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ujarat was a part of the erstwhile Bombaystate during the British rule and also for morethan a decade after India attained freedom.

In 1960, owing to popular demand from the Gujarati-speaking population the state was split into twonew states - Gujarat and Maharashtra - effectiveMay 1, 1960.

In the initial days the economy of Gujarat wasdependent largely on agriculture and there was notmuch industrial activity to speak of. However, thestate’s policy planners brought about a balanceand set in motion the process of industrialisation.As a result many industries came up in and aroundAhmedabad, Vadodara, Surat and Rajkot, mostlyrelated to textiles and its auxiliaries.

Today the industrial base of Gujarat is not only welldiversified, but fairly uniformly spread across theState. Thanks largely to the pragmatic policies ofsuccessive governments and the enterprisingnature of its people, Gujarat has now a significantpresence in the manufacturing sector in thecountry. Gujarat is one of the most prosperousstates of India and is the largest producer of milk(18.97 million litres per day) in India with Amul atAnand being one of the largest milk producer co-operatives in the world. The state produces more

than 6 lakh tons of marine products per annum andits major agricultural produce include cotton,peanuts, dates, sugarcane, milk & milk products.Industrial products include textiles, cement, andpetrol. With 4,122 million kg production of rawcotton and 1,023 million kg of man-made fibres,Gujarat is the leader in textiles as well andaccounts for 20 percent of textile exports from India.

Industry

Between the 60’s and 90’s, Gujarat establisheditself as a leader in a variety of sectors -engineering, chemicals, petrochemicals. drugs &pharmaceuticals. dairy, cement and ceramics,gems & jewellery, apart from textiles. Post-liberalization(1994 -2002), the state’s Domestic

Jamnagar-Loni Pipeline Project

LPG Terminal, Dahej

Laying of water supply pipeline

Ahmedabad-Mehsana road

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Product rose at an average rate of 12.4% perannum in real terms.

Gujarat is the largest producer of salt and soda ashin the country. Surat in Gujarat is home to a thrivingdiamond trade and diamond cutting industry. AlangShip Recyling Yard, located 50 km southeast ofBhavnagar, on the Gulf of Khambhat, is the world’slargest ship breaking yard. Reliance PetroleumLimited has set up the world’s largest grassrootsrefinery at Jamnagar.

Oil & Gas

Gujarat is considered the oil & gas capital of Indiawith 54% share in onshore crude production and39% share in onshore natural gas. Chemicals andpetrochemicals have been the mainstay of industrialdevelopment and account for 60.3% of the state’stotal industrial production. It is one of the fastestgrowing sectors in the state’s economy.

With several new oil & gas exploration ventures, agas grid and two brand new liquefied natural gas(LNG) terminals in addition to the two terminalsalready existing at Hazira and Dahej, Gujarat pitchesitself as the petroleum hub of India. Several publicsector companies and private companies too haveannounced a slew of huge investments in the

sector. While Indian Oil Corporation (IOC) andReliance have established massive refineries atVadodara (5 MTPA) and Jamnagar (33 MTPA)respectively, Essar Oil is setting up a 12.5 MTPArefinery at Jamnagar. The Oil and Natural GasCorporation (ONGC) has also a large explorationpresence in the State.

The State government-owned Gujarat StatePetroleum Corporation (GSPC) has grown fromhumble beginnings to an emerging petroleum sectorgiant in just six years. Buoyed by the opening up ofthe oil exploration sector, GSPC has been highlysuccessful in its efforts to strike oil and gas. ToGSPC goes the credit for constructing India’s one

and only land-based drilling platform, in the Haziragas field in 1998, which produces 3.6 million metricstandard cubic metres per day (MMSCMD) of gas.GSPC has 21 fields or blocks in the country atpresent while its gas transportation subsidiary,Gujarat State Petronet Ltd (GSPL), is developing agas grid across the State to supply gas to variousindustrial clusters and individual customers.

Transportation Infrastructure

The state offers an excellent road and rail network,leading to wide spread urbanization. The total lengthof roads (excluding municipality roads) in the Stateexceeds 74000 km. Out of this the length of surfacedroads account for 70688 km (95.48 per cent) whileNational Highways and State Highways have ashare of 2362 km and 19180 km respectively.

There are eleven airports in Gujarat, the highest inIndia, including an international airport atAhmedabad. Gujarat is endowed with a third of thetotal coastline of India - 1,600 km - and has portsand port-related facilities. Some of the bestmaritime locations in the country are located in theGulf of Kutch and Khambhat. Gujarat boasts 41ports, the highest number for any State, whichhandle more than 20 per cent of India’s cargo. Theinstalled port infrastructure in the country standsat 140 million metric tonnes per annum (MMTPA)and the total cargo handled in 2004 was 90 MMTPA.

Adani Port Limited, Mundra (situated just 40 km fromKandla Port) is a joint venture between the AdaniGroup and the Gujarat government. This privatesector port is a star performer among efficiently

Treated effluent disposal pipeline, Dahej

Cement loading Jetty, Rajula

Gas sweetening unit, ONGC Hazira

Precast conveyors, RPL Jamnagar

Ethylene pipelines, RPL Hazira

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managed ports that can respond quickly to marketrequirements and offer the best deal to customers.When it comes to special economic zones in India,Gujarat again leads the way. The SEZ s provide aninternationally competitive environment for exportsand encouraging investment for generation ofeconomic activity, employment and technicalknowledge. The state has received proposals forsetting up 19 SEZs with a combined investment ofover US$ 1 billion.

Pharmaceuticals

Pharmaceuticals is another segment of industrywhere too Gujarat is a leader, accounting for 55%of the total Indian pharmaceutical production and23% of the country’s exports. Large pharmacompanies like Alembic, Torrent, Zydus, Cadilla,Claris Lifesciences, Sun Pharma, etc. not only havetheir production units in the State, but also carryout extensive R&D work. Gujarat’s biotech industryhas evolved because of a convergence of thetraditional industries thriving in the State.

Tourism

Of late, Gujarat has been pitching itself as not justan industrial hub, but also as an attractive touristdestination. The State is situated between the twogolden triangles of Delhi-Agra-Rajasthan andMumbai-Goa-Aurangabad. It boasts a host ofancient archeological sites, historic architecture,natural history, religious places, wildlife sanctuaries

and handicrafts centres. While prohibition seemsto be a deterrent to the growth of tourism in theState, it continues to attract a large number ofreligious tourists to the ancient temples of Dwarakaand Somnath and wildlife/animal lovers to the GirNational Park (the only habitation of the Asiaticlion), the Porbandar-Dwaraka coast (where whalesharks abound), sloth bear and wild ass sanctuaries,and several lakes that play host to a large numberof species of migratory birds.

IT & ITES Industry

It is a boom time for IT & ITES Industry in Gujarat,which has grown at CAGR of 28% during the lastfive years. Software exports registered a growthof 47% CAGR during the same period. TheGandhinagar-Ahmedabad Knowledge Corridor andVadodara are poised to become major ITdestinations with big developers setting up IT Parks.

L&T Technology Park, Baroda

L&T will be setting up a new facility - L&T TechnologyPark - at Baroda in a sprawling 112-acre area onthe Ahmedabad-Mumbai Highway that will entailan investment of Rs.500 cr. in infrastructure andbuildings over a five-year period. When fullyfunctional, the facility is expected to have around6,000 employees and will create indirectemployment to a large section of local populace.

Business-friendly environment and the incentivesprovided to entrepreneurs are accelerating the paceof industrialization in Gujarat that has become atruly vibrant state and is setting a benchmark forother states to follow.

Piping on racks, ONGC Hazira

LNG Terminal for Shell, Hazira

RPL Jetty, Hazira

MEG Plant, RPL Hazira

Gujarat Narmada water supply project

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oreseeing rapid industrial development inGujarat and the Government’s strategicinvestment initiatives, ECC opened a Regional

Office in Ahmedabad in 1996 to coordinate the entirespectrum of its construction activities in Gujarat.In course of time, the state of Rajasthan also wasbrought under the jurisdiction of Ahmedabad Region.Mr. S.C. Vakil was the first Regional Manager ofAhmedabad Region and was succeeded by Messrs.M.A. Radhakrishnan, P. Dasgupta and Mr. ArabindaGuha. Currently, the Region is headed by R.Chandrasekharan (RCS).

ECC has been playing an active role in the industrialand infrastructure development of Gujarat andRajasthan and today, it is in a commanding positionwith a sales turnover of Rs.1,168 cr. for the yearended March 31, 2006. The Region is likely toachieve an order booking of Rs.2,300 crore foryear 2006-07. Speaking to ECC Concord at hisoffice on the banks of river Sabarmati in Ahmedabad,RCS said that with a healthy order backlog, his

hands are full with multifarious activities andchallenging assignments. “Geographically, myoperations stretch beyond Gujarat and extends asfar as Jaisalmer in Rajasthan. A lot needs to bedone to fine-tune the systems and keep the wheelsof the region moving smoothly and dynamically.”With the nation poised for a giant economic leapand firmly set on the path to becoming a majorworld power, RCS is confident that AhmedabadRegion would contribute significantly to the country’sall-round development. With a staff strength of 93

in the Regional Office, depot and around 850 acrossvarious sites, Ahmedabad Region is executingseveral major projects. The three road packagessecured recently would do well and set a newbenchmark in the transportation infrastructure.ECC has done exceedingly well in some prestigiousprojects like the G.K. General Hospital in Bhuj,Sujalam Sufalam water supply, treated effluentdisposal works at Vilayat and Dahej for GIDC inthe Gulf of Khambhat (the world’s second worstrough tidal zone). In Rajasthan too, we continue tohave a strong presence with clients like HindustanZinc Limited giving us repeat orders. All thesehave helped enhance the reputation of L&T amonggovernment as well as private clients including thegeneral public.

At the time of the 2001 earthquake disaster as wellas during the severe floods of 2006 L&T, as aresponsible corporate citizen, readily came forwardand joined the Gujarat State Government in providingsuccour to the affected people. The Region hasdone exemplary work in earthquakereconstruction at Bhuj and flood relief operationsin Surat, and lent a helping hand in propagatingthe Swasthya Varta programme through distributionof educational material and donation of medicalequipment.

Mr. Chandrasekharan acknowledged thecontribution of his predecessors and thanked them

Sanghi Cements Gujarat

A bulk material handling plant

Gas sweetening unit, ONGC Hazira

Precasting yard for Gujarat schools

Region

Mr. R. Chandrasekharan, Regional Manager, Ahmedabad

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for laying a firm foundation for ECC’s operations inthe region and and building up a very good rapportand cordial relations with all customers. He alsothanked his colleagues in the Region and said, “Ilook forward to keeping the L&T flag flying high inAhmedabad Region and taking the organization togreater heights in line with Project Lakshya.”

Panorama of projects

ECC has made significant contribution to the industrialdevelopment of Gujarat and Rajasthan and hasexecuted many major projects for the core sectorindustries as well as private entrepreneurs. Someof the projects that ECC has executed in Gujaratinclude:

Fertilizers

IFFCO-Kandla; Gujarat State Fertilizer Corporation-Baroda; KRIBHCO-Hazira; and Gujarat NarmadaValley Fertilizer Company Limited at Narmadanagarin Bharuch.

