New Doha International Airport

Taisei Corporation chose Bajaj for the design, fabrication & erection of formwork for 4 V-Piers for their airport project at Doha. The 8 m high pier in the form of V was designed for concreting in a single pour at the rate of 150KN/sq.m. Having an approximate cross section of 2.5 m x 1.4 m (varying). Voided slab constructed above V-pier comprises of 1.8 m thick ribbed slab, in straight and curved plans. For this project, approximately 900 tonnes of Staging, Tranverse & Longitudinal beams, Soffit & Side panels, Inner forms etc. was supplied.

Circular columns with a concrete pour rate pressure of 150KN/sq.m. were designed with height measuring 9.6 m dia varying from 2.0 m to 3.0 m. Pranav also designed, manufactured and supplied elliptical shaped piers of circular ends with straight panels in between dia 2.15 m x straight portion varying from 200 to 1200 mm.

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M.S.R.D.C – Nagpur

For the Nagpur flyover the Municipal Corporation desired a very special shape for the piers. A pier that would represent architectural beauty, as well as state-of-the-art safety, design and construction. The conceived design envisaged a flaring ellipse cast in a single piece. This daring design was also a challenge for the construction industry. Bajaj took on the responsibility to create a construction system for this pier, which would be a landmark of design, engineering and construction excellence. The construction system developed for the pier incorporated about 200 individual components made up in 8 segments. The formwork took a very low assembly and striking time, despite the intricacy of formwork and its support system.

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3B Parallel Road, Al Bashra, Dubai, UAE

For this large project, Pier supports (4 sets), Underpass wall (2 sets) and Box girder (5 span materials) were designed and supplied by Bajaj. This was a high precision and stringent quality driven project where all material was tested, verified and certified at various stages. The Load test of Medium Duty Trestle (MDT) was successfully conducted in presence of client Group 5, main contractor Al Naboodah LLC, client RTA and consultant Parsons. The approval of design was a critical point in this project as MDT is an integral member in shoring/staging for box girder and underpass top slab. Following approval of design, material was delivered at site according to requirement of design drawings, indentified and verified with site engineers of G5.
Training at ground level was conducted for associated labourers in presence of Group 5 site engineers and supervisors for: i) Assembly of panels for underpass wall; ii) Pre-assembly for box girder side form panels (wing frames), inner-form (web and wall) & top slab panels.

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Santacruz Airport Flyover, Mumbai, India

Santacruz Airport Flyover on Western Express Highway is a prestigious project for Bajaj. The company supplied the formwork for pier (2 m x 2.5 m x 5.2 m height), pier cap & I- girder of 35 m and 45 m with 2.0 m depth and 2 m width. Bajaja has supplied formwork for this project in the following quantities – Pier : 1 set, Pier Cap : 2 sets, I-girder : 2 sets 35 m long with 13 sets of diaphragm and Igirder: 1 set 45 m long with 4 sets of diaphragm.

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Anand Rao Circle

A launcher of 46 m span, 14 m height weighing 230 tonnes with built-up Box-girder on 4 corners had to be fabricated, under design guidance of the consultant. To ensure absolute precision, 100% radiography was carried out on the Launcher components, and 5570 holes were drilled for bolting and assembling the components. The complete assembling was carried out at site. Bajaj also handled the casting of 10 Intermediate and 2 Pier segments in the 31.0 m span. The Long Line method of casting was followed with the typical segment being 15.0 m wide x 2.9 m long x 1.7 m deep with 3 cells. The components included Soffit beds for full span, one pair of Side forms, 2 sets Gantry and Inner forms, 2 sets of Bulk heads of 5 types and 1 set of Pier segment. Over 500 components had to be manufactured, including machining items. The work also included Pier and Pier cap formwork of various types for which standard Modular Panels were used along with make-up pieces to cater to different shapes/sizes.

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Lalbaug Flyover

Simplex Infra Project Ltd. is contesting the prestigious flyover at the Lalbaug area of Mumbai. These flyovers will ease the traffic congestion of this busy area of the economic capitol of India. The route & pathway of the bridge required cast in situ application with heavy concrete structures, other than the precast option .Bajaj has the distinction, of designing, fabrication and erecting supervision on both the varied application, which fetched the customer’s confidence on entrusting Bajaj with orders for long line segmental moulds and heavy duty staging (Mega stage) and decking (I- dek). The project is most likely to finish by early 2011 and the bridge will be then open to public making life smoother & easier. The cast in situ was done at spans of 35 meter & above with weight of up to 9 to 10 meters. The bridge required beautiful aesthetic finished for which decoform rubber liners were fixed and they are sure to append to the magnitude of the bridge as one of the landmark projects of Mumbai for years to come

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Flyovers between Sion & King Circle, Mumbai

For the three flyovers between Sion & King Circle – the arterial roads on the city’s Eastern Express Highway, Bajaj has designed, manufactured and supplied several formwork solutions. These include: i) Self-supporting formwork for 2 types of Pier & Pier Cap. The formwork has been provided with quick release clamps for ease of assembly and striking. The design is such that only the clamps at vertical joints have to be removed and the whole system thereafter can be deshuttered by means of jack provided at the bottom of structure and can be immediately shifted to the next location. ii) Formwork for 35 m straight span and 35 m curved span. The total formwork comprised of Soffits, Outer forms, Inner forms & Bulkheads with all kinds of supporting arrangements for quick & easy assembly & striking. Curved Bed Soffits were provided with specially designed Knuckles, so that the bed could be rotated in any direction i.e. 360º to cater various radiuses. iii) Formwork for precast & cast-in-situ crash barriers. iv) The form liner has also been provided by Bajaj to give an aesthetic look to the entire project.

