Mumbai Monorail: India's Pioneering Infrastructure Project

In-house Journal of L&T Construction
Jan - Mar 2012 Volume-35 Issue-1
Focus
With thousands of people migrating to Mumbai every month, the citys infrastructure is hardly able to cater to the burgeoning population, making the lives of people in the already congested city very difficult. With a view of provide a feeder system of mass public transport, the Mumbai Metropolitan Region Development Authority is building Indias first monorail. The Mumbai Monorail is a pioneer project in more ways than one with innovative advances in engineering, construction and management, not just by Indian standards, but at an International level as well. Once completed, the Mumbai monorail is also slated to be the worlds second longest system next only to the 23.8 km long Osaka monorail in Japan. L&T has been making this infrastructure dream of Mumbaikars come true and has also conducted trails runs recently. This issue covers L&Ts own temple of learning - the Management Development Centre at Lonavla. With more facilities added, the training centre has now become one of the best campuses even surpassing some of the best management institutes of the country. Adding the list of firsts, L&T has created a benchmark by commissioning Indias first ever substation for evacuating power at two voltage levels of 765 kV and 400 kV in the state sector for Uttar Pradesh Power Transmission Corporation Limited at Unnao. Hindalco envisaged the setting up of aluminium smelter cum power project at Mahan near Singrauli in Madhya Pradesh. The Mahan Aluminium Project includes a 359-ktpa Aluminium smelter and a 900MW captive thermal power plant. L&T is doing the smleter project and also the coal handling project for the captive power plant. The kaleidoscope section, as usual brings to you a plethora of corporate events, launches and happenings. Wish you a happy reading! - Editor
In this issue
Jan - Mar 2012 Volume - 35 Issue - 1
Mumbai Monorail Indias first monorail corridor
Lonavla - L&Ts 13 MDC Temple of Learning
25 765/400kV Substation @ Unnao 33

Hindalcos Aluminium smelter and Coal Handling Plant
Kaliedoscope
Inauguration . ....................... 47 New Orders .......................... 53 Events . ................................. 56 Corporate ............................. 59 Awards . ................................ 65
Editor
: V. S. Ramana
Editorial team : V. Ramesh Kumar | Gopi Kannan. S V. Eswar | Ashwin Chand | Mayura. K Photography Subha Anand | Shamala Nadendla : V. S. Natanavelu
Design & layout : Global Print Design, Chennai
Mumbai Monorail
Indias first monorail corridor
ECC CONCORD Jan - Mar 2012
he Mumbai Monorail project, currently under construction for the city of Mumbai, India is a pioneer project in more ways than one with innovative advances in engineering, construction and management, not just by Indian standards, but at an International level as well. Once completed, the Mumbai monorail is also slated to be the worlds second longest system next only to the 23.8 km long Osaka monorail in Japan. Although Mumbai monorail is the first large-scale monorail project in India, monorail technology has been used elsewhere in the world for over a century. However some of the structural design concepts and construction methodology adopted and implemented in Mumbai monorail can be considered the first in Indian construction history.
Indias first Monorail corridor, the Mumbai Monorail is the latest dream project that could well make common mans life better and easier. Construction of this prestigious project began in January 2009.
+ 8 side platform stations + 2 platform stations 3. Construction of depot building 100 m X 100 m 4. Construction of depot guideway Sequence of works
Scope of work
The work under this package consists of design and construction of Monorail system from Gadge Maharaj Chowk (Jacob circle) to Wadala (Approximately 10.64 km) and Wadala to Chembur via Mahul (approximately 8.9 km). The various scope of works involved in the project can be categorized into 4 distinct phases: 1. Phase # 1 8.9 km of viaduct + 6 Side Platform stations + 1 Central platform station 2. Phase # 2 10.64 km of viaduct
yy
Finalization of alignment based on the proposed road development plan Finalize the location of foundations as per alignment Trenching and Mapping of Utilities as per the foundation locations Applying for permission to execute the works from Traffic Police, BMC & other nodal bodies To obtain permissions & cut trees falling in the alignment. Removal of utilities, diversion of Utilities and Overhead cables
yy yy
yy
yy yy
Successful Monorail Trial Accomplished
Fact file
1. Indias first commercial monorail is between Jacob circle and Chembur station via Wadala. Wadala also serves as the maintenance depot for the system. 2. The first section of the Mumbai Monorail project between Jacob Circle and Wadala will be 10.6 km long. Passengers will be able to cover the distance in 25 minutes. This route of the monorail will have 10 stations. 3. Second section of the Mumbai Monorail between Wadala and Chembur will be 8.9 km. Passengers will be able to cover the distance in 19 minutes. The route will have 7 stations. In all, the distance of 19.54 km from Jacob Circle to Chembur will be covered in 44 minutes. 4. The monorail train will run at a speed of 32 km per hour and will be completely airconditioned. 5. There will be a total of 17 monorail stations, each at a height of 11 metres above the ground or road level. 6. Initially, a monorail will be available every 4.5 minutes. The waiting period proposed to be subsequently reduced to 3 minutes later. 7. Capacity per carriage or compartment of the monorail is 150 persons (30% seating and 70% standing with occupancy as 6 persons per sq. m). 8. Each monorail with 4 coaches will have a capacity to accommodate 600 passengers. Subsequently 2 cars can be added (the design of structures are based on the higher capacity) 9. Each monorail train will have the capacity to carry a passenger load of 8 - 10 buses. 10. The 19.54 km Mumbai monorail project is expected to carry nearly three lakh commuters who are currently taking buses, trains, taxis, auto rickshaws and private vehicles. 11. Mumbai Monorail should reduce 80,000 bus trips, 28,000 taxi and auto trips on a daily basis. Hopefully, 25,000 cars are expected to go off the citys congested roads. 12. Over 22 lakh people living within 2 km radius on either side of the track will be benefited by the Mumbai Monorail. yy Estimated ridership per day - 1.25 Lakh {upto 2016} and 3.00 lakh {upto 2031} Train Composition - 4 Cars Train Capacity (4 Cars) - 568 persons max. Design Speed - 80 kmph Schedule Speed - 32 kmph Operation Hours - 05:00 to 24:00 hrs No. of Stations - 17 Design Life - 120 years
yy yy yy yy yy yy yy
Client : Mumbai Metropolitan Region Development Authority Contractor : L&T Scomi JV Design for Main Guideway: PJSI SDN BHD, Malaysia Project management Berger Group Inc : Louis
View depicting the curve the guideway beams take while entering the station.
Eagle view of guideway and station
yy
Based on utility mapping, propose for the Pile foundations and design for the same if required Create an encumbrance free for taking up the operations Commence Piling Operations Subsequently, Pile cap, Pier, Pier cap Parallelly commence with the casting of guideway beams Post completion of Pier cap, transportation of guideway beams Erection of guideway beams Stitching of guideway beams Complete the Expansion Joints concreting and fixing the same. Handover the same to system provider
Station locations yy Finalization of alignment based on the proposed road development plan Finalize the location of foundations as per alignment Trenching and Mapping of Utilities as per the foundation locations
yy
After the completion of 3 central piers concourse level slab is casted. 1st stage prestressing is done Subsequently Columns, beams, Slabs, staircases of track floor level is casted. Z beams for escalator and Columns Beams Slabs staircase is casted for platform level thereafter. 2nd stage prestressing is done for the concourse slab, and the guideway beams are casted finally and handed over to the clients for finishing works
yy yy
yy yy yy yy yy
yy
yy
yy
Plant and Machinery

During peak period of construction L&T had deployed Piling rigs 200 t cranes Excavators / JCB Gantries 75 t Gantries 25 t : 15 nos : 10 nos : 10 nos : 6 nos : 4 nos
yy
yy yy yy yy
Design
The design for this project was under the scope of L&T SCOMI consortium. As the passenger comfort is defined by the guideway beams, rolling stock
providers will prefer to undertake the design when such integrated systems have to be developed. In the case of Monorail Project PJSI Malaysia is the structural designer. The station building design has been jointly done by L&T Ramboll for only the concourse level and Geodesic Bangalore for superstructure and architectural works. M/s Louis Berger, the Project Management Consultant (PMC) for this project was nominated by MMRDA.
Structure
The monorail guideway structure is unique in many ways since the structure also forms the running surface for the vehicle, unlike other rail or highway structures, which have additional surfacing, or track laid over the top. This fundamental constraint on the design criteria means that the beams have to be formed to suit the final alignment geometry, including both vertical and horizontal curves, gradients, transition curves and super elevation. The substructure consists of 1000mm diameter bored cast in place piles with cast in-situ Pile caps,
Completed view of Mysore Colony Station
Piers and Pier Caps. The design of the monorail structure is based on individually precast post tensioned beams that are erected and stitched together with in-situ concrete joints and continuity post-tensioning to form continuous frames of beams consisting of between three and five spans. Given that the alignment of the beams is so variable with multiple span combinations, each frame is unique.
Generally, spans are around 25m in length, however, due to various constraints such as road junctions, buried charted and uncharted utilities and drainage, as well as other structures such as stations and switches the spans vary anywhere between 16m to 28m.
Construction methodology
yy Shuttering scheme for casting guideway beams was an innovative design Usage of turnbuckles mounted on the walls to set the correct curvature, radius and fit in +/2mm tolerance was indeed a technology by itself Specialized schemes were devised to ensure smooth transportation of guideway beams. A separate floater assembly was designed to ensure that the bolster can carry the guideway beam of different curvature & different radii Erection of guideway beams on the supporting brackets and turnbuckles for alignment
yy
yy
yy
Finishing works under progress at station buildings
Rebar fixing at precast yard
of the same was specially designed for this project yy Launching of the guideway beams across obligatory spans Erection at critical locations where road width is a constraint is devised based on the actual conditions at the site The scheme which was envisaged is erection with the 200 t cranes (either crawler or Hydraulic). This primary scheme will be revisited and relooked at for critical locations
yy
yy
resulted in many of the activities getting centred on specialized casting, transportation and heavy lifting. The beams are precast in a purpose built factory near Wadala from where they are transported to the lifting location using multiaxle transport trailers. The lifting is typically done during nights using two telescopic mobile cranes and then placed by a sophisticated temporary works systems which will stabilize the beams and allow them to be adjusted later to the their final position prior to continuity works. A typical frame comprises of four precast beams. Each element needs to be erected in sequence with the whole structure supported on a complex system of temporary supports and hydraulic jacks, whilst in-situ concrete joints and post tensioning are completed. Since the
majority of the erection operations could only be undertaken with partial road closures, the lift planning formed an integral part of the traffic management planning. The working window allowed for road closure and subsequent erection operations began during midnight and finished at 5.30 a.m.
Precast Factory
The superstructure of elevated structure is of precast guideway beam. Each guideway beam measures a minimum 16m to maximum 26m in length. Weight of each guideway beam is approximately 85 t. The casting yard consists of: Rebar bay: Soffit adjustment on trolley, rebar tying, insert fixing and shifting of trolley from rebar bay to casting bay
Construction logistics and management

A significant proportion of the construction utilized prefabricated or precast concrete construction, which
8 ECC CONCORD Jan - Mar 2012
Casting bay: Activities such as alignment of side shutters, concreting, de-shuttering of sides and shifting of trolley from casting bay to curing bay are carried out in this bay Curing / stressing bay: Dimensional check, curing, stressing, shifting of beam to stacking yard and shifting of trolley to rebar bay. The rebar bay and casting bay is located in a covered shed to carry out beam production irrespective of climatic conditions. Mono strand jack is used for trolley movement from rebar bay to casting bay and further to the curing bay. RCC walls in casting bay help not only in supporting of side shutters but also ensure that with minor adjustment of turnbuckles, side shutters can be aligned to the required accuracy. This resulted in elimination of side shutter handling and in achieving higher productivity or improved cycle time.
Pre-Cast Yard
Lifting of curved and straight guideway beam

Challenge was to develop a universal lifting system for curved and straight
guideway beams of 26m length using two point lifting system. As the CG position of the beam varies due to curvature and length of the beam, the lifting point in the lifting frame needs to be adjusted to match the CG plane of the curved beam. An universal lifting frame with movable hook was conceptualised and engineered, eliminating the fabrication of numerous lifting frame for different beams.
A detailed calculation and engineering drawing was prepared for every curved beam indicating the position of lifting frame on the guideway beam and the setting position of movable hook in the frame for picking up the curved beam.
Transportation of curved guideway beam

With precast beams typically weighing 85t and upto 26 m in length, multiaxle hydraulic platform transport trailers were used. Sophisticated hydraulic suspension allows the trailer to raise and lower the trailer body by +/- 300mm which enables the transporter to negotiate difficult terrain. The linked hydraulic system even ensures load distribution to all wheels and the full control of the load stability. The trailer system is modular by nature and all axles can steer which permits the transporter to manoeuvre tight road junctions or a constrained site access. As the CG position of the beam varies due to curvature and length of the beam, the position of the
ECC CONCORD Jan - Mar 2012 9
Aerial view of Switch Deck works and Pier works at Depot Guideway
Depot building at the verge of completion
guideway beam on the trailer needs to be adjusted to match the CG plane of the curved beam. A detailed calculation and engineering drawing was prepared for every curved beam indicating the position of guideway beam on the trailer for transportation. Guideway beams also needed to be anchored to the trailer while negotiating sharp curves to prevent it from toppling. This was achieved by clamping the guideway beams to the bolster with stressed macalloy bars.
the planned date of erection, a detailed survey was undertaken to check all site details and constraints such as road width, footpath dimension, trees, utilities etc., so that detailed planning could be done in advance.
Many of the locations were extremely congested and hence the positioning of the transport trailer and crane were studied before implementation. Two numbers of 200 t capacity hydraulic cranes or crawler cranes or combination of 1 hydraulic crane &
Erection of guideway beams