Oil & Gas

Gujarat Refinery’s expansion project at Koyali,IOC’s Salaya-Viramgam-Rajkot-Koyali cross-country pipeline involving erection of equipment,fabrication and erec-tion of piping and tank farms,includ-ing electrical installation and instru-mentationworks; turnkey construction of the gas sweeteningpro-ject (Phase II) at Hazira for ONGC; Kandla–Bhatinda Pipleline; ONGC-Gandhar, Jamnagar-Lonigas pipeline for GAIL; IOCL terminal at Gulf ofKutch; Tapti offshore oil basin works for Enron Oiland Gas India; Essar oil refinery at Vadinar; LPGimport terminal at Pipavav for Bharat Shell Limted;

220 kV switchyard at Mehsana for ONGC; IOC’sGujarat Refinery at Baroda; Vadinar–Kandlapipeline for Petronet/IOC; LNG terminal for ShellInternational, UK; Sidhpur- Sanganer pipeline andthe world’s largest grassroot refinery for ReliancePetroleum at Jamnagar.

Petrochemicals

Gujarat Olefins project of Indian PetrochemicalsLimited, Baroda - erection of equipment, machinery,piping and steel structure, site assembly of columnsand Horton spheres; erection of equipment andpiping for the LDPE plant as well as electricalinstallation for the integrated off-site project andacrylate plant expansion project of IPCL, Baroda;petrochemical project (phase I & II) for Reliance atHazira.

Power

Power plants for Gujarat State Electricity Board atUkai, Dhuvaran, Gandhinagar, includingtransmission line tower works between Kawas andValthan; erection of 35m long, 530 t heavy isotopicexchange towers for the Heavy Water Project atBaroda; lignite based power plant at Surat forGujarat Industrial Power Corporation Limited;power plant for Tata Chemicals Limited atMithapur; combined cycle power plant of GACL,Dahej.

Metallurgical

Civil, mechanical, electrical installation andinstrumentation works for Essar’s sponge ironplant at Hazira including dismantling of the plantat Emden (Germany), shipping to India andinstallation and commissioning at Hazira; coppersmelter and air separation plant at Dahej forBirla Copper.

Industrial Projects

Mother Dairy Gandhinagar; cement plant ofCement Corporation of Gujarat Limited; L&TCement at Rajula (now Ultratech Cement); SanghiCements in the Rann of Kutch; nylon tyre cordplant at Udhana near Surat for Baroda RayonCorporation Limited; float glass factory of GujaratGuardian at Ankleshwar; the heavy engineeringworkshop of L&T at Hazira; Nirma linear alkylbenzene plant in Baroda; copper smelter cableprocessing shed of Standard Wire IndustriesLimited; and the R&D center for TorrentPharmaceuticals at Gandhinagar.

Transportation

The Second Narmada bridge at Zadeshwar nearBharuch; the Watrak bridge near Kheda village;Ahmedabad-Mehsana Tol l Road, Jaipur-Kishangarh Road Project and Rajkot-Jamnagar

ESSAR Sponge iron plant, Hazira

Toll plaza at SecondNarmada bridge, Zadeshwar

A precast school building

Jaipur-Kishangarh Expressway

Adani port

contd. on Page 10.......

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When the management felt the need to havea Regional Office in Ahmedabad in 1996, Iwas appointed the Regional Manager to lookafter ECC’s interests in the new-bornregion. However, I could not hold theposition for long as I was posted to RPL-Jamnagar as Task Force Leader in April1997. This was then ECC’s single biggestassignment in terms of scope of work andcontract value.

To begin with, the Regional Office startedfunctioning from L&T-Baroda and laterre loca ted to Ahmedabad (KarakkaBuilding), closer to Gandhinagar, the capitalof Gujarat.

However, foreseeing a bright future andhigh growth prospects and considering theneed to have a permanent establishmentwe moved to Sakar II on Ashram Roadwhere we rented the entire second floor.Not much later, we purchased the 9th and10th floors in the same building, from wherewe are operating our Regional Office, evennow.

Being centrally located, along the banks ofthe river Sabarmati, the Regional Office atSakar-II offers a congenial atmosphere forour staff. At the same time, a plot of landwas i den t i f i ed and purchased a tChacharwadi for establishing a depot tocarry out all warehouse operations.

It is a matter of pride for me that duringthe very first year of our setting up ABRO,we managed to secure some prestigiousorders such as the multipurpose jetties atMundra for Adani Port Limited, CementPlant structures for Sanghi Cements,Copper smelter for Birla Copper at Dahej,factory buildings for SWIL-Jagadia andNirma Chemicals including the second

Narmada bridge project executed on EPCbasis.

Focus on Gujarat

Gujarat was and continues to be the bestplace to do business in view of a veryfavourable investment climate that the stateprov ides and the h igh ra te o f GDP .Investments have been pouring in fromwithin the country and abroad, strengtheningthe state’s economy and creating moreemployment opportunities.

In addition, it has a well-developed infrastructureand many other locational advantages for settingup new businesses. Hence it makes sense forL&T to focus our efforts on Gujarat and create anew region to expand our activities.

People

L&T has a l a rge poo l o f t a len ted ,experienced and motivated professionals,who are its real strength in the currentcompet i t i ve scenar io . On ly very feworganizations offer the type of freedom andthe culture of caring that L&T-ites enjoy.Even though the attrition rate is somewhathigh today, I personally feel that resourcescan be bought but not talents.

I have a special attachment to L&T and Iconsider it one of the best companies towork for. I would also urge people not toleave L&T for pecuniary benefits but toserve the company on a long term basis forone’s own benefit and of the company aswell.

Warehouses at RPL Hazira

GSFC, Baroda

Ethylene storage tanks, RPL, Hazira

Resources can be bought but not talent - S.C. Vakil

They said it...

Mrs. & Mr. S. C. Vakil

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Hindustan Zinc Plant in Chittorgarh

Adani Port, Mundra

Voice of our ClientsVoice of our ClientsVoice of our ClientsVoice of our ClientsVoice of our Clients

I was inducted as Regional Manager from April-1996 till I was moved to my next assignment inApril-2002. During my tenure, the region executedprestigious orders like multipurpose jetties atMundra for Adani Ports, Jetty for Essar, SecondNarmada bridge, Ahmedabad-Mehsana roadproject, Rajkot-Jamnagar Road project, Watrakbridge, IOCL Baroda etc. Project wise, I wouldsay that IOCL Baroda was the best assignment Iexecuted during my tenure in the region. SimilarlyI feel that Adani Ports Limited and IOCL are verygood clients and I enjoyed a lot working with them.

From business perspective, Gujarat is the bestplace, as plenty of investment opportunities andinfrastructure development projects are comingup at a rapid pace. This means that L&T also willhave ample growth opportunities and it will have afair share in project execution.

Whatever said and done, L&T is a wonderfulorganization to work with. I loved working in L&T.

I like L&T culture very much. L&T People arewell mannered and they have a professionalapproach in dealing with things. The Company asa whole follows the guiding principles and valuesset forth by our founders Larsen and Toubro.

Infact those employees who left L&T, regrettedtheir decision later on. Nevertheless, many peopleare leaving L&T for money, just for money. But Ican assure that in L&T, one can have satisfiedlife, good approach, good technology, nice peopleand chances of quick growth. L&T has a highvalue and brand image, this is evident from thefact that even after my retirement, people aregiving me lot of respect, because I am an L&T-ite.

Young engineers should work hard and gain handson experience at site during the initial learningyears and this is the only way they can gainrespect in future.

Even after retirement, people respect mebecause I am an L&T-ite - M.A. Radhakrishnan

Mr. R. Chandrasekharan, Regional Manager, Ahmedabad (right) greetingMr. M. A. Radhakrishnan (left), former Regional Manager

Hindustan Zinc Limited

ccording to me, L&T is a highlyprofessional and result oriented

organization.

L&T is involved in the construction of HZL’sPhase-I & II projects in Rajasthan andcompleted the phase-I project ahead ofschedule, creating a world record in projectexecution. L&T’s excellent micro-planning,automated construction techniques coupledwith extremely good engineering made HZLcreate this new benchmark apart fromimplementing several cost effective solutions.

L&T employees are a dedicated team ofexcellent professionals. It has the capability tobuild large and complex infrastructure projectswith desired quality within the budgeted costand time.

Jeyakumar JanakrajSenior Vice President

HZL, Chanderiya Complex

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Adani port

find L&T to be a very systematic, organizedcompany, dedicated to the project on hand.

In safety compliance their systems are excellent,with an appreciable stress on creating safetyawareness through training programmes.Once a project is entrusted to L&T, the clientcan rest assured of timely completion as wellas good quality and safety standards. Theemployees are well mannered, technically soundand hardworking.

Debasis Mitra, Vice President (Marine)Mundra Port & SEZ, Ahmedabad

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Sujalam - Sufalam

have been associated with L&T inHathmati Guhai pipeline and Sujalam

Sufalam water supply projects, where progressand workmanship are excellent. Apart fromachieving the desired milestone L&T paysutmost attention to safety and quality duringproject execution.

At Sujalam Sufalam water supply project,L&T has been awarded 3 different packagesand this has considerably reduced our timeand efforts in co-ordination and monitoringof the project. L&T employees are adedicated team and they are very courteous indealing with every customer.

R. G. ChandvaniSuperintending Engineer, GWSSB

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Road Project; several jetties for importingcryogenic liquids for various clients and themultipurpose jetty at Adani Port and thebreakwater project for Shell at Hazira.

Water & Effluent Disposal

Sardar Sarovar canal-based Drinking Water Supplyproject in Amreli and Gandhinagar Districts includingthe Sidhpur & Sami Harij Regional Water SupplySchemes; sewerage network for Surat MunicipalCorporation; sea water intake and effluents disposalsystem for Gujarat Mineral DevelopmentCorporation in Kutch; conveying the treated effluentsfrom Dahej and Vilayat industries and disposingthem into the sea (Gulf of Khambat). The last-mentioned Dahej-Vilayat has the longest disposalpipeline in the country.

Critical Support

ECC has always risen to the occasion to assist thegovernment in times of crisis like earthquake, floods,etc. 600 prefabricated schools were built by ECCin different parts of the state when it was shakenby the devastating earthquake. It re-built the

government hospital at Bhuj and restored theheritage building of Alfred High School in Bhuj andworked closely with the Surat Municipality during thefloods of August 2006 to clear tons of slush and debris.

Rajasthan

Amongst many major projects executed byL&T in the state of Rajasthan, following are

sh in ing examples o f some h igh qua l i typrojects:

♦ Zinc smelter (Phase-I) at Chittorgarh inRajasthan for Hindustan Zinc Limited

♦ Six-lane road between Jaipur and Kishangarhon NH-8

♦ BPO building for GE Capital at Jaipur♦ 220/33 kV switchyard and 220 kV transmission

line for Enercon at Jaisalmer

Projects under execution

Currently the following projects are underexecution:♦♦♦♦♦ Vadodara-Bharuch Road Project on BOT basis♦ Palanpur-Swaroopganj Road Project on

Annuity basis♦ Jetty expansion for GAPL at Mundra♦ Mora-Vapi Pipe Line Project for GSPL♦ Anand-Rajkot Pipe Line Project for GSPL♦ 400 KV transmission line from Ratangarh to

Merta♦ NCD5 Water Supply scheme for GWSSB♦ RJ11 road project in Kota, Rajasthan♦ Zinc Smelter Plant (Phase-II) for Hindustan

Zinc at Chittorgarh, Rajasthan♦ Bisalpur-Jaipur water supply project in

Rajasthan♦ APDRP Projects in Rajasthan

K.SridharanCCD, ECC-HQ

Trestle piping for LNG terminal, Dahej

Petrochemical plant for RPL Hazira

Pipe laying for Anand Rajkot gas line RPL Jamnagar

Mother Dairy, Gandhinagar

....... contd. from Page 7

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ohinoor 2010 is an operational excellenceprogram initiated in June 2005 with theobjective of achieving a ROCE of 20%

and PBIT of 10% in ECC’s operations. Thescope of the Project was defined as DeliveringOperational Excellence in three focus areas(work streams) – Project Management ,Procurement and Assets, Subcontracting &Working Capital Management. After sevenmonths of detailed analysis, interviews, sitevisits, Idea Generation workshops and pilotsby the project team, a number of solutionthemes emerged across the three workstreams.

