RoSPA safety awards are
categorised into ‘Gold’, ‘Silver’, ‘Bronze’, and ‘Merit’
Awards with additional accreditation for specific
issues. In deciding on the winner, RoSPA’s focus
is on total man-machine-environment system to
assess accident potential and prevention of
accidents. Greater emphasis is laid on engineering
techniques in accident prevention than on mere
correction of unsafe practices.
The RoSPA Awards won earlier for excellent safety
performance include the RoSPA Merit Award for
Occupational Safety at ECUs Jawaharlal Nehru
Stadium Site, Chennai, in 1993, the RoSPA GOLD
Award for Occupational Safety at ECC’s Coal
Handling Plant. Paradip Site in 2002, the RoSPA
GOLD Award for Occupational Safety at ECC’s
TISCO Jamshedpur Site in 2004, and the RoSPA
Silver Award for DHDT & HGU Site at IOCL Panipat
in 2005.
Mr. P. L. N. Murthy, Project Manager, and Mr. Ravikant Dubey, Sr. Engineer (HSE),
PTA Project, IOCL Panipat, seen with the RoSPA Award
79
Project Export Awards
L&T has won two Export Awards from The
Project Exports Promotion Council of India. The
awards are in recognition of export projects
promoted and executed by an Indian Company
for the year 2005-2006.
Mr. V.B. Gadgil, EVP and Head-B&UI and PT&D
Sector Business (GCC Countries), received the
award from Mr. P.C. Chaturvedi, MemberAdministration, NHAI, during the awards
presentation ceremony in New Delhi on
December 16, 2006. The categories in which
L&T won the export awards are:
♦ Maximum turnover in overseas construction
and engineering projects
♦ Maximum value of overseas construction
and engineering projects
Mr. V.B. Gadgil, EVP and Head-B&UI and PT&D Sector Business (GCC Countries),
receiving the Export Awards from Mr. P. C. Chaturvedi, Member - Administration,
NHAI
Construction World-NICMAR Awards 2006
One of India’s largest circulated construction
business magazines, Construction World, and
National Institute of Construction Management
and Research (NICMAR) honoured L&T with two
prestigious awards in Mumbai on December 01,
2006.
Mr. K.V. Rangaswami, Member of the Board &
Head-Construction, received the ‘Largest & Most
Profitable Construction Company in India’ Award
from Mr. Rajiv Ratna Shah, Chief Guest and
Member - Planning Commission, Government of
India, and ‘The Most Admired Construction
Company in the Industry’ Award from Mr. Lalit
Singhal, Director-General of SEZ units,
Government of India.
Accepting the honour, Mr. Rangaswami said that
he would dedicate the award to the ECC team,
customers and business associates. In a
magnanimous gesture he further commended all
the prize winners and urged them to collectively
enhance standards in the country’s construction
industry.
Mr. K. V. Rangaswami, Member of the Board & Head-Construction, receiving the
‘Largest & Most Profitable Construction Company in India’ award from Mr. Rajiv
Ratna Shah, Member, Planning Commission, Government of India
Edited by Mr. V. S. Ramana for Larsen & Toubro Limited - ECC Division, from ECC - HQ., Manapakkam, Chennai - 600 089. The views
expressed in this magazine are not necessarily those of the management of Larsen & Toubro Limited. The contents of this magazine
should not be reproduced without the written permission of the Editor. Not for sale-only for circulation among the employees,
business associates and customers of ECC - L&T’s Construction Division.
80