Heavy lifting operations played a significant role in shaping the success of the monorail project. It was imperative to select the right type and capacity of crane for each and every lift. Prior to
Curved guideway beam erection
10
1 crawler crane positioned on either ends of the span picked up the beams from the trailers and erected it over the pier cap. The guideway beam is then temporarily anchored on to the pier cap until the stitch or gaps between the beams are concreted.
Challenges faced
Monorail structures are monolithic in nature, the core of the Monorail project lies in the accurate casting of guideway and erecting the same as per the alignment. These beams which are being cast in a dedicated precast yard were done with utmost precision and tolerance limits as stringent as +/- 2mm. The curvature of the beams varied from 47 m radius to infinity or straight beams. The shuttering scheme was conceived, designed and established entirely by joint coordination with the site team and IET. The team achieved this by using a bottom shutter which
Cross Over switch at 2A Series
could be adjusted to the various super elevation or curvatures and side shutters which can be bent to various curvatures. As the Right of Way (ROW) required for this type of transportation system is very less, this project
bypasses through narrow lanes and congested areas of the Mumbai metropolis. The added feature of the guideway beams which can negotiate horizontal, vertical, circular curves makes this project more challenging for transportation and construction activities.
Erection at creek-a feat during monsoon
11
Guideway beams from depot guideway entering depot building
The clearance of ROW was done in coordination with the customer. The process of applying for nodal bodies clearance and obtaining clearances from traffic department and more importantly creating awareness among the local public about the project was itself was a great task. Despite utmost planning, the presence of charted and unchartered underground utilities and overhead cables posed a major challenge during execution. Carrying out piling operations was crucial to ensure that there is no damage to any underground utilities. The construction of pile caps which embeds major utilities was was under continuous supervision from nodal agencies. Transportation of the guideway beams and Erection of the same
in certain congested localities was indeed a creditable effort. Most of the Operations right from marching of girder from the yard and positioning them on the pier cap very near to required geometry within a time frame of 5 hrs was done meticulously planning ensuring every aspect falls in the correct place for each beam is indeed a commendable effort. Specialized axles were designed and a lot of trails were done before the actual transportation. Construction of station buildings measuring 80 m in length and 18 m in width at highly congested areas with a clearance of hardly 10m from the adjacent houses, for managing heat Environment & addressing all the Concerns on daily basis is actually a Greater challenge. Tailor made shuttering system that could be arranged within the barricaded
width of 8 m was extensively used to achieve results. Logistics of manpower for the project was a perennial challenge. In a crowded city like Mumbai, the workmen colony had to be located 20 km away and the daily logistics was a major challenge. L&T established about 15 labour colonies spread across 20 km radius. The retention of labour during the period of heavy monsoon was a difficult task. Interface with all departments such as signalling, communication and rolling stock right from the initial piling operations was a crucial but challenging task for the smooth progress of the project. Arvind R. Nerurkar Project Manager M. Srinath Planning Manager
MDC Lonavla
L&Ts Temple of Learning

et amidst the idyllic locales of Lonavla, Larsen & Toubros Management Development Centre (MDC) is a state-of-theart, learning center that is spread across a sprawling 21 acre campus. Approachable both by road and rail from its nearest cites, Loanvla is about 90 km from Mumbai and 60 km from the city of Pune.
MDCs location was selected considering the isolated and hilly atmosphere, and the green environment which nurtures learning skills. Every morning, participants at MDC wake up to the chirping of birds and can watch the soft sunlight lifting off a blanket of fog to usher in another bright new day.
Learning centre
The learning centre complex is inspired by the definition of Sir Churchills words on contemporary architecture, We shape our buildings, thereafter they shape us. The learning centre is built to inspire, enthuse and promote higher values and to enhance the skills in an individual. The entire complex has been created without altering or damaging the existing topography, retaining the natural elements and ensuring minimum damage to the ecology of the place. The articulation of space in this centre is a well thought out response both in terms of aesthetics and natural geography, built encompassing the values of yesteryears incorporating the modernity of tomorrow.
Serene Lonavla
Lonavla is one of the most popular weekend getaways for Mumbaikars who wish to unwind from their week long hectic city activities. A small hill-top town with lush green vegetation, tranquil rivers and a cool climate, Lonavla, offers complete peace of mind to visitors. This is also the reason why many corporates choose this location as an ideal place to set their learning and development centers.
The design
The architectural team working on MDC was keen to blend the structures seamlessly into the greenery around the campus. The natural elements of waterfalls, rivulets, and flora were emphasized with fountains, landscaping and building masses. The architecture was such that it gives a feeling of space and enhances greenery at all locations of the campus.
A fully stacked library
14
Dinning in fine splendor
The design of the complex makes maximum use of utility space, thoughtfully allocating room for requirements without compromising on aesthetic values. In order to encourage an eco-friendly atmosphere, cars are parked away from the learning centre complex. The complex has been built prominently by locating it at a higher altitude as this structure is considered the most important building at the campus of MDC.
The halls are placed on either side of central entrance lobby with a modern kitchen placed on its rear end giving no interference to visitors. Separate access has been planned from dining hall to central open area
for any informal gathering and outdoor catering.
Drivers dormitory
Located near the proposed car parking to provide accessibility
Dinning block
Strategically located in close proximity to Learning Centre Complex and the residential quarters, the dinning block has been designed as a single level structure oriented to have a serene view of both the central open area and the pond. It is also oriented for maximum exposure to sunlight and breeze.
Classrooms with plush interiors
15
A GLIMPSE OF THE PAINT INGS
Breathing life into a green campus

Centre, Development Management L&Ts n engaged in established in 1997, has bee the thoughts sharpening the minds and focusing ing them great of many young technocrats mak future. Every the entrepreneurs and leaders of ieve happiness, being on this planet seeks to ach of knowledge is constantly engaged in the search ce. and is in deep pursuit of excellen reflect this very The foyers and galleries of MDC powerful and Searching Mind, through the art by the noted impressive paintings and works of is one amongst artist - Mr Mohan Kumar, who world, and is a UNESCOs 40 chosen artists of the of his works of recognized green activist. Over fifty a LEED rated art aptly embellish MDC Lonavla Green Building. ely a building A brick and mortar structure is mer into it. L&T wn until life in the form of art is blo munications Constructions Corporate Com lized and added (CCD) team had aptly conceptua idors, foyers befitting work of art along the corr vide the much and other vantage points to pro
the visitors an needed relief and also to provide nity. element of wonderment and sere udes a human The artists signature style incl terrain - amidst soul seen in the midst of a large river and snowlandscapes, mountains, jungle, silent search for clad mountains engaged in a flection. These knowledge and perhaps in self-re minds that dwell paintings are also reflective of the se at Larsen & and conquer business and enterpri erate. Toubro - Indias premier conglom had also made Apart from the paintings, CCD bring alive lush effective use of technology to the atrium in green vegetation on the walls of the staircase to the dining hall. As one ascends sents a picture the upper levels, the huge wall pre of tranquility of wilderness giving the visitor feel she is to such and a reminder of how close he/ Constructions natural treats at Lonavla. L&T conceptualized Corporate Communications team themes which and commissioned these inspiring the walls of the have been artistically reflected on learning halls at MDC Lonavla.
Computer centre in the learning centre
to drivers, the drivers dormitory has been created with levels according to the topography of the site along with facilities and amenities arranged around an open courtyard creating a lively space.
Entrance gateway
The entrance gateway was designed to project a world-class image of the company. An elliptical archway, extending into the limits of space and merging with vertical and horizontal
planes, projects the multidimensional facet of L&T. The two columns in the center extending into the space symbolically represent the enviable stature of L&T. The composition is balanced in both planes by adopting the same elliptical shape in plan and section. The gateway along with the security cabin is designed to have a complete control over the entry and exit of visitors into the campus. It is achieved by providing clear glass on both sides to enable a direct view to function efficiently and to restrict trespassers.
Scope of work
The broad scope of work for MDC Lonavla includes concept, design and construction of Management Development Center, The Temple of
View of discussion room
18
Learning a world class training facility spread over 21 acres of land with state-of-the-art infrastructure and facility with modern techniques for residential training programmes. The construction of MDC was done in three phases.
all rooms are air-conditioned and have been luxuriously furnished to provide a home away from home experience. The two residential blocks are connected with each other by an aesthetically designed bridge. To meet the water requirement a 2.5 lakh litre underground water storage tank with pump room and hydro pneumatic water supply system to all overhead water storage tanks on the individual structures has been provided. Apart from the main structures, the surroundings required external developmental works, roads, pathways and beautiful landscaping and water bodies to add to the natural elegance. The scope also included the creation of one additional learning hall with a capacity to accommodate 32 persons to be located on the
terrace of the existing learning centre with high class finishes.
Phase II
Phase two of MDC includes design and construction of learning centre, dining area, main entrance canopy and outdoor sports area apart from other support infrastructure (STP , WTP , WWTP) and landscaping works with Sprinkler & Irrigation System.
Phase I
The first phase of MDC Lonavla involves construction of residential blocks B and C with a built-up area of about 74280 sq.ft. This complex comprises of stilt floor, ground and first floor with a capacity of 64 rooms on a twin sharing basis. Though built on a twin sharing basis, every room offers complete privacy to each and every individual. The blocks also have eight group discussion rooms, four rooms for the caretakers apart from utility and service rooms. In order to enhance the comfort levels,
Learning Centre
The learning centre is a dedicated facility that offers topnotch classrooms, auditoriums, tele presence rooms and libraries. With a built-up area of 65510 sq.ft., the learning centre comprises of stilt floor, ground plus first floor. The centre has five class rooms of capacity 32 to 72, auditorium to seat 300, a 30 person capacity tele
View of learning centre reception
19
A fully equipped gymnasium
presence room apart from advanced video conference rooms, 22 nos syndicate rooms, library with audio visual study, reading and research facility, admin block, other utility and service rooms. The learning centre is marked with a grand
entrance lobby and an impressive atrium with a panoramic view. The entire learning centre is wellequipped with facilities such as Captive DG back-up, UPS, LAN, Telephone, WIFI , voice, data, PA
System, CCTV, fire alarm system, plasma screens, AV systems, video conferencing facility, HVAC, elevators, PHE, Solar water heater system, electrical lighting with dimmer system apart from Interior, furnishing and furniture.
Dining hall with modern kitchen

The dining hall has a built-up area of 22651 sq.ft comprising of ground and first floor with two separate dining areas to accommodate 128 persons each. There are two separate kitchens for cooking vegetarian and non-vegetarian dishes. The kitchen also has a cold room and other utility and service rooms at the ground floor. The first floor comprises of three multipurpose halls to accommodate 50 to 150 persons. The entire Dinning Block is well equipped with captive DG back-
25 x 15 m swimming pool
20
Description Excavation Backfilling Concrete - RCC M30 Concrete - PCC M10 Reinforcement Steel Structural Steel Brick Masonry / Block Masonry Internal & External Plaster Formwork Painting (Internal & External) Flooring, Tiling & stone work False Ceiling Waterproofing SS handrail Doors & Windows Electrical, AV, LAN, WIFI, Fire Alarm, DG, CCTV, ST, HT, Data, Voice, PA, Solar Light Plumbing, STP , WTP , WWTP , Solar Water Heater, Irrigation & Sprinkler Landscaping civil & Horticulture HVAC Interior Work Furniture & Furnishing up, LAN, Telephone, PA System, CCTV and Fire Alarm apart from the regular HVAC and PHE systems. To enhance the dining experience, furnishing and furniture of high quality have been used in the dining area along with dimmer system to adjust light intensities based on the occasion.
Unit cu.m cu.m cu.m cu.m t t cu.m sq.m sq.m sq.m sq.m sq.m sq.m Rm sq.m Lacs Lacs Lacs Lacs Lacs Lacs
PH I 25650 17100 3850 285 215 145 2150 32000 19850 38700 15465 370 6272 478 982 139 87 85 38 49 96
PH II 88600 64350 9275 1750 865 63 4375 53650 51050 56950 21870 8430 20682 564 3138 796 168 147 208 91 242
PH III 48275 38400 4365 455 385 115 3650 39750 26470 47260 19720 3656 8577 585 1765 356 146 72 132 73 174
Total 162525 119850 17490 2490 1465 323 10175 125400 97370 142910 57055 12456 35531 1627 5885 1291 401 304 378 213 512
On Load Tap Changer device (OLTC) yy yy Underground Diesel Storage Tank with Pump Room Roads, Pathways and Landscape, Water Body and Fountains covering a total area of 215000 sq.ft.
Apart from this, L&T also developed a 1.2 km Jogging track which was embellished with landscape horticulture.
Phase III
The scope for construction activities of L&Ts MDC included creation of a swimming pool, indoor sports cum recreation area, dormitory and renovation of old training centre and Gurukul equipped with Modern facility & technology at par with New Learning Center .
Main entrance canopy

The scope also includes construction of an imposing main entrance canopy with a security block and a provision for ATM facility. The plan included a separate drivers dormitory to accommodate 34 persons. Other facilities are: yy 1000 KVA Sub- Station - out door type Transformer with
Outdoor sports area

