The bridge was fabricated at a workshop in Tiruchirappalli (Trichy), Tamil Nadu, approximately 1,300 km from the installation site. It was transported to Maharashtra on trailers and assembled at the site before being launched over the highway.
The project highlights the capabilities of India's domestic manufacturing and engineering sector in delivering complex infrastructure components for high-speed rail projects.
The fabrication process involved precision cutting, drilling, welding and painting in accordance with the prescribed designs, drawings and specifications. Each batch of steel underwent ultrasonic testing (UT), while welders and supervisors were certified by international welding experts.
The bridge was assembled on temporary trestles approximately 17.5 metres above ground level. The installation involved 22 skid arrangements and 54,076 Tor-Shear Type High Strength Bolts (TTHSB). A C5 protective painting system and elastomeric bearings have been provided to enhance durability and control vibration.
The completed bridge was pulled into position using an automatic launching mechanism comprising two hollow jacks, each with a capacity of 150 MT, along with pre-tensioned Macalloy bars.
To minimise disruption to highway traffic, the launching operation was carried out at night during scheduled traffic blocks on NH-3. The operation required detailed planning and precise execution to ensure the safe installation of the structure.
Steel bridges are used in locations where longer spans are required, including crossings over highways, expressways, major rivers and railway lines. Their use in the Mumbai-Ahmedabad Bullet Train corridor supports the construction of high-speed rail infrastructure across complex terrain and existing transport networks.
The bridge measures 100 metres in length, 14 metres in width and 14 metres in height, with the main steel structure weighing 1,405 MT.
Of the 28 steel bridges planned along the Mumbai-Ahmedabad Bullet Train corridor, 16 have been completed. The newly launched bridge marks a milestone in the construction of the high-speed rail project in Maharashtra and demonstrates the role of domestic manufacturing in its execution.
