Wirtgen Group machines work with great performance on the new Samruddhi Expressway.

Wirtgen Group machines with great performance on Samruddhi Expressway

Connecting India – a mammoth task

The new Samruddhi Expressway, also known as Mumbai–Nagpur Expressway, is under construction at the moment and will connect the Indian cities of Mumbai and Nagpur on a total length of 701 km. When completed, this expressway will link India’s largest container port JNPT in Mumbai to MIHAN in Nagpur simplifying import and export activities throughout the country. Additionally, inter-connecting highways and feeder roads are constructed to connect all important cities and tourist places along this route.

The Samruddhi Expressway mahamarg project consists of 16 packages and was awarded to 13 companies: Megha Engineering & Infrastructures (Pkg-1&9), Afcons Infrastructure (Pkg-2&14), NCC (Pkg-3), PNC Infratech (Pkg-4), Sadbhav Engineering (Pkg-5), Apco Infratech (Pkg-6), Reliance Infrastructure (Pkg-7), Iron Triangle (Pkg-8), Larsen & Toubro (Pkg-10), Gayatri Projects (Pkg-11), Dilip Buildcon (Pkg-12), GVPR Engineers (Pkg-13), and Navayuga Engineering Company (Pkg-15&16).

Wirtgen slipform pavers show their potential all the way

With a speed limit of 150 km/h, the expressway is the fastest in all of India, reducing the travel time between Mumbai and Nagpur from 16 to 8 hours. This calls for maximum concrete paving performance both in terms of output and quality to ensure the drivers’ comfort and safety on their journey. Along the whole 701 km, 16 Wirtgen slipform pavers SP 1600 were in operation to lay the concrete surface. Concrete is the ideal material for a gigantic project like this: It is cost-effective, extremely durable and requires very little maintenance. Over a working width of 15 m, pavement quality concrete (PQC) in a depth of 310 mm was used. The proper reinforcement could be managed by an automatic dowel bar inserter and 3 longitudinal tie bar inserters. These make sure that the cracks which are invariably produced as a result of stresses and temperature fluctuations are diverted into the concrete pavement in a controlled manner.

Highlights of Wirtgen slipform paver SP 1600:

Working width of up to 16 meters (Special paving heights and widths up to 18.75 m are available on request.)
Cost-effectively paves concrete surfaces for traffic areas, roadways, industrial areas or surfaces at airports, such as runways or taxiways
Unparalleled concrete paving performance
Long-term reliability
Ergonomically designed, walkthrough operator’s platform for non-tiring, productive working
High-powered, fuel-efficient diesel engine for concrete paving in the optimum performance and torque ranges
Spreading plough for even distribution of the freshly delivered concrete in front of the inset paving mould
Electrically driven vibrators for reliable concrete compaction
Automated insertion of longitudinal joint tie bars to prevent the slabs from drifting apart
Inset paving mould suitable for mounting between the track units, underneath the machine
Pivoting legs for full adjustment of the track units to the conditions prevailing on site

Get an impression of the job site in our video

The Wirtgen Group’s machines are real team players

Whether machines from Wirtgen, Vögele, Hamm or Kleemann, they all have one thing in common: Wirtgen Group quality provides for top quality results. The Samruddhi Expressway construction site featured all of them to produce an even, high-quality surface that leaves nothing to be desired. A large fleet of Wirtgen Group machines has worked on this project actively since its roll out: Wirtgen slipform pavers SP 64, SP 94, SP 15, SP 500, SP 1200 and SP 1600 along with Hamm soil compactors 311, Hamm tandem rollers HD 99, Vögele asphalt pavers SUPER 1400, SUPER 1800-3, SUPER 1900-3 and SUPER 2100-3 as well as Kleemann screens and scalpers.

A true highlight: The complete PQC work of this Greenfield project of 701 km was done by Wirtgen slipform pavers SP 1600. In total, 16 of them worked on this expressway.

Kleemann screens and scalpers did the groundwork. They produced the aggregates.

Different models of Vögele pavers were responsable for the DLC (dry lean concrete) pavement on various sections including approach roads and toll areas. They laid a surface with a thickness of 150 mm.

Hamm tandem rollers ensured an even underground. They also compacted the shoulders on both sides of the expressway’s lanes.

The Wirtgen equipment was the last in line. The slipform pavers SP 1600 and SP 94 laid the concrete surface followed by a TCM 180 that added the finishing touches to the brand-new concrete lanes.

Wirtgen Group service impresses on site

When it comes to the experience and day-to-day handling of their equipment, there is unanimity: Everyone is more than happy with the performance of the machines. “They are doing very well and we are extremely satisfied with their services,” said Neeraj Sharma, Quality Incharge (Sr. Manager) at Apco Infratech Pvt. Ltd., responsible for package 5. “They are good in technology, quality and output.” Wirtgen India, the local subsidiary of the Wirtgen Group, is always at hand, should there be any customer requirements: “They always care for our needs and challenges. From time to time, they guide our team and help. Whenever challenges arise, they are always there.”

“The machines are doing very well and we are extremely satisfied with their services.”

Neeraj Sharma, Quality Incharge (Sr. Manager)
Apco Infratech Pvt. Ltd.

Facts and figures for the works of package 9 on the Samruddhi Expressway

Parameters

Length of the job site: 4 lanes on 54 km (section 9 of 16)
Used material: PQC (Wirtgen slipform pavers) |
DLC (Vögele pavers)
Working depths: 310 mm PQC |
150 mm DLC
Working widths: Wirtgen slipform pavers 15 m |
Vögele pavers up to 4.75 m

Machines

Wirtgen slipform pavers: 1 SP 1600 | 1 SP 94
Wirtgen texture curing machines: 2 TCM 180
Vögele pavers: 2 SUPER 1800-3
Hamm tandem rollers: 2 HD 99
Hamm soil compactors: 3 Hamm 311
Kleemann screens: 1 MS 703 EVO
Kleemann scalpers: 1 MS 800

Technology and environment go hand in hand

The motorway has a positive effect on fuel consumption and thus also on exhaust emissions and, in no small measure, on the costs incurred on the route. The NHAI expects an average daily traffic volume of 100,000 vehicles. Initially, the roadway will be widened to eight lanes, with four lanes in each direction. Looking ahead to the future, however, sufficient space has been set aside in the middle of the road to allow four additional lanes to be added. It is the first e-way in the country, with electric charging stations at every 40 to 50 km. And in total almost 3 million trees, plants and shrubs are planted alongside with geotagging on each tree and a drip irrigation facility turning the e-way into an advanced Greenfield expressway.