In order to provide guests with spectacular outdoor sporting infrastructure, many facilities were created at MDC, Lonavla. With a total built-up area covering 45550 sq.ft arenas such as international standard synthetic coated lawn tennis, basketball, volley ball court and Putting Green were created.
Swimming pool
A swimming pool conforming to international standards measuring 25 m x 15 m along with all utility
rooms was created for the guests. Apart from presenting itself for a refreshing swim, the pool side was barricaded with palm trees and lush green flowered creepers to create a relaxing ambience for pool side events during the evenings.
Dormitory
The scope in Phase III also included development of an existing structure as dormitory to accommodate 24 persons along with recreation areas. Apart from the above scope, there are other ongoing structures that are being developed by L&T at MDC, Lonavla. These include: yy A motor-able bridge over a nallah with a very unique design is poised to become a landmark structure at Lonavla measuring 45 m in length and 4.5 m in width. This bridge will be used to ferry participants from the old premises to the new premises by battery operated vehicles with a view to adhering to the green concept. Out Bound Training Facility - In order to cater to the demands of learning infrastructure from other corporates, L&T is creating a 7000 sq.ft out bound training facility at MDC.
yy
Residential Blocks D (60 Capacity-Single Occupancy) & E (64 Capacity-Twin Occupancy) with built up area of 80000 sq.ft A medical centre with a built up area of 3500 sq.ft
yy
Indoor sports recreation facility
cum
Significant milestones
L&Ts Management Development Centre The Temple of Learning is one of the most prestigious and challenging projects. In the pursuit of delivering an International class T&D centre, L&T has achieved many milestones including the first and most important, an architecture that would blend with the immaculate environs of Lonavla. yy Created an additional class room called Golden Sun Rise of 32 capacity including all interior, services, furnishing and furniture within a record time of 34 days
The Indoor sports cum recreation facility, housed in 9750 sq.ft ground and first floor, comprises games such as snooker, table tennis, carom, chess, playing cards, fuss ball and a post-modern gymnasium with all up-to-date equipment in the ground floor. The first floor presents a calm and relaxed setting with its magnificent dcor offering itself excellently to perform activities such as yoga and meditation. The hall is also designed in such a manner as to offer itself for multipurpose function and social events.
yy
Synthetic coated outdoor sports area
22
View of the passage with paintings mounted on the walls
Building a Landmark
L&T Constructions Buildings & Factories IC have done a stellar job at MDC Lonavala. L&T ites who visit the centre after a long interval are amazed at the facilities built. Not just the sheer size, but the layout, design, quality of the buildings, the finishing and the total impact. Professors from leading academic institutes, both domestic and overseas say that L&T has in the true spirit of an Engineering and Construction Company created a landmark which will be a benchmark globally for Learning & Development institutes. In 2007 when we were planning to expand MDC, what was central in our minds was that in catering to the ever growing demand for booking MDC for training, we should not just build a run-of-the-mill facility. L&T is Indias leading Engineering and Construction Company, and, our learning centre must be world-class, a model that other companies would want to emulate. Further, knowing that learning ambience plays a vital role in ensuring the true success of any L&D initiative, we decided that the layout would be such as to create the feeling of space, and that we would landscape the surroundings in a manner that greenery would be in focus from all quarters, so as to harness the creative energies of participants. The buildings were designed to cater to groups from a batch of 20 to 300 participants. We hoped that all future Leadership Development initiatives and Top Management gatherings for workouts etc., would happen at MDC. Hence we designed the Campus to accommodate a little over three hundred residential participants who would have sufficient learning rooms and dining halls to ensure all could dine at the same time. Games and recreation facilities that would be available only in leading star hotels and clubs were also made available. Our plan may have seemed to be a dream to many, but the MDC project team has created, designed, built and delivered a facility that actually has gone far beyond what we planned, imagined and dreamt of. Neville LOBO Vice President, Corporate Human Resources Director - Management Development Centre
23
Atrium view of learning centre
yy
The gigantic diamond shape atrium was internally clad with Aluminium Composite Panel within 48 hours Construction and commissioning of an international standard swimming pool along with its utilities and beautification completed in a record time of 110 days Being an inter-unit job L&T was involved in the job both as a contractor as well as the owner, there by taking dual responsibility
yy
yy
comforts of the workmen. The terrain also made procurement of material and transporting it a challenge. From the weather point of view, the monsoon was also quite rigorous stalling the project progress during the season. Therefore, the structural work was completed before the monsoon began and all the finishing activities were planned during the monsoon in order to speed up the progress.
scheme, periodical meetings, daily PEP talks, poster display and tool box meetings among staff and workmen.
Quality
In line with maintaining the high standards set by L&T, the job quality was maintained at high levels right from Phase I. L&Ts in-house quality lab, checked and certified the quality of each and every material that was being procured. The project team ensured that the construction was as per the specification, methodology and checklist to avoid discrepancy in the final product. A high level of emphasis was laid on creating mock-up for all key activities before executing the original scope. A. K. Muhury Project Manager
Safety
Safety, being the integral culture at L&T was one of the top priorities at MDC, which has set an example by achieving more than 05 million lost time injury free man hours. This was possible due to the ownership spirit of the entire team that completely abided by the existing EHS culture. Implementation of PPEs was done through motivation
Challenges
Lonavla being a hill station and a tourist attraction, mobilization of labour was a herculean task. L&T had provided basic necessities and good accommodation to cater to the
24
765/400kV Substation @ Unnao
25
Birds eye view of ICT area
n line with setting benchmarks in the engineering and construction industry, L&T has been involved in the setting up of the countrys first ever substation for evacuating power at two voltage levels of 765 kV and 400 kV in the state sector. Uttar Pradesh Power Transmission Corporation Limited (UPPTCL) sought implementation of the construction of 765kV transmission system between ANPARA generating station and Unnao Sub-station. Crompton Greaves Limited (CGL) was awarded the job as the main bidder which was subcontracted to L&T. L&T was entrusted with complete engineering, certain supplies and complete installation of 765kV / 400kV transmission substation at Unnao in the state of Uttar Pradesh.
Scope of work
The scope of work included design, procurement and installation, testing and commissioning of 765kV switchyard and 400kV bay extension to be completed within a period of 18 months. The project was awarded on 29th of January 2010, and after forest clearance, the land was handed over by the client on 7th May 2010. The substation has the unique feature for evacuating power at two voltage levels, such as, 765kV and 400kV using 2x1000 MVA interconnecting transformers. The existing 765kV transmission line, presently operating at 400kV, has been diverted and reconnected to the new 765kV substations at Unnao and at
Anpara-C. A second 765kV circuit will interconnect Unnao to Anpara-D. 400kV supply from transformer downstream shall interconnect to the existing 400kV substation. Major scope of work civil Construction of three control buildings, two store shed buildings, DG and fire fighting buildings, and mulsifier tank three oil collection pits, three underground and one overhead tank, 4177 m of concrete road, 5282 m cable trench, 494 equipment foundations, 36 tower foundation, 135000 sq.m of yard development, 32121 cu.m stone fill, 1703 m switchyard fencing and 8.5 km of drain for storm water disposal.
Concreting Reinforcement steel Structural steel Formwork
: 21391 cu.m : 1016 t : 329 t : 42744 sq.m
plant communication, CCTV & Access Control Equipment (ACE), substation automation system and complete testing and commissioning.
Major scope of work electrical Installation of 7 nos. of 1ph 333.3MVA 765kV transformer, 7 nos. of 110 MVAR line reactor, 4 nos. of 63 MVAR bus reactor, 850 t of tower and equipment structure (36 nos. of tower and 433 nos. of lattice and pipe structure for equipment), 494 nos. of substation equipment, 220 km power (including 66kV voltage grade) and control cable, 30 km of stringing, 54 km of main earth mat, 2 km of aluminium tubing (6, 4 & 3 tubular bus), control relay panels, associated LT panel, UPS and battery charger (In all three control buildings), fibre optic communication system and telecommunication equipment,
Design complexity
The design team of the client side were keen to take additional efforts to standardize and establish systems, since the 765kV Unnao was the first of its kind substation. The geographical distance of consultant M/s SNC Lavalin (core team in Canada) coupled with a very small team of two persons (each from electrical and civil design) from UPPTCL responsible for inspection as well as design approvals was a challenge. Most of the equipment from various vendors were designed and put into operation for the first time at 765kV voltage level, hence a lot of interfacing and coordination was
needed. Equipment such as clamps and connectors from Klemmen, Hardware from ITTPL, Transformers from CGL, Isolators from S&S, Circuit breaker from CGL, TP Y class of CTs from Koncar etc. . Owing to this, the client was doubly conscious of quality and for performance related issues thereby making approvals a tedious process. Since a majority of equipment had to be supplied by the client all inputs were required for finalizing equipment foundations, structures, cabling, earthing and protection schemes. In-ordinate delays in providing these inputs put considerable pressure on L&Ts design team and it also had a cascading effect on the execution team. Regarding cable trench design, client insisted that all equipment drawings was to be frozen first and also restricted the maximum size of cable to 10 core
765 kV HV AIS Equipment
27
Final lift of 14 m High fire-wall
resulting in substantial delays in approval of critical cable trench execution activities which needed considerable gestation period for completion. Other unexpected issues included introduction of swing calculation for conductors (not a standard practice in switchyard), revoking of approved sag tension calculation, clients insistence on un-cracked section for foundation design, etc.
execution for entire transformer, line and bus reactors bays (8 nos. of 765kV Bays and 2 nos. of 400kV bays) leading to massive engineering, execution and commissioning works that had to be completed in a very short time. Delays from client side on areas such as approval of soil investigation, forest clearance and location for dumping surplus earth further increased the pressure on timely completion. Unnao also faced unprecedented rainfall during the execution phase which completely inundated the low lying areas of switchyard, thereby halting the work for almost a months time. Massive efforts of digging trenches through the entire switchyard area and dewatering helped resume work.
L&T sought and got the approval for design mix resulting in savings in cement, however, this also meant that all concreting works had to be carried out using mini batching plants where the mix of raw materials can be controlled. This mandated mobilization of contractors with such equipment at site. Client provided a two day shutdown for erection of 3 bays of 400kV area including removal and replacement of existing conductors. A detailed Work Breakdown Structure was made and adequate resources were mobilized to complete the challenge. L&T identified the requirement of online NAS (National Aerospace Standards) filter and online NAS counter which came as a new
Challenges faced
Unnao was the first project in the country to have come up in the state sector with stringent deadlines for completion in 18 months as against a normal 24 - 28 month schedule for similar such projects. However, unlike other projects, L&T had to do simultaneous engineering and
28
requirement for oil filtration in 765kV Transformers and Reactors. The project team identified able associates to carry out the same for the first time in India. To support the stringent requirement of TBEA regarding total gas content special syringes were used for sending samples to the lab. Since execution of 765kV substation was a first of its kind experience to L&T, the existing safety methods were reviewed and found inadequate. L&T implemented several new safety techniques which emerged out of several brain storming sessions resulting in a Zero Accident accomplishment and achieving 3 million lost time injury free manhours! In order to avoid the cumbersome, expensive and painstaking process of sending frequent samples to lab, L&T set up a quality lab at site which was acknowledged by the client due to apparent advantages. The controller for controlled switching in the Circuit Breakers (which was earlier situated in field) was decided to be shifted to control room. This resulted in
Night view of charged transformer with outdoor Illumination
overhauling of cable schedule and termination details and called for additional panels to fit in these controllers. Further, since DC voltage was pegged by client at 110 V (as against a standard 230 V) it was observed during commissioning that breakers were not tripping satisfactorily due to high voltage drop. A shutdown programme for cable laying, termination and breaker replacement was made and completed ahead of client expectation leading to minimal delays.
Milestone achievement
Since the land area was low lying, the clients decision on raising the level created an inordinate delay. This delay put tremendous pressure on execution team as the tower drawings were on hold. Similarly issues like buoyant effect due to submergence and clients insistence on designing the foundation as un-cracked section also put the tower work on hold. There was a cumulative delay of two months due to these delays. However, with fast tracking and parallel construction activities these delays were mitigated and speedier processing at the subsequent lattice structure erection works which was on critical path ensured faster completion. There was considerable delay in approval of foundation for transformer and reactors, at the same time, there was pressure to have the structure ready by the time the equipment were scheduled for arrival. With barely fifty days to complete nine foundations (3 for transformers, 3 for line reactors and 3 for bus reactors) L&T team planned a detailed and micro
Staging for Slab Casting of Control Building
29
Project site inundated during the monsoons
level sequence and engaged three agencies simultaneously to achieve the milestone. In a similar situation, the control building too, was scheduled to be completed before the arrival of interface control, relay and switch gear panel. Design and approval of cable philosophy and trench sizing delayed the construction process substantially. With detailed planning and close monitoring of respective work packages the assignment was completed in time after working in multiple shifts. Another important milestone to achieve was the completion of 495 numbers of equipment foundations, 5.2 km outdoor cable trench of various sections and simultaneous construction of internal roads and drainage systems. All these activity
fronts were opened simultaneously which made the work site cramped for space. Addition of resources like men, material and machinery to carry out the work round the clock eased the situation considerably. The project also faced an early monsoon with record rainfall leading to flood like situation. With no natural access for selfdewatering, L&T designed and made temporary drains and sump pits along with dewatering pumps to drain the water out of the catchment area. This was very crucial as L&T could continue critical activities like outdoor cable trench, support installation, cable laying, equipment erection, installation of entire fire fighting system (Fire hydrant, pump House, HVW Spray for transformer & reactor and fire alarm system) in the monsoon period itself which
was later found to be an effort that made all the difference for an ontime performance. As the client has a contract with LANCO incorporating reimbursement for losses due to deemed generation there was considerable pressure on project completion and commissioning. However, since the existing line was used for power evacuation at 400 kV, the client were reluctant to provide 765 kV supply for testing and commissioning. L&T project team readied the switchyard bay-wise which opened an opportunity for parallel testing and commissioning so that mechanical completion was achieved by September 2011. These activities were divided into four modules due to which L&T could back charge 400 kV equipment and associated
line on 4th of November 2011 and subsequently commissioned successfully, the countrys first 765 kV transmission substation on 5th of December 2011.
L&T had identified in the very beginning itself that the only way to complete the project in the scheduled time frame despite all odds was to implement complete mechanization of both Civil and Electrical activities. The scope of cable trench was 5282 m and the period of execution was only 90 days. Since the target achievement per day was high, aluminium formwork method to execute cable trench work was implemented and executed to a great success. There were 14 firewalls which had to be completed before transformer and reactor erection since there were little clearances available between firewall and radiators.
Night view of charged transformer with outdoor Illumination
Through indigenous efforts, L&T was able to design a suitable formwork to complete the firewall in a short duration of 12 days. For completion of footpath, 3.5 lakh interlocking tiles were required. L&T planned and initiated onsite fabrication of the same to ensure timely availability and superior quality. Understanding the importance of design approvals and the limitation
of client, a localised setup of design team helped minimise delays and the drawings were made available for the execution team on time for action. L&T identified early-on that fire-fighting activities were running on critical path, therefore imported thread cutting machines were deployed and blanket waiver was arranged from client for material inspection to ensure that the work was completed in totality in a record time of 3 months even during peak monsoon period.
Shuttering for store shed building
31
View of control building with wave trap of incoming line
To facilitate execution, various features were built-in during the design stage itself, such as replacement of massive trapezoidal drains with hume pipes, shaping over-head water tank as square which saved massive construction time while reducing costs.
Plant and Machinery