In February 2006 ECC embarked on theimplementat ion phase of Kohinoor 2010spanning 30 pilot projects across the sevenregions.

The two pi lot projects ident i f ied in theAhmedabad Region were the Vadodara-

Bharuch Road Project (R & R Business Unit)and the Jaipur-Bisalpur Water Supply Project(WET Business Unit). The approach of Kohinoor2010 in each region was to focus on theimplementation of the Project Managementsolution themes in the selected pilot projects,while solution themes of the other two works t reams (Procurement & Asse ts ,Subcon t rac t i ng & Work ing Cap i ta lManagement) were to be implemented acrossall applicable projects.

S ign i f i cant progress has been made inSubcontracting & Working Capital Managementsolution themes in the Ahmedabad Regionthrough use of standardized cost sheets toconduct fact-based negotiations. This themehas been implemented for key subcontractitems at the RJ 11 project and the Vadodara-Bharuch Road Project. Further, an interactivecost sheet workshop was conducted by theKohinoor team on July 19, 2006 to sharelearnings from cost sheet based negotiationand ex tend use o f cos t shee ts acrossBusiness Units in the Region. Another solutiontheme where good progress has been madeis use of furnace oil for heating bitumen in hotmix plants. This initiative is being implementedat all the three road projects in the Region(RJ 11, Vadodara-Bharuch and Swarupganj-Palanpur). Aggregate re-use, the process ofrecovering aggregate from existing pavementand using this in the production of freshasphalt pavement, is another high impact

initiative, and implementation of the same isbeing led by the Vadodara-Bharuch RoadProject team.

In the Procurement work s t ream, keyinitiatives taken up for implementation in theAhmedabad Region are use of high strengthsteel bars (Fe 415 to Fe 500) and use of re-bar couplers for mechanical splicing. Theseinitiatives are currently under implementationat the Vadodara-Bharuch and the Swarupganj-Palanpur road projects.

Another procurement initiative being rolled outacross the Region is use of fuel additives toreduce the fuel consumption of key assets(like DG sets, pavers, motor graders, cranes,etc.). Other key initiatives that the Kohinoorteam is currently working on are globalsourcing of HR coils for the Jaipur-BisalpurWater Supply Project and global sourcing ofbitumen for the Vadodara-Bharuch and theSwarupganj-Palanpur road Projects.

The key project management solution themesbeing implemented in the Vadodara- BharuchRoad Project are Execution Risk Management,Cross Functional Kickoff, Quantity Estimation& Survey and Execution Look-ahead Planning.Another key Project Management initiativetaken up for implementation at the Swarupganj-Palanpur Road Project is Wastage–Norms &Reduction for Diesel through the developmentof a robust diesel control tool.

Rs. 471 crore cheque being presented by Mr. Chandrashekhar Damle and Mr. Awadh Vashista (second and third from right)to Prime Minister Dr. Manmohan Singh and Mr. T.R. Baalu, Union Minister for shipping, Road Transport and Highways inconnection with Vadodara Bharuch Tollway Project, negative grant

Project Kohinoor 2010

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afety is of paramount importance to theconstruction industry as it employs a crosssection of workforce for different activities.

A safe work zone with proper systems andprocedure ensures a conducive atmosphere.Keeping the basic aim of “Zero Accident”, SafetyEngineering Dept. was established in 1996 inAhmedabad Region under the leadership of Mr.R. N. Tripathi (RSC), with the guidance of Mr. S.C. Vakil (RM) and Mr. R. K. Poddar (Head – SEDat HQ). Over the last ten years, the departmenthas spread i ts wings towards Health &Environment aspects and is now renamed asHealth Safety and Environment Department (HSE).Mr. A. K. Das, Regional Health Safety &Environment Manager is ably assisted by 27Safety professionals to meet the HSE challengesin the region.

Challenges

Most of the projects executed in Ahmedabadregion are cross-country in nature like water &gas pipel ines, roads, sewerage l ines,transmission line and APDRP. As the workprogress through rural areas, the workmen areprone to biological hazards (attack by animals,weather condition, local problems etc.). Sinceactivities are of temporary nature and change ofwork place happens more frequently, meetingHSE requirements in different areas is a verytough exercise and requires more involvementfor controlling and monitoring the workforce.Imparting safety education to the illiterate andunski l led workmen (having agriculturalbackground only) drawn from different villagesof Rajasthan and Gujurat is a challenging andarduous task. In addition to this is facilitating thenecessary resources and safety materials to theworking gang deployed at remote locations wherethe major constraints are transportation andcommunication. Coming under the belt of adverseclimate with extreme summer and winter,implementation of safety aspects during theseseasons becomes more difficult.

The challenges in managing safety were takenup with the sprit by dedicated team membersand handled carefully. This has resulted inachieving several accident free man-hours at

different project sites and convinced the clients aboutL&T’s high safety standards and priorities. Safety as away of life is imbibed among all staff at ABRO and thishas ensured the region to establish a safe workingculture and achieve targets on time.

Awards

“Safety Pays Dividend” – Listed are some of thesafety awards - Inter regional and national, bagged byABRO.

♦ American Society of Concrete Contractorsawarded ABRO the safety award twice during2001 and 2002 for safe practices

♦♦♦♦♦ ABRO was adjudged as the safest region forsuccessive years from 1999 to 2004

♦ Ahmedabad - Mehsana Road Project wasadjudged as the safest major job site for theyear 2001-2002

Safest medium jobsite trophy

GCP – Rajula – 1998-99JLPL – Spr. II – 1999-2000Watrak Bridge – 2000-2001Petronet LNG Terminal, Dahej – 2003-2004

Safest minor Jobsite Trophy

APL, Mundra – 1999-2000CII, Bhachau – 2002-03

Good HSE practices followed

In addition to implanting the regular system (ISO –9001 for HSE system) these following systems havebeen implemented at all sites in the Region.

♦ Integration of HSE system and requirement inwork methodology

♦ Job Safety Analysis (JSA)/Group Risk Analysis(GRA) for all the critical activities.

♦ HSE Induction for new staff at RO beforeposting at site

♦ Workmen screening and HSE Induction at jobsites

♦ HSE Training for all levels is ensured♦ Safety gang leader concept has been

implemented for better monitoring of HSEaspects

♦ Regular safety inspection by SPM/RPM/RHSEM at site

♦ Evaluation of HSE aspects by visiting officials.♦ Weekly balance points are escalated to RO if

not implemented at site♦ Implementation of “scaff-tag” system for

system formwork at site♦ Display of HSE rules at the entrance for visitors♦ Conducting regular health camp in labour colony♦ Conducting road safety awareness program

at villages and schools during the execution ofroad projects

♦ Use of mobile scaffolding for internal finishingwork of building jobs

♦ Inspection and certification of power drivenand heavy equipments before using inconstruction activities

♦ Display of work permit and safety precautionsto be taken in the work area

♦ Automated housekeeping in all major buildingsites

A.K. DasRegional Health Safety &

Environment Mangager

Safety programme for workmen at L&T Hazira

Health Safety and Environment

13

onstruction Skills Training Institute,Ahmedabad, is located in the Main Depotpremises of ABRO at Chacharwadi, 25 km

away from the Regional Office. It commencedfunctioning from October 15, 2005.

Strategic Objectives

♦ To have trained workforce in our job sites tomeet the growing requirement of skilledworkmen

♦ To test, ascertain the skill levels and certify♦ To fill perceptible gaps through appropriate

training♦ To enhance safety, quality and productivity♦ To develop Frontline Supervisors (Foremen and

Chargehands)

The Set-up

CSTI campus consists of three blocks in an area of2.8 acres. The Academic Block (size 21m x 6m)has two class rooms, one library and a store roomwhile the Administrative Block (size 15m x 6m) hasa display room and a staff room with utilities. TheHostel Block (size 33m x 9m) accommodates 60workmen and has a kitchen, dining room and toiletblock.

Training facility

Practice Yard (size 65m x 65 m) covers 4,225 Sqmarea and has mock-ups for various trades.

At present, basic training is imparted in the followingtrades:

♦ Formwork Carpentry♦ Bar Bending and Steel Fixing♦ Scaffolding

Candidates for individual trades are selected througha process of entrance test (written and practical)and viva-voce.

Training is being imparted in languages like Gujarati,Hindi, Bengali and Oriya, in addition to English.

Other trades like electrical wiremen, masonry,plumbing and sanitary, hot mix plant operator,grader operator, assistant carpenter, assistant barbender will be added in the near future.

Deployment

CSTI-trained workmen were deployed at varioussites♦ Sanskardham, Gandhinagar♦ RJ 11, Samrania♦ Hindustan Zinc, Chittorgarh♦ RPL, Jamnagar♦ HEW Heavy Fabrication Shop, Hazira

Site-based Training:

As part of overall training in all areas and to facilitateimplementation of proper work procedures andsystems to achieve high quality products in alloperational areas, newly inducted staff as well assubcontract-workers undergo site based training.They get the desired exposure to working methodswith a special emphasis on safety and quality.

Workers are recruited from villages in the vicinityof CSTI-Chacharwadi as also other parts of Gujaratand Dungarpur, Kota districts of Rajasthan. Peoplefrom UP, Bihar and Bengal also have startedattending the training programmes in search offuture gainful employment. Subsequent to thetraining, these workmen are deployed at ourproject sites.

L&T is conscious of its larger social obligations andis committed to the upgradation of common man.Towards meeting this end, CSTI plays a major rolein providing training to the unskilled and lessexperienced people to enhance their competencyand improve their quality of life. This helps theconstruction industry as well in getting a highlycompetent and capable workforce.

In its activities CSTI interfaces with the academiaand construction industry.

S.R. ShahCSTI, Ahmedabad

Trainees learning column shutter alignment

Trainees working at wood planer machine

Construction Skills Training Institute (CSTI)

Ahmedabad

14

urat faced one of its worst floods ever duringthe first fortnight of August 2006, leavingthe city completely inundated. The floods

left their mark on the city with deposits of acuteslush all over apart from damage to materials(including food grains), heavy loss of cattle andother domestic animals, causing untold miseryto the citizens.

When the deluge hit Surat on 07th August 2006,ECC had about 63 of its engineers in the city,most of them living with their families. In thetense 3-4 days that followed, when the surge inTapi River failed to recede due to the onset ofspring tide (Full Moon) in the Arabian Sea, allcommunication channels and means of transportbroke down completely.

The management at the Regional Office atAhmedabad was deeply concerned with thissudden turn of events, which put the staffmembers and their families at grave risk. Trueto the culture of caring and trust the organizationis known for, the Regional Manager sent a reliefteam which waded through waist-high water andprovided the affected staff and their families withnecessary food and potable water.

Subsequently, when the water receded leavingbehind a huge deposition of slush and animalcarcasses, the city faced an outbreak ofepidemics. In such a critical situation theGovernment of Gujarat (GoG) and Surat MunicipalCorporation (SMC) approached L&T and themanagement responded promptly in undertakingrelief work.