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Panjrapole Flyover, Mumbai, India

The Eastern freeway project stretching from Chembur to CST in Mumbai has the unique distinction of having the tallest flyover in India ( 22 meters) as part of it at Panjrapole. Bajaj has supplied engineered system Formwork moulds for Long line, self supporting moulds for Piers, Pier cap and easy stricking I- girder for this project. Also the beautiful leaf pattern which has been created from concrete as is visible on the pier has been made possible by decoform TM formliner designed and manufactured by bajaj.

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Nashik Phata Flyover, Pune, India

Formwork designed and supplied by Pranav sits pretty on the busy Nasik Phata junction on the Old Mumbai- Pune Highway. Imposing, tall piers and boxgirders spanning over busy roads below, bear testimony to the highest quality formwork systems that Bajaj has come to be associated with. Flyovers at two different levels add a futuristic look to the project. The flyover is a two level deck crossing each other, one running over the other.

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Bankhode Junction Flyover – Navi Mumbai, India

The flyover near Koparkhairne Railway station has unique U shaped design. In order to cater to the longitudinal slope as well as the superelevation, a formwork system of the highest precision levels was required. Bajaj met the complex requirements by designing & manufacturing the deck Formwork for the solid slab along with the supporting Staging. The architectural beauty of the flyover has been enhanced by decoform formliners also designed and supplied by Bajaj.

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Amar Mahal Flyover, Eastern Express Highway, Mumbai, India

The Amar Mahal flyover spans over one of the busiest junctions at Chembur. It connects the Eastern Express Highway with the Chembur-Santa Cruz Link Road. Bajaj has finished the supply for the self supporting pier formwork which has already been cast to very high degree of satisfaction. In addition, Bajaj also ensured aesthetic finishes on the Piers through the design and supply of TM decoform formliners which are clearly to see.
The level of satisfaction attained by Pranav has been further augmented by the contractor by providing further orders for the Steel Plate Girders to be erected atop the piers on the curved portion.

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Kapurbawadi Flyover, Thane, India

The Kapurbawadi junction connects the Eastern Express Highway, Mumbai- Nasik Highway and Ghodbunder Road in Thane. Pranav has supplied the formwork for Pier, Pier Cap, Longline & Cast in situ Box Girder for this landmark project which will shorten commuting time and improve connectivity in this satellite town of Thane. Pranav also provided re-engineering services for the reuse of certain formwork moulds for this project, which were earlier designed and fabricated by Bajaj for the same customer in a different project.

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3B PARALLEL ROAD,Al Barsha,Dubai

For this large project, Pier supports (4 sets), Underpass wall (2 sets) and Box girder (5 span materials) were designed and supplied by Bajaj. This was a high precision and stringent quality driven project where all material was tested, verified and certified at various stages. The Load test of Medium Duty Trestle (MDT) was successfully conducted in presence of client Group 5, main contractor Al Naboodah LLC, client RTA and consultant Parsons. The approval of design was a critical point in this project as MDT is an integral member in shoring/staging for box girder and underpass top slab. Following approval of design, material was delivered at site according to requirement of design drawings, indentified and verified with site engineers of G5.

Training at ground level was conducted for associated labourers in presence of Group 5 site engineers and supervisors for: i) Assembly of panels for underpass wall; ii) Pre-assembly for box girder side form panels (wing frames), inner-form (web and wall) & top slab panels.

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M.S.R.D.C (J.J. Hospital Mumbai Flyover)

The J.J.Hospital flyover in Mumbai is a benchmark of engineering quality and architectural design. The challenge was to design anddevelop Pier formwork for an 80 tonne single pour of concrete for pier heights up to 8.5 m. The architectural detail required a flaringshape with a smooth grooved, unbroken finish without joint lines on the cast structure of the pier.

Using in-house technology and expertise, Bajaj met the design and architectural requirements of the U.K. based consultant. For thisunique flyover, formwork was designed using about 400 elements, in two halves. The entire surface was lined with a specially formedrubber to obtain the designed surface finish. Hydraulic systems were incorporated to assemble and strike the formwork accurately andwith high efficiency. The result: The assembly time for each mould casting was about 4 hours and striking time was about 2 hours perpier casting. All 70 piers were comfortably cast using just a single construction system by Bajaj.

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