Quality lab equipped with testing equipment / apparatus and Concrete cube testing Machine Welding Rectifier / Generator Digital Theodolite Tractor with trolley Hydra Crane 125 kV DG : 21 nos : 1 no : 2 nos : 2 nos : 2 nos : 3 nos
was not only able to deliver these critical equipment in time but also at a reasonable cost as well. To avoid permit issues and long lead periods, L&T developed local vendors who could supply smaller items in a shorter period and at a lesser cost.
Vendor sourcing and supply chain management

Realising the importance of timely availability of major client supplied equipment L&T maintained seamless interface with clients and other vendors on a regular basis. For instance, the 765 kV transformer and capacitive voltage transformer was a critical component of supply. Most organisations manufacturing 765kV transformers in India had
Auto Level instruments : 2 nos
Resources
During peak period the project employed around 20 staff and 900 workmen
Awards
Received British Safety Council International Safety Awards 2012 in Distinction grade Ramchandra Yadav Project Manager Mr Y.S. Chauhan Project Co-ordinator
a high sales backlog buoyed by demand and hence were unable to deliver within the time frame and the prices were also very high. Considering this, L&T introduced an overseas vendor named Koncar (Croatia) who
Aluminium smelter and captive thermal power plant for Hindalco
33
indalco, the flagship company of the Aditya Birla Group is the worlds largest aluminium rolling company and one of the biggest producers of primary aluminium in Asia. Hindalco envisaged the setting up of aluminium smelter cum power project at Mahan near Singrauli in Madhya Pradesh. The Mahan Aluminium Project includes a 359-ktpa Aluminium smelter and a 900-MW captive thermal power plant. L&T is also doing the Coal Handling Package in the captive thermal plant, the details of which is covered in a separate section at the end of this article. One of the most crucial activities during the execution of 359 ktpa Aluminium smelter was the construction of two Pot Rooms; each measuring 1.2 km consisting
of 90 bays. The pot rooms required 180 columns measuring to a height of 7 m. The 90 bays in the Pot rooms were divided into
Major Quantities
Excavation : 3.6 lakh cu.m Piling (500mm dia.) : 4800 no Reinforcement : 16000 t Shuttering : 2.4 lakh cu.m Concreting : 1.40 lakh cu.m Precast elements : 45000 nos Structural : 20000 t Static Roof ventilator : 2.4 km Sheeting : 1.6 lakh sq.m
Since the tolerance limits for the civil structures were a stringent +0 to 5 mm, the construction proved to be very crucial and required constant monitoring from quality point of view. The erection of precast elements weighing from 12 to 28 t was one of the most difficult tasks as a 150t crane was used among confined spaces to erect these elements. Client: HINDALCO INDUSTRIES LIMITED (A Group of Aditya Birla) Consultant: Engineer India Limited. Process Consultant: Pechiney (AP) Contract Start November 2009 Date: Alumina 17th
Period of Contract: 25 Months Expected Completion Date: 30th November 2012 The scope of work includes civil and structural works in:
two parts of 45 each having a central passage.
Annexe building
34
yy yy yy
Pot Room A & Pot Room B ( each measuring 1.2 km) Conversion substation Annex buildings (cathode sealing shop, lining & delining shop, pot tending assembly shop & pot tending maintenance shop) Substations (East and West substations, reduction substations) Control room buildings Coke silos Bath recycling system Precast casting and erection
View of Cooling Tower 1
yy
yy yy yy yy
Manpower period
Staff Workmen
at
: 117 : 7000
peak
Among one of the first-of-itskind initiatives in the country, was the implementation of static roof ventilation systems in Pot Rooms. The wings of the ventilation systems were specially designed in such a manner that most of the
waste gases would be effectively released but not even a single droplet of water would enter the pot room from outside. This ventilation system was erected at a height of 16 m was is highly appreciated by Hindalco. In order to maintain the electric conductivity throughout the pots, all reinforcement of smelter packages were tied using welding process and not by the conventional binding
bars. This is a crucial requirement as the plant process will not happen if the conductivity is not uniform. The quality of welding is ensured by a process consultant representative and an electrical engineer was specially deputed for ensuring the electrical conductivity. Another important point to ensure is that a one lakh ohm resistivity is required for ensuring proper insulation of the Pot Structure with other structures. Through appropriate planning and perfect execution, L&T had completed all activities required for the commissioning of stageI well before the scheduled time to the utmost satisfaction of the client.
Challenges faced
Due to remote location of the project site and the associated geographical limitations, the availability of material was a big constraint. With the nearest open market being located 250 km away, procurement of material was a big challenge. In order to mitigate this challenge, the project team went with proper planning and
Work in progress at the Pot Rooms
View of Roof ventilator in Pot Rooms
scheduling from the very beginning of the project and also developed local vendors for ensuring timely receipt of material at site. As part of the corporate social responsibility and a commitment towards the society, L&T had provided employment to the project affected people who were displaced due to the acquisition of land by the client. Since most of these people were unskilled, they had to be trained extensively to employ them suitably for various construction activities. The project site also witnessed heavy monsoons during the months of July and August 2010. The heavy rains brought the project activities to a complete stand still. The project site was completely inundated with an
entire boom placer completely submerged underwater. Further, material such as formwork, tools and tackles had got washed away and the whole project site turned into a flood like situation.
Pot Super Works (PSS)
Structure
The scope comprises of fabrication and erection of 362 Pot Super Structures, two handling beams. The highlight of the project is that AP 36 technology was used for the first time in India and Aluminium work for positive riser was carried out for the first time by L&T.
The fabrication yard of pot super structure covers an area of 30,000 sq.m that comprises of 36 workstations (including16 workstations for positive riser), Intellectual Property office, yellow block, etc. All the structures had to get validated from Aluminium Pechiney (AP). The fabrication of PSS is a very critical job as there are a total of 66 types of material used. Every single PSS consists of 38 sub-assemblies made from a whopping 5152 components. Of these components, 738 are steel components, 1274 are equipment components and 3140 are aluminium components. The welding length of one PSS is 726m and for Positive Riser it is 324 m which requires aluminium welding. The client / AP consultant checks 2979 dimensions out of which 1158 are in PSS and 1821
Major Quantities
Fabrication : Erection 7783 t : 11946 t
are in Positive Riser. The project team faced some quality related issues such as porosity in welding and roughness during machining of aluminium bar. L&Ts quality engineers worked fervently on the porosity issue and resolved it by using a mixture of Helium and Argon gas (He-15%+Ar85%) for aluminium welding instead of the usual Argon gas. This was done after a lot of research and conducting various tests.
Challenges
Getting IP Validated Company for the fabrication of IP Product was a challenging task. The task of maintaining IP system as per approved Intellectual Property manual as desired by Aluminium Pechiney (Technology Supplier) was also difficult. For instance, mobile phones with camera are not allowed in the IP premises and only authorised employee can enter the IP protected workshop, therefore employees should sign the confidentiality agreement, etc. All IP drawing / confidential document were to be stored only in the yellow block at the
Compressor Room
designated IP protected area and all the printing of IP drawings were to be done only in yellow paper (for traceability of confidential document). All Jigs and Fixture were developed by L&T after application of engineering method by site engineers at the project site itself. Aluminium machining and Aluminium welding was very critical and a lot of research was carried out to finalize the desired welding quality and purity of argon gas.
35 TPH Carbon Recycling Shop

The scope of works include detail design, engineering, procurement of equipment and bought-out components, fabrication, assembly, inspection, testing, painting, packing and supply, erection, testing and commissioning and performance guarantee run test at site of 35 TPH Carbon Recycling System for Mahan Aluminium Plant. The consultants for this were Engineers India Limited.
Major Quantities
Structural fabrication and erection : 700 t Equipment supply, erection and commissioning : 550 t Cable tray Cable laying Sheeting : 4500m : 60000 m : 1300 sq. m
Carbon recycling is basically a reusable carbon conveying, crushing and storage system. The
Work in progress at the Alumina Silo
37
Crusher House of Carbon recycling
process starts from Apron conveyor of 104 TPH capacity. The rejected rodded anodes and spent anodes will be initially stripped out in the butt-stripping machine of Anode Rodding Shop (scope of client), and will be fed (maximum dimension of 800x250x650 mm) to L&Ts Apron Conveyor through chutes. Scrap paste from various areas will be fed to the hopper by pay loader (not under L&Ts scope). The carbon from hopper will be drawn by vibrating feeder of 25 TPH, which will feed the apron conveyor. The rejected green anodes (1560x655x665) from Green Anode Plant (scope of client) and rejected baked anode (1550x650x660) from Anode baking furnace (scope of client) will be placed on Apron conveyor by an electromechanical Jib Crane (L&Ts scope). The first feeding point on apron conveyor shall be
the scrap paste feeding from the hopper and then the full anode feeding by the jib crane. The apron conveyor discharges the carbon to Outotecs 35 TPH Single Toggle Jaw Crusher. The crusher reduces the grain size to 0-300 mm. The Jaw crusher throughput shall be received by an inclined belt conveyor, which discharges materials into a surge hopper, placed above L&T Kansbahals secondary roll crusher. The roll crusher shall be fed by a vibrating feeder fitted below the surge hopper. The roll crusher further reduces the grain size to 0-80 mm. Roll crusher output shall be collected by an inclined belt conveyor for onwards storage at Green or Baked Silo. L&T has introduced reversible shuttle conveyor on the top of silo for four feeding zones. This will help reduce the dead zones of Silo.
Each belt conveyor carries carbon through two isolated magnetic separators. The storage capacity of baked and green silo is 1600 t and 400 t respectively. Apart from this scope, L&T is also providing Vacuum Floor Cleaning System and Bag Filters for dust prevention in the shop.
Special Equipment
Apron Conveyor: L&T Kansbahal works has designed and manufactured Indias longest (76.76 m) VFD operated apron conveyor in non-ferrous sector with 104 TPH rated capacity for Mahan Carbon Recycling Shop. Jaw Crusher: Outotec has designed and manufactured 35 TPH Single Toggle Jaw Crusher with a deadweight of 110 t. The L&T Mahan project team erected the jaw crusher on a slab with a height of 4.5 meters using a 150 t capacity crane.
38
Alumina Silo
The construction of 21000 t capacity alumina silo measuring 43 m in height with 34 m in diameter was a very demanding job. The task of erecting structural roof weighing 335 t over both the alumina silos
Major Quantities
Excavation : 56800 cu.m Reinforcement : 4800 t Slip Form : 16000 sq.m Concreting : 36263 cu.m Structural : 2100 t Pile : 460 nos (800 dia) & 621 nos (500 dia) and pouring concrete slab over the structural roofs was one of the toughest challenges. Both silos were executed in tandem in order to meet the clients schedule and to complete the job within the stipulated time period. One of the major highlights of silo was that it was constructed in 3 steps. The scope also included the construction of compressor house, blower room
Silo structural roof erection Using Strand Jack system
and screen house apart from a coke unloading shed.
Execution started with casting of 460 piles - 230 piles for each silo. Firstly a raft comprising major concrete quantity of 2500 cu.m was cast after completion of the piles. After pouring the raft, a wall of 8 m height was made. Over the wall a1100 cu.m slab was again cast. After casting the
slab, slip formwork commenced. Slip formwork was completed in 35 days at an average rate of 1.2 m achieved per day.
Erection of Alumina Silo Roof

Strand Jack system was used for erecting the 330 t structural roof of alumina silo. For the erection, a 110 t temporary structure was fabricated which was designed to be used again for executing similar types of work. 4 strand jacks, each having
Major quantities for Alumina silo

Excavation : 44300 cu.m Piles : 460 nos Concrete : 22500 cu.m Reinforcement : 3551 t Structural Fabrication : 760 t Structural Erection : 760 t 180 t erection capacities were used. Strands of 18 mm diameter were used for erection and 450 mm lift per stroke was achieved per lift. By
View of Coke unloading platform
View of plant
using strand jack the structure was successfully erected at 42.3 m height. For executing the work an 80 t crane and concrete pump was extensively used. Due to proper planning and
Major Scope
Excavation Concrete : 28080 cu.m : 4500 cu.m
Reinforcement : 675 t Structural Fabrication & Erection : 1400 t
Compressor House
Excavation Concrete Reinforcement : 4800 cu.m : 1207 cu.m : 105 t
Birds eye view of Pot rooms
execution, the structural roof was successfully erected within a short period of 5 hours.
Blower Room
Excavation Concrete : 4500 cu.m : 723 cu.m
Coke Unloading Shed