Surat Municipal Corporation entrusted reliefoperations on a stretch of 10 km to ECC. A team ofabout 35 engineers was urgently formed as per theinstructions of Mr. R. Chandrasekharan, RegionalManger, ABRO, who set the tone for the operationby leading the team himself to Surat. Mobilisationwas done overnight and on 13th August 2006, thework of clearing the affected areas commenced onthe earmarked roads. Later seeing the excellentprogress made by the L&T team, SMC handed overan entire ward for clearing operations consisting ofan additional 18 km of roads.

Bacgkround

The city of Surat is located on the banks of riverTapi and it has the Ukai Dam upstream. Duringthis monsoon season, unprecedented rains hit theupstream catchment area, resulting in heavy inflowof water into the dam and raising its level abovethe danger mark. In order to protect the damfrom damage and to prevent possible breach theauthorities concerned were constrained todischarge excess water into the river, as a resultof which, Surat city got inundated.

The situation deteriorated further as the release ofwater from the dam coupled with the high tide inthe sea made the water level in the sea rise to itshighest levels. As a result, the sea was unable totake any water from the river, leaving the waterstagnant in Surat and its vicinity.

The maximum discharge from the Ukai Dam was900,000 cusecs of water. During the flood, the lowlying areas of Surat were subjected to 10-20 ft ofstagnant water for a period of 3-4 days, whereasall the other areas got submerged under a columnof 4-8 ft. of water.

Nature of Work

The operation was directed at clearing up theaccumulated slush, waste materials (from thehouseholds and shops) and decaying food grains(dumped on the roads by the general public), so asto minimise the chances of outbreak of diseasesand epidemics and bring back a semblance of orderto the city.

The nature of relief work is different from theprojects we execute, since there are no specificguidelines or documents for execution of work. Infact, the work was taken up against verbalinstructions from the authorities concerned on aday-to-day and hour-to-hour basis.

Since the entire community was badly affected,though in varying degrees, there was tremendouspressure from all quarters on the authorities. Thissort of an operation needed to be executed withurgency and action initiated on a war footing. Inthis particular case, the plight of the people of Suratcan be understood if one considers the fact thateven the basic services like water supply, hygiene,medical facilities, telecom, electricity and other suchservices were paralysed and efforts were on bythe authorities to restore normalcy.

Like the general public, our relief operators toofaced health hazards as they were exposed to theaccumulated waste consisting of animal carcasses,slush, decaying food grains and apart from workingunder total wet conditions due to frequentintermittent rains. Hence, the work had to be carriedout with utmost caution and we took care to providethe right operator-kit, food and drinking water toevery member of the team.

Scope of Work

Initially L&T provided SMC and other departmentswith 4 excavators and 4 dumpers for the clearingoperations in various parts of the city. The equipmentwere utilized by the corporation to develop adumping yard at Katargam and for excavation workand burial of animal carcasses at Ugatgam nearPalanpur village on the outskirts of Surat amongother activities. This work at various locations inSurat continued till 21st August 2006. In these areasalso, L&T engineers assisted SMC in the supervisionof works.

However, the day after the floodwaters receded,on a request from GoG/SMC, L&T took up thecleaning operations with an additional fleet ofmachinery under their direct supervision. Thecorporation awarded the work to L&T in smallstretches, stage-wise, in the area of Randher Road,Anand Mahal road from Palanpur patia to Prime

Scraping work in progress at Anand Mahal

Surat Flood Relief Operations

A Mammoth Risk Management Project

15

Market totaling to about 10 km. The L&T team tookup this work with full energy and vigour andcompleted the same in a matter of three days,during which a lot of public support and goodwillwith the SMC officials was built up.

The general public was especially happy with L&T’swork and we were told that there was a lot ofpressure on the SMC from various quarters of thepopulation for deployment of L&T team in moreareas. After witnessing the fast and efficient paceof work, SMC awarded an additional scope ofapprox. 18 km, covering the internal roads in Adajanand Randher area under Palanpur Patia Ward.

At the end of the operations, L&T had executedclearing work to the extent of 28 km, lifting about25,000 ton of slush, garbage and debris. The liftedmaterial consisted of silt and clayey river slush,mud, polythene, jute, metal and wooden articles,household furniture, kitchen waste, rotten grocery,animal carcass, decaying food grains, damagedshop articles and many other assorted items.

Survey and Estimation

On being handed over the first stretch of roads, theinitial work comprised the survey of affected roads.Along with the SMC personnel deputed for thesurvey, a thorough reconnaissance was done forassessing the quantum of work to be carried outfor clearing and making the roads serviceable. Inmost cases, the roads were congested due toaccumulation of slush and also mass dumping ofwaste materials from the nearby shops, lanes, by-lanes and houses. Under these conditions, theprimary concern was to block the roads (one lanein the case of roads with divider and both to & frotraffic in all others) and divert the traffic to theadjacent lane or provide a bypass route. For ensuring

this, we took the assistance of police, prior tocommencement of work for blocking the traffic,which was carried out by our site engineers inclose coordination with the officials of SMC. Thesurvey for the roads to be cleared was carried outa day in advance based on the priority set by SMC,so that the next day’s work could be carried out infull swing smoothly.

The following points were considered in the survey:

♦ Traffic direction and possible diversion plan (inconsultation with local authorities and police)

♦ Quantum of waste materials and slush to bedisposed and resources required for totaldisposal

♦ Identification of utility services/obstructionsto muck removal

♦ Identification of shallow trees/utility lines whichcould pose a problem to smooth scraping andloading operations.

Another matter firmed up in advance was theidentification of suitable disposal yards for the largequantum of waste materials collected from theroads. Three such yards were earmarked by thecorporation in various parts of the city. Based onproximity from the location of clearing, quantum ofwaste to be handled and accessibility of the yard(some yards were inaccessible during wetconditions), the location of dumping yard for eachclearing location was finalized and accordingly,instructions passed on to the Section headconcerned.

In many cases, though the yards were identified inadvance, dumping got delayed due to incessantrains. In these cases also, SMC took prompt actionand constructed approach roads on priority to ensurethat the work progressed unhindered.

Resource Planning

Based on the quantum of work, resources werequickly mobilized both departmentally and throughsubcontractors. The resources included staff anddepartmental supervisors, plant & machinery, skilledworkmen like operators, drivers and mechanics,unskilled labour for scraping and such activities.These resources were augmented as and whenfresh scope of work was to be taken up.

Support Services

Once staff mobilization was made, action wasinitiated on the support services for enablingunhindered flow working in the affected areas. Thisincluded:

♦ Accommodation for staff and departmentalsupervisors in hotels

♦ Work in 10-hour shifts♦ Rented accommodation for workers in areas

close to the workspots.

It was also understood as a fact, that the skilledworkmen would be the key for successfulcompletion of the operation at hand. Hence, for theoperators, drivers and mechanics, rented make-shift accommodation was arranged close (about 3-5 km) to the work site within Surat, for the selectionof which, a great deal of effort was put in by theteam stationed at Surat to ensure that proper lodgingand clean lavatory facilities were available.

♦ Transportation arrangements for staff andworkers

♦ Catering services♦ Mobile diesel dispensing units to meet the

requirements of site vehicles and P&M items(Courtesy: SMC)

♦ Co-ordination between sites, Resources Dept.and Regional Office

Micro-Planning

Based on the priorities chalked out afterdiscussions with the senior officials of SMC, amacro plan was worked out, identifying thelocations of work and resources for each shift.At the clearing location, prior to start of eachshift, the concerned engineers drew up a microplan for deployment of resources, blocking oftraffic, selection of dumping yards and the routeto be taken by the dumpers.

P&M Mobilised

Based on the job requirement and the deadlinefixed by the corporation for the substantialcompletion of works, i.e. 21st August 2006, thefollowing resources were mobilised:

Hon'ble Minister Narottambhai T. Patel interacting with Mr. Senthil Raja

16

♦ Backhoe : 2 Nos♦ Loader cum backhoe : 18 Nos♦ Loaders : 2 Nos♦ Dumpers : 41 Nos♦ Bus : 1 No♦ Conveyance Vehicles : 10 Nos♦ Pickup Van : 2 Nos♦ Water Tanker : 1 No♦ Tempo : 1 No♦ Tractors : 2 Nos♦ Staff : 80 (30 working

and balance onrotation)

♦ Skilled Workmen : 160 Nos♦ Unskilled Workmen : 100 Nos

Work Methodology

The steps involved were as follows:♦ At the beginning of each shift, the engineers

give all workmen pep talks on the safety andhealth precautions to be taken during theoperation.

♦ Meanwhile, another team identifies the areasto be barricaded for controlling with the help ofpolice.

♦ The required resources like vehicles andequipment, already mobilized at the location,are provided with diesel through the mobilesdispensing units and kept ready to initiateoperations. Generally a relief operations unitconsisted of 4-5 loader-cum-backhoes and 16-20 tippers. Work was taken up simultaneouslyat 2-3 stretches.

♦ Dozing/ Scraping of the slush/muck wasundertaken using the loader end of the loadercum backhoe and heaps are collected atintervals of 50-100m.

♦ The waste material/slush so collected is liftedwith the help of excavators and loaded on thedumpers, which then carry it to the identifieddisposal yard.

♦ Once this activity is completed, the scrapingoperation is taken up to remove the stickymuck, first mechanically and then manuallywith hand scrapers. The waste so collected isagain disposed of in the manner explainedabove.

♦ After the end of night shift all the equipmentwere parked near the location where workwas to be taken up the next day.

Safety Health and Environment

A. Safety – The following safety precautionswere taken:

♦ A safety plan was prepared identifying thehazards, utilities and care to be exercised duringnight operations.

♦ Suitable safe distances were maintained whileworking in proximity to electric lines/cables

etc. Each stretch was manned by safetyengineers during the operation to oversee thesafety aspects.

♦ Pep talks were given to staff and workmen ineach shift, with specific attention to the carerequired for safeguarding one’s own personalsafety and health.

♦ Various personal protection devices like gloves,gumboots, etc. were provided to the staff andworkmen.

B. Health - Clean and hygienic food and waterwere provided at the messes and all work locations.A team of doctors were identified who could treatthe relief team members in case of need.

C. Environment - The key issue in theenvironment management of such operations is thelocation of suitable dumping yards, which was doneby the civic authorities. It was ensured that thewaste materials were dumped only at the designateddumping yards. The civic authorities carried out adisinfection exercise.

Risk Mitigation Steps

The major risks in the operations were as under:Health hazards to staff – These were neutralizedby :

♦ Reducing the number of working days perperson and operate by rotation after 3-4 days

♦ Providing hygienic living conditions♦ Providing hygienic food and water♦ Providing suitable gear for safe working

Health hazard to workmen – These wereneutralized by :

♦ Reducing exposure to the conditions by workingin limited hour shifts

♦ Providing hygienic accommodation andtransport

♦ Providing hygienic food through caterersoutside Surat and packaged mineral water.

♦ By giving adequate medical facility and care.♦ By providing suitable gear for work viz.

gumboots, gloves and masks.

Mr.T.E. Senthilraja was the Project Leader ofthe Flood Relief Operations. He was assisted bya core execution team lead by Mr. E.P. Sajit,Construction Manager-WET Bu, and wellcoordinated by Mr. S.H. Vora, SPM-TI sector.The execution team was from Mora Vapi pipelineproject, Vadodara Bharuch road project, AnandRajkot pipeline project and ABRO.

The execution support team which worked onrotation basis involved sub teams from Accounts& Administration, Plant & Machinery, Planning,Safety etc.

Demobilisation

Immediately on acknowledgement by theconcerned officials of Surat Municipal Corporationof the completion of the work allocated to L&T,demobilization was set in motion.

