Developed in a record time of 23 months, Ramboll provided detailed engineering services for the greenfield six-lane access-controlled highway from Firozabad (Village Gurha) to Etawah (Village Moonj). Part of the Agra-Lucknow Expressway the greenfield section covering an approximate length of 62km increases connectivity between Lucknow and Delhi via high-speed corridors.
The new expressway
The design included road over bridges, road under bridges, interchanges and flyovers that ensures uninterrupted traffic flow.
The main objective was to expedite the infrastructure improvements in Uttar Pradesh to reduce the cost of travel and time for traffic, particularly heavy traffic in this part of the state.
The development of this stretch connects communities stimulating socio-economic growth and investments for the concerned regions of the state.
Ramboll’s scope included preparing post-bid detailed engineering designs of roads and interchanges as well as the conceptual layout design of foundation, substructure, superstructure and miscellaneous structures with multiple options.
The detailed design services included the provision of Definitive Design, Construction Reference GFC Drawings, and Calculations.
In addition, Ramboll carried out the complete modelling of the alignments and was involved in the process of value engineering to make the structures and roads economical in terms of cost, time, ease of construction, safety and aesthetics. Apart from reviewing the alternatives for optimisation of the project, Ramboll’s experts participated in discussion with the client for finalisation of the construction scheme.
Ramboll also undertook the review of topographic surveys and geotechnical investigation reports prepared by the contractor/agencies.
The skewed bridges were designed with high skew angles for large deck widths. The skew angles vary from 30 to 60 degrees, and all the bridge structures are designed for four-lane deck width of 21m. Three-dimensional analyses were carried out for all such bridges for better distribution of forces both in normal and seismic conditions.
Standardisation of sections and maximum use of pre-casting resulted in time-saving for the development of the project. The project thus got completed in a record time of two years.
All safety norms prescribed by the Ministry of Road Transport and Highways were adhered to during the design stage. Ramboll’s team of engineers
were fully committed to ensuring that the project is delivered with the highest safety standards, low environmental impact, within programme and cost requirements.
To ensure a swift and continuous delivery, the operational deliveries were phased out and then gradually optimised and aligned. Effective utilisation of resources was made during the entire tenure of the project through better planning. As
part of it, a resource pool was created for the project which provided better visibility and accuracy of resource utilisation.
Along with this, a schedule was ideated of the resources engaged in the project to accurately determine the workload and identify and minimise possible conflicts, if any.
A contingency plan was also chalked out which allowed for an optional way ahead in case of an
The designs of the structures were carried out through three-dimensional analysis on Finite Element Methods (FEM) based software.
In a structural simulation, FEM helped tremendously in producing stiffness and strength visualisations and in minimising weight, materials, and cost. The use of FEM software allowed detailed visualisation of where structures bend or twist and indicated the distribution of stresses and displacements.
The software provided a wide range of simulation options for controlling the complexity of both modelling and analysis of a system. Similarly, the desired level of accuracy required and associated computational time requirements were managed simultaneously to address most engineering applications. FEM allowed entire designs to be constructed, refined, and optimised before the design was manufactured.
The introduction of FEM has substantially decreased the time to take products from concept to the production line. It is primarily through improved initial prototype designs using FEM that testing and development have been accelerated.
Overall, the benefits of FEM included increased accuracy, enhanced design and better insight into critical design parameters, virtual prototyping, fewer hardware prototypes, a faster and less expensive design cycle, increased productivity, and increased revenue.