A coke unloading shed measuring 720 m in length is under execution for unloading the refined coke. Major scope of work for L&T is civil
foundation, structural fabrication and erection work for coke unloading shed. The scope requires the construction of 110 bays of 6 m length. J. Suresh Project Manager S.M. Parab Planning Manager
40
1600 tph Coal Handling Plant at Mahan

Located in the power hub of India, Singrauli, the 6x150 MW Mahan Captive Power Plant will have access to the Mahan coal block (off the main basin in the Singrauli coal fields) through a joint venture with Essar Power. A 900 MW Captive Power Plant is the source of power for the 359 KTPA Aluminium Smelter Plant of Mahan Aluminium Project Hindalco Industries Limited has awarded the Coal Handling Plant Project to L&T Constructions Bulk Materials Handling Business Unit on a turnkey basis through stiff competitive bidding with a scheduled completion period of 20 months.
Major Quantities
Excavation of hard rock using blasting : 315000 cu.m Excavation in ordinary soil Concreting Formwork : 135000 cu.m : 62000 cu.m : 195000 sq.m
feeding system consisting of Emergency Reclaim Hopper, Wagon Tippler and Track Hopper. The scope of work includes design and engineering, supply, civil and structural work, erection and commissioning of Coal Handling Plant for 6x150 MW captive Power Plant at Bargwan District of Singrauli in the state of Madhya Pradesh. The scope also includes construction of crusher house, transfer points, MCC buildings, pump house, office building, maintenance workshop including other auxiliary structures such as in-motion weighbridge (on railway track), road weighbridge and coal settling pond. Apart from the above scope, utility systems for pollution control
Reinforcement : 6700 t Structural fabrication & erection : 6300 t Pre-coated sheeting : 42500 sq.m Plant Road Drains Utility Piping : 4.6 km : 13.50 km : 68400 in-m
Scope of work
The project is a 1600 TPH coal handling plant with 3 way coal
Conveyor 8 A/B feeding to Crusher House
41
Highlights
Name Of Equipment / Structure Stacker Reclaimer (Reversible Type) Wagon Tippler Paddle Feeder Crusher Grizzly Feeder Travelling Tripper Conveying System Track Hopper Complex Wagon Tippler Complex Emergency Reclaim Hopper Complex Settling Pond Complex Buildings & Transfer Points (a) MCC Buildings (b) U/G RCC Tunnels (c) Office Building (d) Pump House (e) Compressor House (f) Maintenance Workshop (g) Pent House (h) Transfer Points 3 nos 3 nos. 1 no 1 no 1 no 1 no 3 nos 5 nos 440 m Qty. 2 nos. 2 nos. 4 nos 4 nos. 4 nos. 6 nos. 8.2 km 1 no. 2 nos 2 nos 1 no. 8 x 60 cu.m 1600 TPH, Holding Cap. 4500 t 1600 TPH, 20 Tips Per Hour each 1000 TPH 4 x 1000 TPH Capacity
Conveyor 5A/B Drive in TP-4
42
Conveyor 8 A/B
such as dust suppression system, dust extraction system, ventilation system, compressed air, airconditioning system, service and drinking water system are also part of the scope of work for L&T. The Mahan CHP is a fully PLC operated coal handling plant with CCTV facility and Public Addressing system.
rake consisting of special bottom discharged wagons, unload the coal into the Track Hopper of 280 m length. Two Wagon Tippler complexes are situated adjacent to the Track Hopper for unloading the conventional wagons. Uncrushed Coal from Track Hopper
and Wagon Tippler is fed to Crusher House through Conveyor 1A/B & 2A/B and crushed coal from Crusher House is fed to Bunker unit of CPP. Coal from crusher, if found excess, is stacked in Coal Stock piles with the help of Stacker Reclaimer.
Coal feeding
Three Way Feeding of coal is designed for Mahan Coal Handling Plant i.e. from Wagon Tippler, Track Hopper and Emergency Reclaim Hopper. Coal Flow Path starts from (-) 22 m EL. to Bunker transfer point (+) 57 m. EL. The bulk size handled is between -120 mm to 20 mm. Coal transportation is planned through railway track laid from mines to the power plant. The coal
Coal Stock Yard with Yard Conveyor 6A
43
Stacker Reclaimer-I Ready for operation
In addition to railway line, coal is also transported to Emergency Reclaim Hopper by road using dumpers. Un-crushed coal from reclaim hopper stock yard is fed
to hopper using bulldozers. Coal from the emergency reclaim hopper reaches the crusher via. underground tunnel conveyor 7A/B, TP-5 and conveyor 8A/B.
Stacker Reclaimer
The Mahan Coal Handling Plant has two reversible stacker reclaimer. The yard conveyor 6A & 6B operates in conjunction with the stacker
Stacker Reclaimer-II
44
reclaimers. The yard conveyor delivers coal to stacker reclaimer, which is then stacked into stock piles with total holding capacity of 4.5 lakh cu.m. The stock yard coal is subsequently reclaimed by bucket wheel, boom conveyor and then fed to bunker through conveying system and travelling tripper. Bucket wheel drive and boom luff system is hydraulically operated. All other drives are of electro-mechanical type. The system is designed in such a way that it can be operated in both remote and manual mode. Since it is a PLC operated machine, it can be operated remotely from the control room.
Crusher & Crusher Drive on Floating Deck Slab
Resources
Plant and Machinery 150 t Crawler Crane : 1 no. 75 t Crawler Crane : 3 nos.
40 t rough terrain Hydraulic Tyre Mounted crane : 1 no. 14 t Pick & Carry Hydra : 5 nos. 40 x 40 Trailers : 4 nos. Batching Plant 30 cu.m./hr. : 1 no. Concrete Placer boom 30 cu.m./hr : 1 no.
Concrete Pump 30 cu.m/hr. : 1 no. Transit Mixers 6 cu.m. : 3 nos. Excavators cum Rock Breaker - PC 200, PC 300, : 1 no. each JCB 3DX : 1 no. Wheel Loader : 1 no. AMW Dumpers : 6 nos. Staff and workmen During the peak period the Mahan coal handling project had about 52 staff and close to 1820 workmen.
Challenges
Hard rock The Mahan Coal Handling Project site encountered massive hard rock which was not anticipated during the early stages of the project. Being a green field project, the people living in the area adjoining the plant had to be mass evacuated for carrying out the blasting operations. Controlled blasting operations in hard rock areas were subsequently carried out and approximately 3,15,000 cu.m of hard rock was excavated upto a depth of () 22 m.
Emergency Reclaim Hopper RH-1 & RH-2
Front handing over Graded land is to be provided to L&T for commencing construction activity. Process of land acquisition ran slow in the initial stage of the project
despite many efforts by the client. The area grading in the hard rock was another time taking activity. Both these process resulted in considerable delay in front handing over, which was another big challenge to cope up with the stiff time schedule. Engaging project affected people The engagement of project affected people was imparted on L&T by the client. Since the villagers were mostly raw hands, they had to be trained in specific areas of requirement. About 180 people were trained and engaged by L&T in its daily construction activities. Terrain The project location is situated at finish ground level of 397.00 m elevation with the surrounding areas having FGL as 399 and 400 m. Therefore during the monsoon period, the project team faced a lot
of logistic problems as there was inundation of land. Mass dewatering was done to restore work and to enable logistics to the project site. Project period The civil and structural fabrication jobs of such large magnitude were to be completed in a short period of 20 months. It was a great challenge to execute, as a lot of planning and interface management had to be in place for the smooth progress of the project activities. These challenges were overcome through meticulous planning and implementing the right construction sequence with frequent inter discipline interaction. S. Nath Project Manager P .S. Purani Planning Manager
Crusher House
46
I N A U G U R AT I O N
ICE Chennai Chapter - Working Committee inaugural function
Mr.S.N.Subrahmanyan along with members of ICE Chennai chapter
To enhance the professional activities of Institution of Civil Engineers (UK), L&T Construction has taken another effort in forming a new working committee. The Chairman Mr. S. N. Subrahmanyan, CEng FICE released a planner and addressed the members. He emphasized that the members should now promote all the technical programmes and also take advantage of using the professional charter membership in developing a strong professional civil engineering hub at Chennai. The values of ICE (UK), which is the oldest institute in the world, can be imbibed. ICE Chennai chapter already has an executive committee and now it has been strengthened with many young professional chartered engineers. The committee members represent all ICs of L&T, Foster wheeler, and other independent professionals.
Dr. B Sivarama Sarma, Country Representative (ICE, UK) and Head Research & Development Department explained to all the members about the functions and roles of the Local Association (LA) at Chennai. The Chairman, appreciated Dr.Sarma for his passion and continuous promotional activities of the LA. Mr. Rajeev B. Bhatnagar, VP & Head-HR, MMH IC traced the growth of ICE (UK) in Chennai, under patrons guidance of Dr. A. Rama Krishna and Mr. K. V. Rangaswami. Mr. C Sankaralingam expressed that ICE, Chennai already has conducted very good professional programmes and it will be strengthened further with a systematic approach.
47
Bhoomipooja for L&T GeoStructures Prestige Bella Vista project
L&T GeoStructure, the newly-formed foundation and geotechnical engineering entity in L&T, celebrated the Bhoomipooja of Prestige Bella Vista project, at Chennai on March 28, 2012. Situated near Ramachandra Hospital, the Bella Vista project is laid out in an area of about 25 acres with a built-up area of about 5.4 million sq.ft and comprises 33 towers. This project marks the foray of the Prestige group into the residential market of Chennai. From the client side, the function was attended by Mr.Irfan Razack - Promoter, Chairman & Managing Director, Mr. V. Gopal Executive Director (Projects & Planning), Mr. Stephen Daniel Vice President (Projects) and other senior Prestige officials. Mr. S. Kanappan, Head & Chief Executive of L&T GeoStructure welcomed the clients. L&T GeoStructures scope in this project comprises about 7500 nos of piling - both bored castin-situ and driven cast-in-situ piles, within a time frame of 6 months. L&T GeoStructures state-of-the-art piling rigs deployed at site were commissioned immediately after the pooja.
Wonder Cement Plant Commissioned at Chittaurgarh, Rajasthan

Wonder Cement plant, a 6500 TPD green field plant executed by L&T Construction in a record time of 18 months at Chittaurgarh in Rajasthan was commissioned on March 23, 2012. Mr.Vimal Patni, Chairman and Mr. Ibrahim Ali (Technical Adivisor) Wonder Cement, commissioned the plant in the presence of WCL and L&T project teams. Project Highlights The major structures executed by L&T include Raw Mill, Pyro section consisting of Pre-Heater, Kiln and Cooler, Cement Mill, Packing Plant, 7 nos. of Silos and a Chimney. L&T scope of work comprised 120000cu.m of excavation, 123800cu.m of concreting, 320,000 sqm of shuttering, 45000t of structural fabrication and equipment erection. The site achieved a peak performance of 3200t of structural and equipment erection and 9300cu.m of concreting in a month. The induction of 25t capacity tower crane for equipment erection in the pre heater ensured a time saving of two months.
48
Prayas website launched by Mrs.Naik
Mrs.Geeta Naik unveiling the Prayas website
Prayas Trust Chennai launched its new website on 19th March at the HQ campus. Mrs.Geeta Naik unveiled http://ecc-prayas.org/ in the presence of Mrs.Jyothi Venkataramanan, Mrs.Chitra Rangaswami, Mrs.Sharada Shankar Raman, Mrs.Swasti Roy, Trustees, Affiliates, Office Bearers and members of Prayas Trust. It was a joyous moment for the ladies of Prayas Trust as they saw this new website with a fresh look and feel, reflecting the dynamic efforts and activities of Prayas members. The new website also includes its affiliates across other L&T units, all over India.
L&T commissions the countrys first 765kV transmission substation

L&T was entrusted with the installation of 765kV / 400kV transmission substation at Unnao in UP . The scope of work included design, procurement and installation, testing and commissioning of 765kV switchyard and 400kV bay extension to be completed within a period of 18 months. The project was awarded on 29/01/2010, and after forest clearance, the land was handed over by the client on 7th May 2010. The substation has the unique feature for evacuating the power at two voltage levels, such as, 765kV & 400kV using 2x1000MVA Interconnecting transformer. The existing 765kV transmission line, presently operating at
400kV, has been diverted and reconnected to the new 765kV substations at Unnao and at ANPARA-C. A second 765kV circuit will interconnect UNNAO to ANPARA-D. 400kV down side line interconnect to existing 400kV Substation. Despite inherent challenges such as interfacing with various other agencies, delay in availability of material, drawing, work front and natural hindrances such as monsoon floods, the project team, under the able stewardship of Mr. S.K Saxena Sector Project Manager, worked with dedication to commission the countrys first 765kV transmission substation in Unnao, Uttar Pradesh on 5th of December 2011, exactly 18 months from the date of commencement of project. The client, UP Power Transmission Corporation Limited, has given an appreciation letter to L&T for this great achievement after the successful charging of substation and evacuation of power.
LD # 3 & TSCR inaugurated at Tata Steel Jamshedpur
Mr.Ratan Tata arriving at the LD # 3 & TSCR plant
The LD # 3 & TSCR Plant at Tata Steel project Jamshedpur was inaugurated by the Chairman Mr.Ratan Novel Tata on 3rd March which was the Founder s Day of the Tata Group. Mr Ratan Tata along with a host of dignitaries including Tata Steel MD, Mr H.M. Nerurkar, former Managing director Mr B. Muthuraman and officials from Tata Steel, L&T and other associated companies participated in this event. Mr.Ratan Tata appreciated all the people involved in the LD # 3 & TSCR projects. Prior to the inaugural function, Mr Ratan Tata visited the IBF Project and observed the recent developments in project expansion. Mr D.R. Ray & Mr D.M. Shah along with Mr. Uttam Singh, Chief of IBF project received him and briefed him on the 3 million ton Capacity I Blast Furnace.
L&T Construction Commissioned Indias Largest Solar PV Power Plant