Most of the staff and workmen were withdrawnon August 21 itself. A skeleton team was retainedto attend to minor works that arose.

On 22nd August, the workers were called to theoffice and given a pep talk acknowledging theircontribution to the successful completion of theclearing operations. Further, each individual waspresented with a T-shirt by the management asa memento.

S.H. VoraSPM-TI Sector

Manual scraping of Surat road in progress

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s a part of L&T’s corporate socialresponsibility, ECC’s Construction Division inthe Ahmedabad Region has been rendering

an yeomen service to the Society. Various CSRactivities carried out by the region under the twobroad categories of Mother and Child Health Careand School Health.

On December 27, 2005, woolen blankets weredistributed to 50 female works at ECC’s AnandRajkot Pipeline project of GSPL. During 2006programmes were orgnised at various locationsunder the under the following categories:

♦ Health Check-up camps♦ Swasthya Varta♦ Child health programmes♦ Donations of medical equipment

Health Check-up Camps

On January 25, 2006, Health Check-up Camp forfor Mother & Children was conducted by ECC’ssite team at RJ – 11, Road Project Kota in thepremises of Anganwadi Kendra, BanshkhedaVillage, Rajasthan. Nearly 60 families from nearbyvillages availed the benefit of the programme.

On May 16, 2006 another Health Check-up Campwas organized for site-labourers at TorrentResearch Centre, Gandhinagar (Gujarat) site in co-ordination with Kanoriya Hospital. During this Campthe hospital distributed free medicines andsubsidised treatment to approximately 75 male andfemale workers.

Swasthya Varta

To spread awareness on health & hygiene andidentif ication of cl inical requirements, aprogramme called (SWASTHYA VARTA) wasorganised at two sites.

Nearly 70 women and girl children attended thecamp held at Chacharwadi Main Depot (SariVillage) near Ahmedabad on July 6 & 7, 2006 and60 women and girl children attended camporganized on July 23, 2006 at Torrent ResearchCentre site in Gandhinagar.

During this programme valuable tips andinformation were furnished to the participantson the following:♦ Health – physical health, psychological health

and hygiene♦ Physical and mental changes and ageing♦ Age for marriage and safe pregnancy♦ Pre & post natal care♦ Preparation for child birth & family planning♦ Nutrition

In addition, adequate information on child healthcare, immunization, nutritious food for children,identification of child diseases and services wereprovided and an awareness on good health wascreated amongst the children.

Programme for Children

In order to create and spread health awarenessamongst children, a special programme was orga-nized on July 17, 2006 at Anganwadi Centre-SariVillage near ECC Chacharwadi Depot, where 35 chil-dren were benefited from the programme. Topicscovered maintenance of self health & hygiene andnutritious diet. Medical equipment worth Rs. 75,000were donated by ECC’s site at Adani Port Mundrato eneral Hospital, Mundra on May 24, 2006.

School Health Programme

In addi t ion to the above ECC has beenorgan i z i ng severa l hea l th educa t i onprogrammes fo r Schoo l Ch i l d ren anddistributing educational materials freely forchildren in collaboration with the VillagePanchayat, Anganwadi Centre, Bal Mandir,Youth Groups, Community Centres etc.

Under the above programme near ly 50students (both boys & girls) picked up class 3

to class 7 were selected and trained as peereducators to train other students. Thisprogramme was assisted by two teacherseach from many school in the area. This eventtook place on three different days betweenJune and September 2006 at the GovernmentPrimary School, Sari Village near ChacharwadiMain Depot & Stores and at HUDCO PrimarySchool, Bhat Village near Torrent ResearchCentre on July 21, 2006. Out 100 studentparticipants about 50 students were trainedas peer educators.

Educational and stationery materials likenotebooks, compass box etc. were distributedto needy students who are below poverty linefrom 9 selected centers.

The Sarpanch of concerned village, PanchayatMember, Media Persons, Anganwadi Workersand villagers participated during the materialdistribution programmes and around 550students availed these benefit. The distributionwas done at the following sites:

♦ Chacharwadi Main Depot, Ahmedabad♦ RJ-11, Road Project, Kota (Rajasthan)♦ Torrent Research Centre, Gandhinagar♦ Mora Vapi Pipeline Job Site♦ Anand Rajkot Pipeline Job, Anand♦ HEW Hazira Site♦ APDRP, Tonk Site (Rajasthan)♦ Hindustan Zinc Ltd., Chittorgarh (Raj.)♦ Adani Port, Mundra

Action plans are initiated to carry theseprogrammes on wider and intense scale in2007 for the benefit of the society.

V.V. ChapekarRegional P&OD Manager

SWASTHYA VARTA - Awareness programme

18

CC Recreation Club, Ahmedabad, formedon 26th December 1998 is continually active,developing vibrant outlook, healthy culture

among all its members, their siblings andassociates working in the Regional Office and atnearby sites in Ahmedabad Region.

Under the leadership of the Regional Manager asthe President, the club provides sporting andrecreational facilities to all its members at work.The club is monetarily self-sustained by themembers with monthly easy to pocket but vitalcontribution from their salaries.

The club organizes participation in communitysocial gatherings, cultural events comprising ofsinging and dancing, talent programs, indoor andoutdoor sports events at various places ofrecreation in the Ahmedabad city which help instrengthening the bonds among all and also boostthe morale of the members within the region.

The club also takes part in cultural and sportscompetitions, debates and other recreation meetsorganized among various regional offices, sitesand head quarters thereby providing the staffand their families a broad platform to bring

forward their aspiring and creative talents andnurture the positive attitude of being together asone large L&T family.

Widening the horizons beyond the said activities,the club is also actively addressing social needsfor the betterment of the underprivileged,conducts in house blood donation camps once ayear, extends welfare hands for noble causesviz. distributing clothes, books and educationalstationeries, medical and monetary help to thepoor, etc. and is strongly committed towardsfulfilling the social responsibility towards thesociety.

The club organized a blood donation camp on 11th

of August 06 with voluntary help and supportfrom Red Cross, Ahmedabad, which was a grandsuccess.

In addit ion voluntary contributions fromassociates of ECC at Ahmedabad are welcomedby the club for contributing to social causes.

Adding more value in return to their vital supportfor the club, the club provides all its associatesan opportunity of wide exposure and introductionof their organization/agency with L&T’s widespread business center offices and sites, byplacing their organizat ion’s/agency’sadvertisements in the club SOUVENIR.

The SOUVENIR also encourages all the clubmembers and their families to express theircreative talents by publishing the articles, poems,quotes and drawings submitted with greatinterests and enthusiasm.

Blood donation camp in progress

Blood donors seen with the volunteers and support staff from Red Cross

19

&T Concrete, a ready mix concrete was firststarted in Bangalore in the year 1996. Since,then it has come a long way and has emerged

as largest producer of ready mix concrete in India.As per the policy of continuous growth andexpansion, L&T Concrete entered Ahmedabad cityin the year 2003. It started its commercial productionin November-2003 from its first plant at Changodar,on outskirts of Ahmedabad.

The local market was not ready to accept the readymix as a better substitute to site mix concrete asthere was many negative perceptions about theready mix concrete. L&T’s marketing team workedhard to educate people about advantages of L&TConcrete over their site mix concrete.

In last three years, L&T Concrete has seen a seachange in acceptance of ready mix concrete and

many new players entered the Ahmedabad marketfollowing L&T’s footsteps.

At present L&T has seven plants in Gujarat andRajasthan. Out of them 3 are in Ahmedabad, 2 inSurat and one plant each in Vadodara and Jaipur.

The L&T Concrete in Ahmedabad region is poisedfor growth with the cumulative production estimated

to cross 4.5 lacs cum, and there are plans to expandthe base in Vadodara, Rajkot, Udaipur next yearand also to many other cities in the state of Gujaratand Rajasthan in the coming years.

Ravi KhuranaRPM–RMC

Ready Mix Plant at Changadar

Ready Mix Plant at Gota

L&T Concrete

20

orrent Pharmaceuticals Limited (TPL) is oneof the leading Indian pharmaceuticalbusiness groups based in Ahmedabad. TPL

awarded L&T, the contract for constructing theirResearch Center Building – Phase II, AnimalHouse and Bio Evaluation Study Center at theexisting campus located at village Bhat inGandhinagar.

M/s VMS Engineering & Design Services (P)Limited, Ahmedabad, were nominated as theproject structural consultant and M/s MunjalBhatt, Ahmedabad were the architects. L&T’sscope of work involved construction of RCCfamed structure with trapezoidal foundation,tunnel works including all finishing works likeflooring, false-ceiling, Al. doors and windows,glazing, water proofing, painting etc.

Salient Features

The Research center bui lding structurecomprises of four stories with three differentblocks (Block A, B &C) and two core areas forconnecting the blocks, the total plinth area of

main building is around 3500 Sqm and floor area is16000 Sqm. The ancillary buildings of animal houseand bio-evaluation study center has a plinth area of1500 Sqm and floor area of 3500 Sqm.

The contract value more than doubled due to theintroduction of additional works and features suchas special sections for Al doors and windows,louvers, vitrified tile flooring, temporary animalhouse building, finishing works in ancillary building,special roof insulation material (vermiculite) for overdeck insulation, polycarbonate roofing andornamental teak wood railing for all staircases andcore area of entire building.

Construction Methods

Structures have been constructed using L&Tform work materials with the guidance ofCMPC and formwork team of region, Special

steel shutters were fabricated at site forexpose finish round columns of 600mm and900mm diameter. Flat slab of 400mm thickwas cast by using heavy duty H frame andsteel shutters. Vitrified tile flooring was donefor all office area; polished kota flooring andskirting is provided in the utility area andstaircases.

Over-deck insulation was carried out usinglightweight material of vermiculite upon whichBrick Bat Coba (BBC) waterproofing wascarried out. Above BBC, white china mosaicflooring was laid over the entire terrace areato reflect the heat.

Structural glazing, special type aluminumdoors, windows and louvers, ornamentalwooden hand railings with MS tubular supportgive an aesthetic look to the entire building.

Torrent Research Center - a landmark in Gandhinagar

The research wing where drugs are developed

Torrent Research Center (Phase-II),

Gandhinagar

21

Challenges

Since the project was located in the existingcampus, space was a constraint for the construction

activity. Hence no temporary structure was made;portable office and steel containers were availed toaccommodate the staff and materials. Ready MixConcrete was used for major pours and site

concrete production was kept at a minimum. Labourcolony was established outside the site premises.All finishing activities were planned in sequence toavoid blockage of stock yard (for example: flooringwork was started on completion of false-ceilingwork).

Being a research center, it was essential tocreate a dust free environment hence all floorand wall corners were made by epoxy covingwhich gave a smooth radius and a slippage tothe dust accumulation.

Temporary animal house (@ 300 Sqm) wasconstructed using aeriated cement board ofnon-asbestos grade (High density light weightcement board) with in a short span of 15 days.Following which all animals available in theexisting house were shifted and expansion ofexisting animal house was carried out within3 months.

Commencing in February 2005, the entire projectwas completed successfully by July 2006. The clienthas given a good appreciation for the quality ofwork executed.

Saurabh ShrirupConstruction Manager

One of the blocks of the research center

The finished view of a typical room before partitioning

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hmedabad is the largest city in the stateof Gujarat and the seventh largest urbanagglomeration in India, with a population

of almost 50 lakhs (5 mil l ions). The cityestablished itself as the home of a boomingtextile industry, which earned it the nickname“Manchester of the East”. A rising centre ofeducat ion , in format ion techno logy andscientific industries, Ahmedabad is the culturaland commercial heart of Gujarat. The needfor a quality health care facility was alwaysfelt as the people of Gujrat had to visitneighbouring states for medical facilities.