L&T Construction has commissioned Indias largest solar photo voltaic based power plant (40 MWp) owned by Reliance Power Limited at Dhursar Village, Jaisalmer district of Rajasthan. As the largest EPC player in solar power, L&T Construction executed the solar power plant from concept (including detailed design) to commissioning in 129 days. With the commissioning of this plant, L&T Construction has installed 114MW of utility scale solar PV power plants over the last fiscal a benchmark in Indias solar EPC industry. The solar PV power plant, equipped to supply more than 70 million units of clean and green energy
50
to 75,000 house holds, was commissioned in the presence of Mr.Farooq Abdullah, Minister for New and Renewable Energy, Mr. Ashok Gehlot, Chief Minister of Rajasthan, Mr.Jitendra Singh, Energy Minister, Mr. Anil Dhirubhai Ambani, Chairman of Reliance Power and senior officials from L&T. The clean energy generated by the plant is expected to displace nearly 70,000 t of CO2 annually. The Solar PV power plant, which comprises more than 5,00,000 high output generating thin film technology based Solar PV modules and thirteen 3.5 MVA power transformers to generate 40MWp, is spread across 350 acres. The thin film Solar PV modules for the project were procured by Reliance; while L&Ts scope of work included complete design, engineering, procurement and construction of 40 MWp solar power plant, including construction of a 5km33 kV double circuit transmission line. L&Ts EPC expertise led to benchmarks in scale and pace of execution. It under took installation of 13000 modules per day and laid more than 1400km of cables. Adopting mechanized construction including sophisticated ramming machines, L&Ts engineers and workforce achieved 7, 37,409safe man hours during the execution of the project.
CEFD Commissions Mini Weather Station at HQ Campus

As a part of its research and development initiatives, L&Ts Centre for Excellence and Futuristic Development (CEFD) has commissioned a mini weather station at L&T Constructions Manapakkam campus in Chennai on the terrace of Technology Centre III, Tower B. It will help in measuring the ambient air temperature, relative humidity, wind velocity, wind direction and rain fall intensity. The data
generated will provide a picture of micro-climatic variations in and around the HQ campus as compared to the meteorological data. It will also enhance L&Ts capabilities in carrying out campus sustainability initiatives. In addition to its in-house use, the system can be used to portray micro climatic conditions in Manapakkam and its vicinity areas. Similar mini weather stations have already been installed by CEFD at Ahmedabad, Bangalore, Lucknow and Hyderabad to understand the micro-climatic conditions in the vicinity of L&Ts construction sites. These installations are a part of a major study which is being taken up to establish the thermal comfort performance of RC wall buildings in different climatic zones.
51
L&T Constructions Panchangam Calendar Released during National PR Day Celebrations organized by PRSI
Top: Kris Srikkanth releasing L&Ts Panchangam Calendar in the presence of Mr. K. V. Rangaswami Below: The display at Gallery Sri Parvati
The 2012-13 Panchangam Calendar based on the theme Games in Ancient India was aptly released by the ace cricketer Kris Srikkanth, Former Captain Indian Cricket Team and Chairman Sr. Selection Committee, BCCI in the presence of Mr. K.V. Rangaswami, Advisor to Chairman, L&T at a function held at Hotel Savera on March 11, 2012. As part of its National PR day celebrations, the Chennai Chapter of the Public Relations Society of India launched the 11th year Panchangam Calendar of L&T Construction and explored the impact of branding through ethnic calendars that were based on the Indian Almanac. Speaking on the occasion Mr.Srikkanth appreciated L&T for bringing out such calendars because he believed
52 ECC CONCORD Jan - Mar 2012 2011
that deep down everybody was superstitious and wants to begin auspicious things by seeing the right Muhurat or Muhurtham. Sharing the dais with Mr. Kris Srikkanth, Mr. K. V Rangaswami, Advisor to Chairman, L&T, recalled with passion the relentless zeal with which L&T Construction had released its Panchangam Calendar over the past decade. Following the release an exhibition on The Decades collection of Panchangam Calendars was held between 13th to 15th April 2012, at Gallery Sri Parvati, Eldams Road at Chennai. The exhibition had a display of the genesis of Panchagam Calendar and takes the visitor right through the various themes correlating Indian Mythology, Values, Culture and Heritage.
NEW ORDERS
L&T Construction Bags Orders Valued `1880 crore
L&T Construction has bagged new orders valued over ` 1880 crore across various business segments during the fourth quarter of FY2012. The Infrastructure IC has secured new orders aggregating to ` 1048 crore from various clients. A major order has been bagged from The Government of West Bengal, State Highway Circle-I, for the Construction of four lane elevated corridor along Kazi Nazrul Islam Sarani (VIP road) from Kestopur to Zora Mandir in the district of north 24 Parganas under JNNURM scheme, GOI. Two more orders have been secured from DMRC for design and construction of tunnels for underground works between Mandi House to Jama Masjid including three stations under Delhi MRTS - Phase III Project and for the construction of a viaduct including ramp for Badarpur-Faridabad corridor. In the Water and Effluent Treatment business unit, L&T Construction has secured orders worth ` 348 crore from Gujarat Water Infrastructure Limited for providing, supplying, lowering, jointing & commissioning of bulk water transmission by M.S.Pipeline at Surendranagar and Junagadh Districts in Gujarat under Swarnim Gujarat Saurashtra - Kutch Water Grid programme. In the Power Transmission & Distribution IC, new orders valued at ` 263 crore have been bagged from esteemed clients. The orders include construction of e-BOP system for 2x600 MW Coal fired thermal power plant at Singhitarai in Chhattisgarh from a private developer and another order from DMRC for supply, installation, testing & commissioning of EHV cables, Receiving Cum Traction substation and Auxiliary Main substation at Jaipur for Jaipur Metro Phase-I Project. L&T Construction has also received additional orders worth ` 221 crore from various ongoing projects.
`1306 Crore Orders

L&T Construction has bagged new orders valued over `1306 crore across various business segments in February 2012. The Power Transmission & Distribution IC has secured new orders aggregating ` 514 crore from various clients. This includes a major order from Power Grid Corporation of India Limited for the construction of a 765 kV Double Circuit Transmission Line from Varanasi to Kanpur and 400 kV Double Circuit lines from Varanasi to Saranath and Sasaram to Allahabad. Additional orders have also been received from other reputed customers. The Building & Factories IC, secured new orders worth ` 451 crore for the construction of residential towers and also for civil, structural and mechanical erection works for construction of a cement plant. In the solar business unit, L&T Construction has secured an order worth ` 220 crore from a leading developer for the construction of a 23 MW Solar PV plant on EPC basis in Rajasthan. In yet another development, the Infrastructure IC has secured new orders valued at `121 crore from Kolkata Metro Rail for the construction of a 2.7 km viaduct from Madhyamgram to Hridaypur including a station building at Madhyamgram and other related works in connection with the extension of the Metro Railway from Noapara Barasat at Kolkata.
Orders Valued `1140 Crore

L&T Construction has secured new orders valued over `1140 crore across various business segments in March. The Companys Building & Factories IC has secured a major order worth ` 970 crore for the design and construction of a large IT campus facility in Kolkata from a reputed customer. This project will be executed on a JV model along with Shapoorji & Pallonji Co.(SPCL) within a period of 32 months. In yet another development L&T Oman LLC has
53
bagged a new order worth ` 170 crore from Oman Electricity Transmission Co for replacing portions of the existing 220 & 132 kV OHL from Mawaleh to Seeb GS to be completed within a period of 15 months.
` 1875 Crore Orders

L&T Construction won new orders valued over ` 1875 crore across various business segments in March 2012. The Power Transmission & Distribution IC secured new orders in both domestic and international markets from reputed customers. Domestic orders worth ` 701 crore include a major order from the Tamil Nadu Electricity Board for the construction of 148km, 400kV DC (Quad) transmission line from Pugalur to Pandiankuppam in Tamil Nadu. The project will be completed in 18 months. The Company has bagged two additional orders for construction of substations at Malaysendra from Karnataka Power Transmission Corporation and at Jind, Haryana from Power Grid Corporation of India Limited. International orders, valued at ` 194 crore, include those for construction of a 220/33 kV substation and various orders for ongoing projects at UAE. The Building & Factories IC has bagged new orders aggregating ` 841 crore. This includes construction of residential apartments in Chennai and Mumbai from leading developers. Another new order has been received for construction of a mall in Bangalore. In the Solar Business Unit, L&T Construction has secured orders worth ` 139 crore from reputed developers for the construction of a 5.75 MW Solar PV plant on EPC basis in Rajasthan and general civil works for 1x125 solar thermal power project in Gujarat.
Orders Valued ` 1120 Crore

L&T Construction has won new orders valued over ` 1120 crore across various business segments in March 2012. Power Transmission & Distribution IC has secured new international orders worth ` 548 crore from Abu Dhabi Water & Electricity Authority, UAE for the construction of 220 kV overhead lines, switching stations and other related electrical works. L&T Oman LLC, part of L&T Construction, has bagged a new order worth ` 156 crore from a reputed client for the construction of an electrical substation and associated work. The Building & Factories IC has secured orders aggregating ` 416 crore from various customers. Major orders include those for construction of factory projects, and include contracts for additional work from various ongoing projects.
L&T Construction Bags Order Worth ` 1700 Cr

L&T Metallurgical & Material Handling IC, part of L&T Construction has secured a ` 1700 crore order from Tata Steel for a new 6 Million Tonnes Per Annum (MTPA) steel plant at Kalinganagar, Odisha. As part of the greenfield steel plant, L&T is executing a slew of projects like blast furnace, sinter plant, coke oven, balance of plant for steel melt shop, hot strip mill, utilities and construction works for other areas. The Companys Minerals & Metals Strategic Business Group has strengthened its leadership position in the iron making area as an EPC player for the Indian steel industry. With this new order L&T has enhanced its capabilities to provide integrated solutions for the entire steel plant.
PT&D signs contracts worth QR 1.1 Bn (300 Mn USD) with Qatar General Electricity and Water Corporation (Kahramaa)
Larsen & Toubro has signed the largest value contract with Qatar General Electricity and Water Corporation (Kahramaa) worth QR 1.1 Bn (300 Mn USD) for Extra High Voltage (EHV) Substation and EHV Cabling for their Phase X expansion project.
54
of 400 kV Switchyard with GT, GCB, CHP and AHP Electrics. The e-BOP Package for Unit -1 has to be completed in 17 months schedule and Unit 2 in 20 months. Mr.R.Srinivasan-VP-BU Head, Industrial Electrification, Mr.N.Sudhakar, Regional Manager & Cluster-HeadHyderabad Region along with Mr.S.P .Mathai-Director (Thermal), Mr.T.Ashok-Director of Abir Infrastructure Private Limited were present during the contract signing.
The contracts were signed by the Minister of Energy and Industry H E Dr Mohammed bin Saleh Al Sada, who is also Chairman of the Permanent Committee of Water Resources, with Mr.J.S.Sudarsan (EVP & Head PT&D IC) at Doha on 27th March 2012. The contracts are for the Phase X, for the expansion of electricity transmission networks. Kahramma Phase X comprises of 13 EHV Substations and 66 km of 220 Kv EHV cabling. The investments are in line with Kahramaas mission and objectives to provide high quality electricity and water services in the state and its sustainable development commitment toward Qatar National Vision 2030 and National Development Strategy plan 2011-2016.
Solar BU signs contract with Areva to construct Asias largest solar thermal power project
L&Ts Solar BU has recently signed a Solar Field Construction Contract with M/s. Areva Solar India for Reliance Infrastructure Limiteds 1 X 125 MW Solar Thermal Power Project at Pokhran, Rajasthan, which is Asias largest solar thermal power plant project. The power plant is using Compact Linear Fresnel Technology (CLFR) which can generate steam at 400oC and 96 bar using heat from solar radiation. The other prominent technologies include Parabolic Trough and Power Tower. This is a first-of-its-kind contract for L&T which includes erection of solar steam generator units, piping, electrical, instrumentation and civil construction works. The construction works has to be completed within 13 months. This project is one among the 470 MW of solar thermal power projects allocated under the Jawaharlal Nehru National Solar Mission (JNNSM). The National Solar Mission is a major initiative of the Government of India to promote ecologically sustainable growth while addressing Indias energy security challenge. It will also constitute a major contribution by India to the global effort to meet the challenges of climate change. It enables a policy framework for deployment of 20,000 MW of solar power by 2022.
PT&D signs ` 195 crore e-BOP contract with Abir Infrastructure