Apo l l o Hosp i ta l s , As ia ’ s mos t t rus tedhealthcare provider, envisioned setting up asuper specialty hospital for the people ofGujarat. With the backing of Government of

Gujarat and the allotment of land on theou tsk i r t s o f Ahmedabad , t he p ro jec tcommenced in 2000. Initially the job was sub-let to a local contractor who abandoned thetask leaving half built foundations.

At this critical juncture, in October 2000, L&Twas called upon to take up the project andwas awarded the construction of a world-class hospital. When the works were on infull swing, natural disaster struck in the formof earthquake on January 26, 2001. It wasthe worst earthquake ever in the area, whichchanged the lives of the people of Gujarat.Fortunately there were no causalities at siteand a l l were sa fe . The a f tershocks o fearthquake and psychological fear among theworkers resu l ted in work coming to astandstill with many personnel leaving the site.

However , w i th in a month ’ s t ime , t heworkforce was re-mobilized and the projectwork was resumed. The second setback tothe project was the communal riots duringFebruary 2002. Again L&T stood strong andcarried on with the work on hand. Finally thehospital was inaugurated on May 13, 2003.The Chief Minister appreciated L&T’s role increating a truly world class state-of-the-arthospital for the people of Gujarat.

The hospital is strategically located betweenAhmedabad and Gandh inagar , o f fer ingservices to the residents of both Cities. Thissuperspecialty hospital is a multi-facilityhospital with the latest equipment and gadgets.The hospital was designed for 350 beds witha provision to add another 50 beds. TheHospi ta l has one hel ipad, 10 operat iontheaters, 75 OPD rooms, 4 delivery rooms,cancer unit , and many other special izedfacilities.

Scope of Work

L&T’s scope included all civil, structural,architectural and finishing works, plumbingand sanitary works, fire fighting system,electrical works, internal services, internalRCC roads, parking lot for 300 cars includingspecial items like space frame, curtain walletc.

Salient Features

♦ 350-bed hospital with total 5 blocks (3blocks of ground + 4 storeys and 2 ofground + 6 storeys)

♦ Service blocks♦ Water body♦ 825 rooms with 249 toilets

Front view of Apollo Hospital, Ahmedabad

Akshaya Apollo Hospital Limited

Ahmedabad

23

♦ Flooring and tilecladding : 50,650 Sqm

♦ Painting : 1,20,560 Sqm♦ False ceiling works : 24,460 Sqm♦ Water proofing : 14,200 Sqm♦ Glazing works : 1,950 Sqm♦ Aluminum cladding : 1,350 Sqm♦ Polycarbonate skylight : 480 Sqm♦ Electrification works

Fire fighting works : 12.50 km

Major Equipments Deployed

♦ Tower crane : 1 No♦ 18 T cap Crane : 1 No♦ Concrete Mixer M/C : 6 Nos♦ Tough Rider : 1 No

Sukalyan RoySenior Engineer, B&F

♦ No of teak wood doors: 1261♦ Fully automatic fire fighting system♦ Presidential suites and deluxe rooms♦ Effluent treatment plants♦ Raw water storage and fire water storage

tanks and equipment♦ Electrical Works♦ Compound wall, internal RCC roads and

parking lots♦ Separate helipad slab on top of the building

Highlights of the Project

♦ Cost of the project : 2192 Lacs♦ Commencement Date : Oct 20, 2000♦ Completion Date : May31, 2003♦ Staff mobilized during

peak hours : 26♦ Workmen deployed

during peak hours : 600

Major Quantities

♦ Earth work in excavation : 65,500 Cum♦ Concrete : 13,800 Cum♦ Shuttering : 65,526 Sqm♦ Reinforcement : 1850 t

(top and bottom) Different views of the state-of-the-art Apollo Hospital, Ahmedabad

24

n the devastating earthquake that hit Gujarat onJanuary 26, 2001, G.K. General Hospital, Bhujwas so severely damaged that the then Prime

Minister decided to have it re-built and make it amultidisciplinary hospital. The re-constructioncontract, funded through the Prime Minister’sNational Relief Fund, was awarded to L&T on aturnkey basis.

The Prime Minister’s Office appointed M/s EFNRibeiro Associates (ERA), New Delhi as architectsand principal consultants for the project. The projectmanagement and financial management functionswere assigned to M/s National Dairy DevelopmentBoard, Anand.

ERA engaged sub-consultants for different disciplinesas listed below:

M/s. Ce-Con Engineers - Structural ConsultantM/s.M.K.G. Consultant - Public Health EngineeringM/s. Udayan Chaudhary - HVAC ServicesM/s. Service Consultants - Electrical ServicesM/s. Bhalla Ribeiro & Bhalla Associates - Landscapingworks

The total contract was awarded to L&T on a turnkeybasis and was to be executed in four packages. Thearchitect/consultant provided the basic conceptualdrawings and the detailed shop drawings weredeveloped by L&T.

♦ Package one comprising civil, landscaping,plumbing, sanitary, fire fighting and HVAC workswas awarded in October 2001 and was to becompleted by December 2002

♦ Package two comprising electrical and baseIsolators works commenced on January 2002and was to be completed by December 2002

♦ Package three comprised the construction ofancillary building which was awarded duringMay 2002 was scheduled for completion byMarch 2003

♦ Package four comprised medical equipmentsinstallation which commenced on August 2002and had to be in place by December 2002

Base Isolators: Since Bhuj is located in the highseismic activity zone, construction was planned tomake the building seismic proof. There are totallyfour floors including basement. Ceiling has been donewith pre-cast slabs. The ground floor and the floorsabove have been isolated from the basement bybase isolation technique. There are totally 178 leadrubber bearings installed on the columns and 101slider bearings installed along the periphery columns.Such type of base isolation is first of its kind in India.

HVAC System: The hospital is equipped witha centralized air conditioning system. The total

A/C load of the building is 617 TR. There are 2trane chillers of 300TR capacity each which workon vapour compression principle and 2 Thermaxmachines of 300 TR capacity each which workon vapour absorption principle. There are totally31 air handling units located in various floors ofthe building and 45 fan coil units for pay wardsand suites. Each operation theatre is providedwith a separate AHU.

Water Treatment Plant: A dual mediaactivated carbon filter of 40 cum flow capacityand a softener plant of 30 cum flow capacitytakes cares of the water services of the hospital.The main water source for the building is fromthe six bore wells erected around the campus.

Boiler: There are two steam boilers each ofcapacity 160 kg/hr out of which one is standbyand two hot water boilers each of 4,00,000 kcal/hr out of which one is standby.

Electrical services: The hospital has beenprovided with 3 HT panels & 75 LT panels & 8transformers. For emergency purpose it isprovided with 3 nos 1000KVA DG sets.

Medical Package: This package includes equipmentsof international repute. We have supplied and installed1 ct scanner, 2 X-ray machines, radiology instruments,colour Doppler’s, monitors, ophthalmology instruments.This package also include a full fledged kitchen andlaundry equipments. Totally 300 beds, surgicalinstruments were also supplied.

Finishing and Interior Works: The building hasbeen given a good finish with its front elevation having

GK General Hospital - a medical center of par excellence

GK General Hospital, Bhuj

25

Precast Yard: It was decided to construct allfloors and roof as structural and pre-cast slabswith steel frame. A precast yard of size 200mx20m was setup just behind the main hospitalbuilding, which was within the reach of towercranes for easy handling and erection of pre-cast planks. 120 moulds made of form floor ofsize 2400mmx1200mm of capacity were cast.Two curing tanks were made for curing the pre-cast slabs. One gantry crane of 20t capacity -span 20m was engaged for shifting of precastslabs to tank and painting area. In addition twotwo manual gantry of 3t capacity electric hoistwere used for de-moulding of moulds and placingof pre-cast slabs in cradles. A Batching plant of25 Cum/hr capacity was installed inside projectpremises near to the pre-cast yard.

Fabrication Yard: A 8 working platformfabrication yard was constructed for fabricating allstructural beams, girders and pre-cast slab angleframes. Around 1500 t of fabrication was completedwithin 4 months. Fabricated structural steelmaterials were stored in separate stack yard behindmain hospital building.

Power Supply: A 400-kVA temporary powersupply for four different locations inside projectpremises was obtained from Gujarat ElectricityBoard – Bhuj. One 250 kVA power generator wasused during construction. Permanent power supplywas obtained from project authorities on January2003.

Quality Control Methods: The projectmanagement appointed the QA engineer asmanagement representative for effectiveadministration of the quality systems during contractreview, design, document and data control, controlon customer supplied materials, materialidentification and traceability, process control,inspection and testing, calibration of equipments,control of non confirming products, corrective andpreventive action taken, control of qualityrecords,internal quality audits.

Safety Measures: Safety procedures werestringently implemented at all work zones in site.Safety meetings were conducted at differentwork areas of project to educate workmen onsafety awareness to all workmen and trainingalso given for working in height, Gas cutting,Grinding, etc., Safety appliances like safetyhelmets, safety belts for working in heights,scaffolding, ladders, etc provided to all workmenon free returnable basis.

Challenges

The earthquake and communal riots created asense of fear among the workmen. To overcomethe crisis, frequent pep talks were orgnaised, inaddition to this, workmen from other regions,skills training institute, Chennai were also mobilisedto meet the huge requirement of skilled workforce.

Fabrication of huge quantity of ducting was notpossible at site due to manpower and spaceconstraint. Hence semi-fabricated ducts wereordered and fabricated at Chikly, near Surat andthen transported to site.

Uniform motor thickness in AAC Blocks of 625 x 250 x150 mm was difficult to obtain and hence it was decidedto adopt square bar of 10mm x 10mm. AAC Blockswere not to be merged in water before use. Only thejointing surface was to be made wet. Since it waspractically not possible to wet only the jointing surface,a GI Tray of 10mm thick was provided so that theblocks were placed in the tray before being used intothe masonry.

Installation of base isolators to precise line and levelswas done through templates provided at both top andbottom portion and pockets made in RCC columns,subsequently grouted after alignment.

S. GunasekaranSPM-B&F

a structural glazing and the rest of the area finishedwith heritage painting in english green. The generalflooring is done with kota stones except for the ICUSand OTS departments which is with granite. The falseceiling is of armstrong type.

Salient features

♦ Earthquake resistant structure♦ Base Isolation Technique adopted for

Foundation for the first time in India♦ 300 Bed Hospital♦ Basement + Ground + 2 Storied Structure♦ Floor area for Main Hospital - 33800 Sqm♦ Plinth Area for Main Hospital - 8450 Sqm♦ Medical Equipments♦ HVAC System♦ Water Treatment Plants (Filtration & Softener

Plant)♦ Steam Boilers♦ Hot Water Generator♦ Sewage Treatment Plant♦ Fire Fighting (Sprinkler, Hydrant & Smoke

Detector)♦ 10 Passenger Lifts♦ Ancillary Building includes Nursing School,

Staff Quarters, Doctor’s Bungalow,Commercial Center, Staff & Nurses Hostel,Hospital Inn & DCMO Building

Major Contractual Schedules

Project awarded on Turn-Key basis♦ Date of Issue of LOI : 15.10.2001♦ Date of Commencement

of Work : 16.10.2001♦ Contractual Completion

(Main hospital) : 31.12.2002♦ Date of Completion

(Main hospital) : 31.03.2003♦ Completion of Ancillary : 31.08.2003

buildings

Project Logistics

Land Clearance: Since the project was to becompleted in a short duration, logistics planningwas a key feature. The land al lotted bygovernment had existing structures which hadto be demolished, after a feasible study some ofthe them which were in stable condition wereutilized temporarily for office, store, QA/QC lab,Cement Godown, site office, etc. till the basementroof was cast.

Labour Colony: The planned labour strength atpeak period was 2500 per day. So the labourcolony was made to accommodate the strengthof 2500 within the project campus for easy accessto the work spot. Area for labour colony wasprovided by client on free of cost, a Governmentland near to the project site.

View from the main entrance

26

n January 26, 2001 a major earthquakedevastated the state of Gujarat, India. Mostof the villages in the Bhuj, Anjar and Bhachau

districts were seriously affected in thecatastrophe. Alfred Boys High School, anheritage building in the Bhuj city that wasconstructed in the year 1870 was very badlyhit by the devastating earthquake. Built withstone masonry it is one of the monumentalbuildings and has a capacity to accommodatemore than 1200 students.

Being a heritage structure as well as aneducational institution of repute, utmostimportance was given for rehabilitating andretrofitting structure. Funds for meeting thereconstruction cost was met from The PrimeMinister’s National Relief Fund, New Delhi. L&Twas entrusted with the responsibility forrehabilitation and re-construction.

L&T executed the complete civil, structural andfinishing works including restoration works andpreserved the originality of this heritage building.The Architect/Consultants provided all the basicdrawings and the detailed shop drawings wereprepared by L&T in l ine with the tenderspecifications. The Prime Minister’s officeappointed EFN Ribeiro Associates, New Delhias Architects and CE-Con Engineers as StructuralConsultants.

Commencing the work in October 2003, ECCcompleted the entire civil and structural worksin three months and the finishing works includingrestoration operations in three months.

Scope of works

The scope of works involved civil, structural andfinishing works including restoration works inline with preserving heritage structures as wellas converting the building as an earthquakeresistant structure. Basically, this is a two-storybuilding, with a ground and first floors coveredwith Mangalore tile roof above the central hallsupported on wooden trusses. This involved atotal floor area of 1200 Sqm and plinth area ofabout 590 Sqm.

Project Execution

Site Clearance

The old building was strewen with a variety ofschool furniture dumped haphazardly (bothusable and damaged) and covered by debris dueto the earthquake. As a result of this the schoolwas operating under a pre fabricated structureand it was a hindrance for smooth operation ofsite activities. Therefore, in consultation withthe school authorities the entire operations ofschool was shifted to new premises.

Due to space constraints, initially, the availablepre fabricated school rooms were used for oursite office and store. Then two rooms in the groundfloor of the old damaged building were retrofittedfor our use.

Thus, site clearance and disposal of debris wasthe first activity to be carried out at site. Attimes walls and slabs weighing up to 500 kg usedto fall down. Hence, while removing debris fromthe bottom, scaffolding was used to arrest fallingobjects from top. A tractor with trolley wasused to dispose the debris.

Labour Colony

The labour strength at peak period was 150 perday. And the area for labour colony was providedby client, free of cost on a Government land closerto the GKGH project site. Also, the old labour colonyof GKGH Project was availed for Alfred School.

Structural Steel Fabrication

Since there was no adequate space available inthe school area for fabrication of structural steel,we availed the space in the GKGH area aftertaking permission from the hospital authorities.After completing 60% of fabrication, the samewas handed over to the hospital and theremaining fabrication works were shited to theschool area, in a phased manner as per theconstruction Program.

Construction Materials

Bulk materials for the construction l ikeaggregates and sand were sourced from adistance of 30 to 40 km. Cement and Steel weresourced from as far as 350 km. Temporarypower was obtained from GEB and a stand bypower generator was provided for supplyingemergency power. In addition, the site wasprovided with one 10/7 Cum. Concrete mixer, threewelding generators, electric winches/builder‘s

27

hoist, curing pumps etc.apart from sufficientnumber of lighting fixtures.

Dismatling and Restoration

The next in the sequence and the most critical taskwas to carefully dismantle the damaged portion ofbuilding. It was to be carried in such a way thatthere is no damage to the foundations and unaffectedportions of the building structures.

Staircase

Dismantling the staircase was the most difficulttask, as it was broken from the center and therewas no access to it. Hence, the dismantling of thiswas done in a sequential manner and restored itsoriginal shape. The stone staircase waist, landingslab and steps were then replaced with RCC.

The steps were cladded with Dholpur stone to looklike its original. The wrought iron grill wasreplaced with teak wood handrail restoring itsoriginal design.

Ground Floor Slab

Ground floor slab was protected from falling debrisusing sand bags. The existing slab was supportedusing Heavy Duty Tower staging to enable it towithstand excess load of falling objects. A specialmethod was used to remove only the damagedportion of 600mm thick stone masonry slab. Thesteel girders encased in the slab were supportedusing steel props and dismantling was done in asequential manner to avoid bending of girders.

To retain the original heritage shape, size and lookof the existing ground floor slab, it wasdecided to dismantle only seriously damagedportion of it and restore the balance portion byspecial repairing methods. Using 160 mm thickM30 grade RCC, matching was done at the bottomlevel and in the balance portion sand was filled tomaintain uniform thickness of 600 mm throughout.

First Floor Slab

First floor slab was repaired in the same manneras that of the ground floor slab. L&T scaffolding

system was used forsupporting the slabwherever required.Moreover, the debrisof first floor slab wasdirectly shifted to thetractor trolley usingchutes.

Stone MasonryWalls

Walls were dismantledin a special manner bynumbering individualstones and stacking themin order to avoid anymismatch during re-fixing.

ReinforcementAnchors

Framework of existingbuilding was required tobe strengthened toconvert it to an earthquakeresistant structure. RCCfootings were provided at inside of the building atthe corners and center of the room.

Then stone masonry pillars were provided withreinforcement anchors by drilling holes, andanchoring reinforcement rods using special sealant.These reinforcement rods were in turn attachedto additional RCC columns, cast and extended upto first floor roof.

These girders were extended from face of additionalRCC columns and columns were pierced throughthe ground floor roof by making openings. in it.

Precast Handrails

The old handrails in the parapet portion wasdamaged badly during earthquake. After retrievingone span of the handrail, a new RCC pre-casthandrail was constructed. Pre-cast elements werecast in such a way, that it was assembled manuallyat the desired locations.

Painting

The outside stone masonry wall was painted to itsoriginal look without the use of any available paintin the market. For this purpose, the original stonewas powdered and mixed with a colorless adhesiveadding adequate water to make the paint in linewith the original color of the stone. This was appliedafter cleaning the surface and a silicon coat wasapplied over the painting.

Top Floor Roof

Roof over the central hall at first floor wasconstructed using wooden trusses and Mangaloretiles. Special agencies were engaged by L&T forwaterproofing; recast hand railing and anti-termitetreatment works.

The job was very challenging in every respect as itwas unique and filled with several constraints. Asclasses were conducted in the adjacent premises,safety of workmen and safety of people were givenprime importance. A total 1.7 lakh man-hours werespent to execute the project with a peak strengthof 704 workmen and the entire project was executedwithout any accidents. On the whole it was awonderful experience to handle such unique pieceof execution.

S. DuttaConstruction Manager

28

&T has a modern, r iver front heavyengineering fabrication facility situatedon a 200-acre plot at Hazira near Surat

in Gujarat. Located on the banks of the riverTapi, this is connected by a navigation channelto the Arabian Sea and is equipped with aload-out quay, covered fabrication shopsextending over over 34,500 Sqm and openfabrication yard of around 2.0 lakh Sqm tomanufacture extra-large and very heavyequipment for power projects, chemical,re f i nery , pe t rochemica l and fe r t i l i se rindustries, oil exploration, and marine relatedsectors.

The fabrication activities are complemented by well-equipped machine shops with sophisticated CNCvertical and horizontal boring machines which arecapable of handling equipments as large as12,000mm diameter and 250 to more than 1000 t inweight.

With the help of the load out facility at Hazira, L&Tis capable of navigating large dimensional vesselsand other equipment for a wide variety o fcustomers in India as well as abroad. Forloading out these heavy equipment, ECC hasconstructed a jetty and the extension of thesame is now in progress.

In order to meet the increasing demand infabr icat ion of heavy equipment , L&T isexpanding its manufacturing shops. As manyas six shops are under construction at Haziraand Gherzi Eastern Limited, Mumbai are theStructural Consultants for fabrication shopsHFS – V & VI, PPS & PFS – II. For the QA –QC building Ashok Desai, Architect & Plannerare the Arch i tec ts and Technocra tConsu l tan ts , Sura t a re the S t ruc tu ra lConsultants. Recently HFS IV and the Sub-Assembly Shop were completed by ECC andhanded over to HEW.

Expansion in progress for Fabrication Shop at Hazira

S.No Features HFS IV & V HFS VI PPS II PFS II

1 Height of structureRafter Top Level (in m) 28.085 32.786 28.149 28.149Monitor Top Level(in m) 32.502 36.203 31.566 31.566

2. Areas in (Sqm) 6850 6850 4800 1656

Dimensional features of structures under construction

29

Features of various structures under construction

No Items of works UOM HFS IV HFS V HFS VI PPS & Sub –PFS II Assembly

Shop

1. Precast piles Nos 360 521 401 493 2252 Gutter casting

and erection Nos 50 50 25 25 -3. Rafter casting

and erection Nos 52 52 52 50 -4. Monitor casting

and erection Nos 26 26 26 25 -5. Purlins casting

and erection Nos 550 525 550 506 -6. Gantry girder

Casting and erection Nos 80 80 40 42 -7. Excavation Cum 3660 3700 3800 3000 9508. Rubble Soling Sqm 6215 6215 6215 4500 59229. Tremix Flooring work Sqm 6215 6215 6215 4500 545010. Concrete Cum 5660 8472 6500 5250 119011. Formwork Sqm 27800 31000 28500 26000 505012. Reinforcement work MT 925 1464 1200 975 8413. Structural Fabrication

& Erection MT 510 510 510 475 59214. Galvalume & FRP (500

Sqm) sheet roofing Sqm 7500 7500 7500 6900 573815. Metacolour sheet

cladding Sqm 1000 1000 1000 1500 527016. North Light glazing Sqm 1370 1370 1370 1260 -17. Painting Sqm 12350 13630 12750 11500 14750

Scope of works

Construction involved composite works suchprecasting for pile foundations, precast elementsfor roof, structural fabrication and erection forgable ends, casting columns with slip form techniqueas well as flooring with Tremix technique. Thisinvolved innumerable activities like casting precastpiles, rafters, purlins, monitors, gantry girder forvarious capacity of cranes 50, 150/200, 500 t etc.,Pile driving, excavation, PCC / RCC for foundation,cast–in-situ columns.

Fabrication and erection of structural steel, erectionof precast members, roof cladding with Galvalumesheets, vertical cladding with Meta colour sheet,rail fixing for gantry, etc,. Tremix flooring work forheavy duty floor having capacity of 60 t per Sqmincluding construction of toilet block and minorfinishing works.