PT&D IC signed an e-BOP works contract worth Rs. 195 crores with M/s Abir Infrastructure Private Limited for executing works at Athena Chhattisgarh Power Limiteds 2 x 600 MW TPP project at Singhitarai, Champa. The e-BOP scope, a first of its kind contract for L&T includes construction and commissioning
55
EVENTS
World Water Day Celebrations
Mr.S.N.Subrahmanyan addressing the gathering on world water day
22nd March is celebrated as World Water Day across the world and L&T, as the countrys largest construction company, reaffirmed its commitment towards conservation of this depleting natural resource. The celebration included a thought provoking and enticing street-play performed by the students of Madras School of Social Works (MSSW) apart from e-water quiz competitions and other activities. The celebration was marked by a special lecture by Mr. R.K. Garg, Ex - Engineer Member, Delhi Jal Board, New Delhi & Former Chief Engineer (Haryana Irrigation Dept.)
Students of Madras School of Social Works performing the street-play
L&T - MIOT association fortified at the 13th Anniversary celebration of MIOT Hospitals
Mr.S.N.Subrahmanyan addressing the gathering
MIOT Hospital Chennai celebrated its Founders Day and 13th Anniversary on the 14th of February 2012. Mr.S.N.Subrahmanyan, Member of the Board and Senior Executive Vice President graced this occasion as the Chief Guest and addressed the gathering. L&T has been associated with MIOT for the past many years executing design and build projects within the MIOT campus - Retreat Building, Medical block, Extension of the existing building etc., and more recently the 450 bed multi-speciality hospital named MIOT International will soon be completed by August 2012.
Citing this long term relationship, SNS congratulated the Founder Prof. Dr. P .V.A.Mohandas, Chairman, Ms.Mallika Mohandas and the entire team during this occasion. Referring to L&Ts business expansion to the Middle East, he said that people from the Middle Eastern countries are travelling to India for medical support. He appreciated the quality care extended by the medical practitioners at MIOT for such international patients and assured that the new project being executed by L&T will help MIOT serve them better.
World Plumbing Day was celebrated at L&T Construction across project sites and offices on March 11, 2012. Mr. S. Virapan, Chairman of Indian Plumbing Association (IPA), Chennai Chapter and the chief convener of event flagged off the proceedings from HQ Chennai by welcoming the Chief Guest Mr. G.V Prasad, COO of L&T IDPL and other dignitaries, members of the Indian Plumbing Association. A short film on plumbing Day 2011 was played to reminiscence the events that took place 365 days ago. World Plumbing Council Chairman Mr.Russy Chaneys message was telecast along with messages from the top management of L&T. Mr. G.V. Prasad in his key note address threw light upon Indias position in context to the global issues on common infrastructure parameters. Acute shortages faced by our country compared to world standards were compared with precise statistical data.
World Plumbing Day Celebrations
Mr. S. Virapan, Chairman of Indian Plumbing Association (IPA), Chennai Chapter addressing the gathering
RENERGY 2012
L&T Construction was the lead sponsor at RENERGY 2012 an International Conference and EXPO on Renewable Energy, which was organised by Tamil Nadu Energy Development Agency during March 12-13, in Chennai Trade Centre. The conference and exhibition was inaugurated by Honble Minister for Electricity, Prohibition and Excise, Mr.Natham R Vishwanathan. As the largest EPC player in the Indian solar power, L&T displayed its multi-dimensional capabilities highlighting its leading position at this EXPO in a 36 sq.m stall.
among them were 400kV and 220kV transmission lines, 132kV and 33kV substations and 200MW cycle gas based power plant executed in the middle-east.
WETEX 2012
L&T Construction put up an impressive stall at WETEX 2012, International Exhibition on latest technological advancements in Water, Energy, Environment and Oil and Gas sectors held at Dubai during March 13-15, 2012. L&T projected its multi-dimensional capabilities in power transmission and distribution through its 36sq.m stall displaying images of signature projects. Prominent
Host of visitors comprising clients, consultants, contractors and suppliers from UAE and abroad visited L&Ts stall. Officials, contractors from Ethiopia, Libya, Sudan and Iraq evinced keen interest in L&Ts Power Transmission and Distribution capabilities. Also, officials from Solar, Water industries, enquired about L&Ts capability in setting up Solar, Water Desalination plants in UAE and India.
C O R P O R AT E
Performance for the quarter ended March 31, 2012
Larsen & Toubro recorded Gross Revenue of ` 18646 crore for the quarter ended March 31, 2012, registering a growth of 21.1 % y-o-y. Excluding exceptional and extraordinary items, Recurring Profit after Tax (PAT) for the quarter ended March 31, 2012 stood at ` 1877 crore recording an increase of 24.8% over the corresponding quarter of the previous year. Order inflow for the year at ` 70574 crore took the Companys Order Book to ` 145723 crore as on March 31, 2012. The order inflow and order book include proportionate share in the Integrated Joint Ventures. Decelerating growth momentum across the sectors during 2011-12 led to deferment of capital expenditure and fresh investment decisions. Still the Company was able to garner sizeable new orders mainly from Building & Factories, Infrastructure, Power Transmission & Distribution and Minerals & Metals sectors. Gross revenue for the year 2011-12 at ` 53738 crore registered a growth of 21.3% over the previous year. Recurring Profit after Tax (PAT) for the year 2011-12 stood at ` 4413 crore recording an increase of 20.1 % over the previous year. The Board of Directors has recommended a dividend of ` 16.50 per equity share. Engineering & Construction (E&C) Segment E&C recorded Net Segment Revenue of ` 16638 crore for the quarter ended March 31, 2012 recording a y-o-y growth of 23.4%. For the year ended March 31, 2012, Net Segment Revenue was ` 46768 crore registering 23.3% growth over the previous year. Most of the ongoing projects progressed well contributing to growth in the revenue. This revenue growth was achieved despite deferment of some of the anticipated orders and delays in obtaining clearances in a few projects in the infrastructure, power, power transmission & distribution sectors, having temporary impact on the pace of activities. During the year, the Segment secured orders totaling to ` 63574 crore with International orders constituting 18% of the total order inflow. The Order Book of the Segment stood at a healthy ` 143448 crore as at March 31, 2012 with international orders constituting 12% of the total order book. The Segment recorded Operating Margin of 12.7% during the year ended March 31, 2012 through an efficient management of costs and its superior execution capabilities.
Larsen & Toubro appoints Mr.K.Venkataramanan as Chief Executive Officer and Managing Director Mr.A.M. Naik to continue as Executive Chairman
The Board of Directors of Larsen & Toubro decided to bifurcate the role of Chairman and Managing Director into two positions. At the Board meeting held today, it was decided to appoint Mr. K. Venkataramanan as CEO & MD with effect from April 1, 2012 while Mr.A.M.Naik, will continue as Executive Chairman of the Group. Mr. K. Venkataramanan, a Chemical Engineering Graduate from IIT (Delhi), joined L&T as a Graduate Engineer Trainee and was elevated to the Board of the Company as a Whole-time Director in the year 1995. He has won many national and international accolades, viz. Honorary Fellow of IChemE, U.K., Honorary Doctorate in Project Management, distinguished Alumni of IIT, Delhi, to name a few. He is an excellent leader and is very well-known in science, technology and business
59
circles. He is an active sportsman who still plays tennis and badminton regularly and cricket occasionally. While commenting on the Boards decision, Mr. A. M. Naik stated, I am pleased that the Board has appointed Mr. K. Venkataramanan as CEO & MD. I have full confidence that under Mr.Venkataramanans leadership, L&T will continue on its growth path. L&T undertook the journey of LAKSHYA to simplify its portfolio and created 10 Independent Companies (ICs) and 7 Subsidiaries with a view to bringing focus, autonomy and accountability and had engaged the services of the global strategy firms for the same. While the journey is already on, changes in the economic environment necessitated the company to undertake a Mid-Term Review of Strategic Plan, which is now under finalization. In line with the vision of the company to become an Indian Multinational as also looking at the current global competitive environment, it needs to develop leaders who will manage the Company, going forward. In view of the above transformation phase that L&T is going through, the Board decided that there is a need for continuity and accordingly requested Mr.A .M.Naik, to continue for a period of 5 years as Executive Chairman of the Group. Mr. K. Venkataramanan will be responsible for the businesses of the Company. Mr. A .M. Naik will focus on completing the portfolio restructuring, institutionalizing the IC structure, mentoring and developing the leadership team and future leaders to face the global challenges. Thanking the Board, Mr.Venkataraman said that I am honoured with the responsibility that the Board has placed on me. I am also happy that Mr. A . M Naik s guidance will continue to be available. The Board is condident that this step is in the best interest of all stakeholders.
Mr.Shailendra Roy Elevated to L&T Board
The Board of Directors of Larsen & Toubro (L&T) approved the elevation of Mr.Shailendra Roy as a Whole-time Director, with immediate effect - March 9, 2012. Mr. Roy is currently Sr. Vice President Power Development Business, Corporate Affairs & Corporate Initiatives. He is also a Member of the Executive Management Committee of the Company. This induction is part of L&Ts succession plan. Mr. Roy, 59, holds a Bachelor of Technology degree, and started his career in 1975 as an Engineer with Bharat Heavy Electricals Limiteds (BHEL) manufacturing unit at Haridwar. Before joining L&T, he was Managing Director & CEO of Bharat Heavy Plates & Vessels Ltd. (BHPV) from 2002 to 2004. Mr. Roy s notable contribution in L&T includes the Company s entry into Railway business, Power Development and growth of new business ventures including public-private partnership initiatives.
60
L&T Ranks Among Top 10 in S&P ESG India Index Environment, Social & Governance Performance
L&T has ranked among the Top 10 in Standard & Poors (S&P) ESG India index of companies in terms of Environment, Social and Governance performance. The index is sponsored by International Finance Corporation (IFC), and is developed by a consortium of Standard & Poor, CRISIL and KLD (an international research organisation) specialising in global equity market research.
COMPANIES
TO WORK FOR
THE BEST
Mr. A. M. Naik Ranked One of Indias Top Two CEOs from 1995 to 2011
L&Ts Chairman & Managing Director, Mr A.M. Naik, was rated as one of the top two of Indias Best CEOs in a study conducted by Indias leading business magazine Business Today (part of the India Today Group), leading international business school INSEAD, and the Harvard Business Review. The Business Today issue dated February 5, 2012 carried an extensive report, featuring a profile of Mr Naik and an account of his numerous achievements that have had a decisive influence on the transformation of the company. While media recognition of Mr Naiks accomplishments have been regular, the Business Today recognition puts his list of accomplishments in a long-term perspective and recognises him as an exceptional value-creating industry leader. Mr.Naiks mantra has always been value creation this study reaffirms his success in putting his concepts into practice. The study stands out among other surveys for the rigour of the processes used and because it was carried out by internationally recognised professionals. The ranking was based on a comparison of 374 CEOs of 202 publically traded companies on the Indian stock markets, drawn from the S&P CNN 500 since 1998. The CEOs were ranked based on the shareholder returns that they generated during their tenures. The ranking combined three measures: countryadjusted company returns, industry-adjusted company returns and market capitalization change.
1 TCS 2 Infosys 3 Wipro 4 IBM 5 Google 6 RCom 7 Microsoft 8 Accenture 8 HCL Tech
10 L&T
10 Tata Motors 12 ICICI Bank 13 ONGC 13 RIL 15 HDFC Bank 15 Tata Steel
The index highlights the profile of companies that perform well among their market peers on environmental, social and corporate governance parameters. It uses an innovative model and a two-step process, based on quantitative and qualitative factors. The index annually screens the ESG practices of the top 50 companies from the pool of 500 Indian companies based on market capitalization and listed on National Stock Exchange (NSE). The index measures environmental, social, and corporate governance practices based on quantitative rather than subjective factors, with the use of a unique and innovative methodology. It is built on information available in the public domain as well as through a due diligence process, offering complete transparency to investors by a quantitative scoring system. L&Ts listing in the Top 10 of the S&P ESG India Index for the first time reaffirms its position as an organisation with a growing commitment to responsible business.
61
Mr.Naiks most notable achievements that resulted in value creation include: yy Setting up the L&T Employees Welfare Foundation, which, for the first time, gave the company some protection from predators, preserving its independence, and retaining its professional character.
yy yy yy yy
Issue of ESOPS that gave employees a strong sense of participation & ownership Emphasizing meritocracy within the Company to retain top talent Adding an international dimension to L&Ts operations Restructuring the company for increased business effectiveness
L&T Ranks 3rd in BSE Green Index

SR No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Tata Steel Ltd. State Bank Of India Larsen & Toubro Ltd. ICICI Bank Ltd. Tata Motors Ltd. Sun Pharmaceutical Inds. Ltd. NTPC Ltd. Dr Reddys Laboratories Ltd. Housing Development Finance Corporation Ltd. Bharat Heavy Electricals Ltd. GAIL (India) Ltd. Hindustan Unilever Ltd. Cipla Ltd. Sterlite Industries Ltd. Tata Power Company Ltd. Ambuja Cements Ltd. Lupin Ltd. DLF Ltd. Glaxosmithkline Pharmaceuticals Ltd. Reliance Infrastructure Ltd.
Name
Market Capitalization*
24,211.12 24,040.43 23,603.11 23,566.41 23,308.38 21,315.29 21,298.11 20,484.17 20,312.97 19,468.49 18,918.07 18,657.39 18,222.10 17,489.93 17,251.05 12,321.64 11,633.80 9,166.12 8,188.03 7,804.71
Weight
6.70% 6.65% 6.53% 6.52% 6.45% 5.90% 5.90% 5.67% 5.62% 5.39% 5.24% 5.16% 5.04% 4.84% 4.78% 3.41% 3.22% 2.54% 2.27% 2.16%
*Capped Free Float Market Capitalization in the index in INR CRS.
L&Ts performance in environmental conservation won market recognition today as it was ranked third in a weighted tally of the Green Index published by the Bombay Stock Exchange. Called the BSE-GREENEX, this first-of-its-kind index assesses the carbon performance of companies drawn from the BSE Top 100. L&Ts high ranking is specially commendable since the BSE-GREENEX is not a subjective assessment and applies sector-specific algorithms to determine energy performance and is based on publicly disclosed data. The high ranking secured by L&T affirms the commitment of the Company to corporate
sustainability and the success of eco-sensitive initiatives across all its operations and product portfolio. In addition, the BSE-GREENEX will provide progressive retail and institutional investors a dependable tool to measure the performance of companies with regard to environment sustainability. It is widely acknowledged that the green performance of companies is assuming critical significance across the world for businesses and investors. The Bombay Stock Exchange is among the oldest in Asia and the worlds largest in terms of the number of listed companies.
L&T extends solidarity towards Thane Cyclone relief assistance in TN
Mr.S N Subrahmanyan, Member of Board and Sr. EVP, L&T Construction, handing over the cheque to Chief Minister of Tamil Nadu Ms.Jayalalitha. Mr. Mr.R.Anbalagan, Head- Hydel BU, looks on
Mr.S N Subrahmanyan, Member of Board and Sr. EVP L&T Construction met the honorable Chief Minister of Tamil Nadu Ms.Jayalalitha on 3rd February and presented a cheque for Rupees Two Crores and Thirty Five Lakhs towards the Thane Relief Fund. Mr.R.Anbalagan, HeadHydel BU accompanied SNS. The said sum marks L&Ts Corporate support along with one days salary contribution from its employees extending their solidarity to the noble cause. This contribution will be used by the State for rehabilitation programmes of those affected by the Cyclonic Storm that ravaged districts of Tamil Nadu.
off-grid and decentralized solar power projects. The mission has envisaged that RESCOs (Renewable Energy Service Company) and System Integrators obtain an accreditation from a rating agency like Credit Analysis & Research Ltd (CARE) so as to enable them submit project proposals directly to MNRE to avail capital and interest subsidy for their proposed off-grid & decentralized solar power projects . CAREs Grading is aimed towards categorizing Renewable Energy Service Companies (RESCOs) and System Integrators into grades based on their performance capability (such as track record, project management, etc.) and financial strength (such as networth) to undertake off-grid & decentralized solar projects. L&T Constructions Solar Business has been given the highest rating - SP1 A and has been certified as a highly rated RESCO (Renewable Energy Service Company) and system integrator, enabling it to become one of the most reputed channel partners of MNRE to execute off-grid solar power projects. With this accreditation, L&T Solar is poised to set new benchmarks in the Indian Solar industry.
L&T Constructions Solar Business receives highest CARE rating

Ministry of New and Renewable Energy (MNRE) has launched Jawaharlal Nehru National Solar Mission with an objective to promote the use of renewable sources of energy and setting up an environment which will facilitate increased penetration of solar technology in the country through grid connected and
CSTI Signs MoU with Jindal Steel and Power Limited

The Construction Skills Training Institute (CSTI) of L&T Construction has signed a MoU with Jindal Steel and Power Ltd (JSPL) on April 3, 2012, to promote construction skills training centres in Angul and Barbil in Odisha, Godda in Bihar, Patratu in Jharkand and Punjipathra in Chattisgarh. Mr. S.N. Subrahmanyan, Member of the Board and Sr. Executive Vice President, L&T Construction along with Mr. S. Natarajan, HeadConstructions Skills, exchanged the MoUs with Dr.Sanjeev Sahni, Head Education, Jindal Steel and Power Ltd and Ms. Miriam Carter Director, OP Jindal Community College L&T will be the knowledge partner and will impart training in in Formwork carpentry, Bar bending, Steel fixing and Masonry trades to start with. Initially JSPL will impart training at their premises for a month and for the balance two month training will happen in L&Ts CSTI institutes across India. Welding and Plumbing trades will be included later on. Presently there is a shortage of 30 million skilled workers in the construction sector. This joint initiative by L&T Construction and JSPL will train and provide employment in the construction sector to the school dropouts, youth from economically weaker and socially backward sections of the society.
L&Ts Former Director John Hover passes away

Mr. John Hover, Former Director of L&T passed away on 24th March, Saturday at Denmark. He is survived by his wife Mrs. Birte Hover and daughter Mrs. Michaela Hover. Mr. John Hover was associated with the Company since 1949 in various capacities. He joined the Board in 1964 and was designated Deputy Managing Director in April 1969. He was responsible for developing the Companys marketing organization including the creation of capacity to undertake major complex engineering projects. As a Director of various Subsidiary and Associate Companies including ECC, he has contributed substantially to the development and growth of these companies. The companys high reputation in the fields of nuclear, petrochemical and fertilizer projects is largely due to Mr. Hovers efforts. He retired in 1974. A condolence meeting was held at L&T Constructions HQ campus at Chennai to mourn the demise of Mr. Hover. The top management team paid their respects to the departed leader.
64
AWA R D S
National Record on Fastest Erection & Commissioning of M1 Batching plant at Cognizant, Shollinganallur
Adding to the exceptional credentials of setting benchmarks, L&T Construction has set a new national record by erecting and commissioning a M1 batching plant at Cognizant Technology Solutions, Shollinganallur in Chennai. As a process of mentoring safe and expeditious erection process, a trend of meticulous planning before actual execution has been initiated by Chennai Cluster recently. This trend began with the erection of MC 205 B tower crane with 60 m Jib erected, commissioned and handed over to TCS, Kochi project site in 15 hours. Following this was the
erection of CTT 231 with 70 m Jib that was handed over in 13 hours consecutively. This initiative has been implemented with great success in many sites such as HCL Technologies, Cognizant, TCS, etc. This effective trend had paved way for the creation of a new national record in the fastest erection of a batching plant at CTS, Sholinganallur. A batching plant becomes one of the most indispensable enabling structures for any major project site. The delay in commissioning of a batching plant usually has a cascading effect of delaying the project execution.
65
Ornamental Garden at TLT Pithampur factory wins an award for its beauty
TLT Pithampur factory has been awarded for its beautiful Ornamental Garden in the Annual Rose Show Exhibition 2012 held at Indore on 21st January. This event organized by Malwa Rose Society in association with Department of Horticulture & Farm Forestry, Government of MP, has presented the first prize for the largest and the best ornamental garden along with many prizes for the different varieties of roses in this garden. Mr R.B.Parhi, Manager Accounts and Admin Pithampur works received the Trophy and citation from the MLA Mr.Ashwini Joshi in presence of dignitaries from Malwa Rose Society.
pumped 310 cu.m of Heavy Density concrete in a single pour! This unique concreting done for Unit#3, Calandria vaults Base Slab for Indias First 700MWe Atomic Power Project, is considered a milestone achievement using innovative construction methodologies. The Calandria vault is a stainless steel reactor vessel and is considered the heart of a Nuclear Power Plant. The concrete used is therefore of heavy density, having unit weight of over 3700 kg/cu.m. Maintaining this density is crucial and is a special requirement for the prevention of any radiation. In the past, heavy density concrete was placed using only tower cranes and buckets. Owing to the high density of concrete, it was not possible to pump the same. L&Ts Quality Control team at KAPP has successfully designed and developed Pumpable Heavy Density Concrete (H35/20/19C) with Hematite aggregates and micro silica. For the first time in the history of Indian Nuclear Construction, Heavy Density Concrete was pumped and placed through static boom placer uninterruptedly with a rate of pour of 20cu.m/hr. Thus, cold joints were avoided in spite of the large size of the pour. The advantage with this innovation is that the tower cranes could be kept free from concreting and could be utilised effectively for feeding other construction materials. Various teams from Planning, Batching Plant, P&M, QA/QC and Nuclear Building#3 worked with dedication and commitment to achieve this benchmark.
KAPP 3 & 4 achieves 310 cu.m of heavy density concreting in a single pour
Heavy Density Concrete was pumped for the first time in the history of Indian Nuclear Construction! 22nd February 2012 was a field day for the project team at Kakarapar Atomic Power Project (KAPP 3&4), Gujarat. The team successfully
Earlier In February 2011, the KAPP 3 & 4 project team had successfully placed the single largest normal concrete (N45/20/19c) pour of 5100 cu.m for Reactor Building 3 within a record time of 72 hrs. Kudos to the project team on this significant achievement!
66
L&T bags two awards at the World HRD Congress
L&T has been conferred with Two Awards in the World HRD Congress held at Mumbai during February 15-18, 2012. The first one is an Award for Organizational Development & Leadership by shine.com (The Hindustan Times Job website). In an award ceremony held on 15th February 2012 at TajLands End, Mumbai, Mr. N. Dharmarajan, Vice President & Head Human Resources received the award from Dr. Dennis Reina, President - The Reina Trust Building Institute & Co-Author and Dr. Michelle Reina, Co-Founder & CEO, Principal - The Reina Trust Building Institute & Co-Author. This
award is in recognition of the standards in Excellence in HR Leadership, Mentoring and Nurturing Talent. The second is an Award for Continuous Innovation in HR Strategy at Work by Institute of Public Enterprise. Mrs.Poonam Chandok, DGM-Human Resources &Mr.Prabhat Kumar, Manager Talent Management received the award from Mr.Bhaskar Chatterjee, Director General and CEO of the Indian Institute of Corporate Affairs and Prof. R. K. Mishra, Director, Institute of Public Enterprise (IPE). This award is in recognition of setting benchmarks in talent & HR practices and setting highest standards in HR Strategy and Innovation.
L&T Top Engineering Company in Business Today Listing of Best Companies to Work For
10th in Overall Ranking among 4436 Cos. L&T was ranked 10th in a prestigious listing published by Business Today of the Best Companies to Work For. The listing is based on a survey carried out by the research firm Indicus Analytics. The exhaustive nationwide survey covered 6176 employees across 4436 companies spread across 323 cities and towns. Around 12 per cent of the employees surveyed were women. Business Today said that data collected from the survey showed that the key factor to employee engagement
lay in providing growth opportunities, varied roles and empowerment. Focusing on L&Ts specific achievements in this space, the magazine features a brief interview with a young L&T employee with multi-disciplinary experience in design, on the shop floor and in business development over a span of four-and-ahalf years. It quotes her as saying that this kind of varied experience would not have been possible in any other company. The survey also revealed that among the criteria valued highly by respondents in evaluating an organisation was the culture of the place. L&Ts professional work culture and its continuing efforts at enhancing employee engagement have obviously yielded positive results.
67
Mr. A.M. Naik Honoured with CNBC TV18 Infrastructure Leader of the Year Award
Mr. A.M. Naik accepts Infrastructure Leader of the Year Award from the Union Minister, Mr. Kamal Nath
Mr. A.M. Naiks role as leader of Indias premier infrastructure company and his contribution to nation building found affirmation once again as leading business channel CNBC TV18 honoured him with the prestigious Infra-structure Leader of the Year award. The award was presented at a ceremony in New Delhi on May 08, 2012. Mr.Naik received the award from the Chief Guest, Mr. Kamal Nath, Union Minister for Urban Development. Mr.Naik received several encomiums, and was described as a living legend in
the infrastructure space. Accepting the award, Mr.Naik said L&T would continue to augment its capabilities to play a leading role in the development of this crucial sector. In a further honour for the Company, L&T Hydrocarbon business was presented the Infrastructure Excellence Award for the successful execution of the worlds longest heated and insulated pipeline from Barmer in Rajasthan to Salaya in Gujarat. This award was received by Mr. K. Ravindranath, EVP , Hydrocarbon Mid & Downstream, and Mr. T. Chinnappa, EVP , Hydrocarbon Construction & Pipelines, L&T.
Printed at RR Donnelley Publishing India Pvt. Ltd., Sriperumbudur. Edited by Mr. V.S. Ramana for L&T Construction from L&T Construction Headquarters, Manapakkam, Chennai - 600 089. The views expressed in this magazine are not necessarily those of the Management. The contents of this magazine may not be reproduced without the written permission of the Editor. Not for sale. Only for free circulation among employees of L&T Construction and their customers.

Mumbai Monorail: India's Pioneering Infrastructure Project

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mumbai Monorail: India's Pioneering Infrastructure Project

Uploaded by

Copyright:

Available Formats

In-house Journal of L&T Construction

Jan - Mar 2012 Volume-35 Issue-1

Jan - Mar 2012 Volume - 35 Issue - 1

Mumbai Monorail Indias first monorail corridor

Lonavla - L&Ts 13 MDC Temple of Learning

25 765/400kV Substation @ Unnao 33

Design & layout : Global Print Design, Chennai

ECC CONCORD Jan - Mar 2012

Successful Monorail Trial Accomplished

ECC CONCORD Jan - Mar 2012

ECC CONCORD Jan - Mar 2012

Eagle view of guideway and station

Plant and Machinery

Completed view of Mysore Colony Station

Finishing works under progress at station buildings

ECC CONCORD Jan - Mar 2012

Rebar fixing at precast yard

Construction logistics and management

Lifting of curved and straight guideway beam

Transportation of curved guideway beam

Depot building at the verge of completion

Erection of guideway beams

Curved guideway beam erection

ECC CONCORD Jan - Mar 2012

Cross Over switch at 2A Series

Erection at creek-a feat during monsoon

ECC CONCORD Jan - Mar 2012

Guideway beams from depot guideway entering depot building

L&Ts Temple of Learning

A fully stacked library

ECC CONCORD Jan - Mar 2012

Dinning in fine splendor

for any informal gathering and outdoor catering.

Classrooms with plush interiors

ECC CONCORD Jan - Mar 2012

A GLIMPSE OF THE PAINT INGS

Breathing life into a green campus

Computer centre in the learning centre

View of discussion room

ECC CONCORD Jan - Mar 2012

terrace of the existing learning centre with high class finishes.

View of learning centre reception

ECC CONCORD Jan - Mar 2012

A fully equipped gymnasium

Dining hall with modern kitchen

ECC CONCORD Jan - Mar 2012

Main entrance canopy

Outdoor sports area

Indoor sports recreation facility

Synthetic coated outdoor sports area

ECC CONCORD Jan - Mar 2012

View of the passage with paintings mounted on the walls

ECC CONCORD Jan - Mar 2012

Atrium view of learning centre

ECC CONCORD Jan - Mar 2012

765/400kV Substation @ Unnao

ECC CONCORD Jan - Mar 2012

Birds eye view of ICT area

Concreting Reinforcement steel Structural steel Formwork

: 21391 cu.m : 1016 t : 329 t : 42744 sq.m

765 kV HV AIS Equipment

ECC CONCORD Jan - Mar 2012

Final lift of 14 m High fire-wall