Looking at the massive work involved, the height ofthe structure and from our own past experience ofbuilding HFS III we had to change our methodologyof work for certain activities as follows:

♦ As against conventional methods we haveadopted the slip-form technique of continuousconstruction for concreting the columns. Threepairs of columns were concretedsimultaneously. Apart from drastically reducingthe requirement of man power and shutteringmaterial this resulted in speedier construction

♦ With modification in slip form assembly, wewere able to change the height of the Yoke toget better productivity

♦ We are managing erection activities using 150ton crane for (PPS II, HFS V) and 225 toncrane for (HFS VI) supported by one 75 toncapacity crane for jacketing of the rafter endsduring rafter erection in place of the AmericanHoist crane of higher capacity and tower cranefor purlins and monitor erection

♦ Ready mix concrete was procured from ECC’sIchhapur RMC plant, Surat, which minimizedthe inventory on equipment, material and extralabour for on-site mixing. Apart from gettingconsistent quality in concrete, this helped RMCto raise its market share in Surat during, initialstages of its establishment

♦ During construction of HFS V and VI, we hadto face severe space constraints. However,this has been sorted out with HED by occupyingnon-priority areas and removing some of theexisting structures to create required space

S. DuttaConstruction Manager

Panoramic view of L&T’s Heavy Engineering workshops at Hazira

30

he history of Surat (known earlier as“Suryapur”) dates back to 3000 B.C.Though a major port during the 15th century,

the real foundation for growth of Surat City waslaid during 1960’s with the expansion of diamondtrade and its gradual shift to zari, textiles andthe intensification of the modern oil and gasexploration activities.

However, Surat City once again shot in toprominence with the establishment of Hazirabased industrial area, which is in proximity toIndia’s major companies like ONGC, Reliance,Kribhco, Essar, L&T, Shell, etc..

L&T Hazira, the brainchild of Mr. A M Naik,Chairman & Managing Director, L&T is a moderncoastal heavy engineering complex, with a loadout quay on the banks of the river Tapi, close tothe Arabian Sea. It is wel l equipped tomanufacture extra-large and very heavyequipment for power projects, chemical,refinery, petrochemical and fertiliser industries,oil exploration, and marine related sectors. Andprovided with sophisticated facilities to ship theseequipment through sea to various destinationson a global scale.

As a part of the ambitious expansion programmeat L&T Hazira and in the words of our CMD toutilise ‘‘each and every inch of coastal area ofTapi’’ ECC, is executing two major marine projectsunder the Ports & Harbour Business Unit namely:(a) Main jetty Extension and (b) SlipwayConstruction.

Jetty Extension

In order to meet the expanding needs of themodular fabrication facility (MFF) at L&T Hazira,the existing main jetty is extended up to RO-ROJetty end. The construction programme whichinvolves a duration of 13 months, began in April2006, Shirish Patel & Associates are theConsultants. The salient features of this projectincludes:

♦ Extension of the jetty to 100 m in length and25m in width at the main Jetty side and 33mat RO-RO Jetty side

♦ Superstructure to rest on 750mm dia marinepiles, 1200mm dia contiguous piles and400mm dia filler piles. Boring Depth variesfrom CD (-)15.0 to CD (-) 22.5.m

♦ Superstructure is built up with 251 precastpile caps, 280 precast beams covered by850 precast deck slabs including 11 fendersand 7 bollards. Casting of the 600 mm thickdeck slab involved pouring 1900 Cum ofconcrete

♦ Piling involved 8102 rm of drilling, 6200 Cumof concrete, fabrication and supply 975 t ofliners, 900 t of reinforcement and 6720 rmof liner driving

To accomplish the entire construction target in13 months and drive piles in 10 months, 17 pilingwinches and 7 gantries each weighing 20-30thave been mobilized. In addition, three gantriesare deployed at Jetty end, three at Ro-Ro endand one at the location of filler pile. Three cranesof varying capacities such as 75, 45 and 11 tonsare also mobilized for this work.

We have completed around 220 piles, castingthe entire quantity of precast beams, pile capsand 650 precast deck slabs including erection ofmore than 25% of precast elements andconcreting more than 140 deck slabs till thebeginning of December 2006. This was achievedby 15 staff and 290 workmen engaged at thepeak.

The Exist ing jetty which is 55m longaccommodates a barge of size 100m long for

loading / unloading purposes. When theextension work is completed, it will help L&THazira to load /unload two barges of 75m lengthsimultaneously.

Slipway

The Construction of Slipway is one of the mostchallenging assignments and also it is a dreamcome true of our CMD. The slipway involvesconstruction of 320 numbers of 500mm dia piles,320 precast muffs and 80 precast track girders.The Slipway 80m long, 150m wide slopes downfrom CD +7.330 to CD +0.00. Half of thisstructure is on land and the other half is in water.The slipway will facilitate large size ships andvessels as a whole to slip down in to the waterover rails fixed on the track girder. However,the movement of the ship in the river will beparallel to the shore and not perpendicular to theshore.

After a long drawn deliberation and discussionon the type of construction method to be adopted,it was decided by all concerned to execute themarine piles using gantries. For this purposethree 70 ton gantries are mobilized includingaccessories. In addition, muff had to be erectedby making a localized sealed casings and carryingout all operations through specialized divingagencies.

The casing for precast muff was driven byvibrohammer. After erection of muff, precastgirders were placed by using 225 ton crane and450 ton capacity cranes from the land side.Weight of each precast girder varied from 14

Aerial view of Hazira jetty expansion

31

tons (6.5m to 7.5m long) to a maximum of 34tons (10m long).

Case driving using vibrohammer (2.0m dia and 15mlong), erection of precast muff and erection ofprecast track girder in the required accuracy ofline, level and slope, from the land side of marinearea is the most challenging task in this project;both from target point of view and safety point ofview.

In L&T’s map of Gujarat, however, the pride ofplace goes to the Hazira Works. In the early 1980s,the company’s leadership took a strategic decisionto set up heavy engineering facilities near Haziraon the banks of the river Tapi in south Gujarat. Thefacility is a part of the company’s heavy engineeringdivision, and is engaged in the design, engineeringand manufacture of plant and equipment for coresector industries such as cement and steel, nuclearpower, aerospace, oil and gas, petrochemicals andfertilizers.

L&T had acquired about 200 acres (80 hectares) ofwasteland at Mora village on the northern bank ofthe Tapi. Construction began in 1985, and productioncommenced in November 1987. Major expansionhas been carried out since then in two phases, in1992-93 and 1998-2000.

Today, Hazira Works has emerged as a world-class heavy engineering facility, supplying criticalhigh-tech plant and equipment to its customerslocated all over the world. It undertakes thecomplete design, engineering and manufacture ofheavy equipment such as reactors, pressurevessels, columns and towers. Hazira Worksspecialises in nuclear power plant components suchas endshields and steam generators, aerospace

equipment for the Indian Space ResearchOrganisation (ISRO), offshore platforms for oilexploration and special project equipment for entitiessuch as the Bhabha Atomic Research Centre (BARC)and the Defence Research and DevelopmentOrganisation (DRDO).

Unlike process industries, heavy engineering is alabour-intensive industry. Hazira Works directlyemploys 1,150 people. It also provides employmentto about 3,000 people through its variouscontractors. The company does not believe in hiringskilled labour from the markets but has evolved anelaborate in-house training programme for itsemployees drawn from nearby areas. The companytook special permission to train youth from Gujarat

under the scheme, and has imparted training toabout 1,400 youth from different districts. Out of635 workmen on the rolls of Hazira Works, 450 arefrom this in-house training scheme.

L&T follows the credo of thinking global and actinglocal. Accordingly, the company has been workingto get international recognition. Hazira Works is anISO 9001-2001 company. It was the first unit in thecountry to get accreditation to EHS (Environment,health and Safety) standards of ISO 14001 andOHSAS 18001. In April 2003, Hazira Worksorganised a comprehensive quality audit of itssystems by Det Norske Veritas of the Netherlandsagainst their quality protocol IQRS (InternationalQuality Rating System) and became the onlyorganisation in the country to be placed at Level 7.The efforts have paid off, and 60 per cent of thetotal sales of Hazira Works come from the highlycompetitive export markets. Hazira Works feels itcan take on the challenges of a global market andturn them into opportunities.

The company has represented to the Stategovernment that the Hazira seafront should bedeveloped into a full-fledged port for break bulkcargo with adequate loading facilities. At present,Shell is developing an LNG (liquefied natural gas)port at Hazira. L&T also feels that the GujaratMaritime Board should maintain adequate draughtin the river by periodic dredging of the channel sothat larger ships can dock at its jetties and atMagdalla port. As of now, Hazira Works has toship its equipment by barge to Mumbai port, fromwhere it is transhipped to larger ships. As L&Texpands its stature as an Indian multinational, HaziraWorks will have a greater role to play in the group’sactivities.

K.S.S. KumarConstruction ManagerNight view of river side work at Hazira jetty expansion

Work in progress at Hazira jetty expansion

32

nfrastructure is defined as the physicalframework of facilities through which goodsand services are provided to the public. Its

linkages to the economy are multiple and complex,because it affects production and consumptiondirectly and creates both positive and negative spillover effects apart from involving large inflow ofexpenditure. Good transportation systems serveas a lifeline to the development of a Nation. A goodroad network helps in the movement of people andgoods apart from developing agriculture, trade andcommerce, education, health, social welfare,cultural diversification and maintenance of law andorder and security.

The design, engineering, construction, development,finance, operation and maintenance of 76 km longPalanpur-Swaroopgunj highway on NH -14 passingthrough the states of Rajasthan and Gujarat is underexecution by L&T.

Construction of this road corridor commences atPalanpur on km 340.000 and ends at km 264.000on NH -14. The initial 34 km stretch of the projectfrom Palanpur (km 340.000) to Amirgarh (km306.600) falls within the state of Gujarat and theremaining stretch of 42 km spreads in to Rajasthan.The highway passes through some of the importantdistricts like Banaskantha in Gujarat and Sirohi,Udaipur in Rajasthan.

Some of the national and state highways substantiallyaffect travel characteristics of this road project.Among the National Highways, NH-8 and NH-15are most significant. NH -8 passes through Udaipurand intersects a section of NH -76 known as Udaipurbypass within the city of Udaipur. This stretch alsocarries heavy traffic from Mumbai and Ahmedabad,bound for Jaipur and other northern areas viaUdaipur.

NH-15 carries traffic from Kandla Port and leadsto Jaisalmer, Bikaner in Rajasthan and manyother northern parts of India. State Highway SH-27 carries traffic from Kandla, Deesa etc. andpasses through Sirohi. Palanpur is like aconfluence or a hub city, which meets SH-41,NH-14, and SH-55. SH-55 passes throughMehsana, Himmatnagar, and joins NH-8. Thus,SH-55 carries Udaipur bound traffic and this is

also an important highway. This apart, there areseveral other places of tourist attraction like theDelwara Temple, Mount Abu and Sun Temple on thesurrounding areas, which makes this highway, allthe more significant.

It was found during the survey that traffic originatingfrom Kandla/Gandidham destined to Uttar Pradesh/Northern states are using NH-14 up to Abu Road andfrom there, they use SH-27. This is to avoid ghatsections between Sirohi and Pindwara. It is also to benoted that the section of SH–27 between Deesa andSirohi is a toll road. From the survey it is inferred thatfor goods traffic originating from Kandla and destinedto Uttar Pradesh / North Eastern states, alternativeroute 3 i.e. via NH-14 and NH-76 is the shortest route.Also for the traffic originating from Kandla and destinedto Udaipur, the distance travelled via Palanpur (i.e.NH-14 & NH-76) and via Mehsana, Himmatnagar (SH-55) is about 550 km and 586 km respectively. Hence,there is a savings of 36 km.

Due to this savings in distance and by the willingnesssurvey conducted it is clear that about 9% of traffic onSH-27 whose origin/destination is either Kandla &Uttar Pradesh/North Eastern states and about 11%of traffic on SH-55 whose origin/destination is eitherKandla/Udaipur/Uttar Pradesh/North Eastern statesare willing to divert via Palanpur if the same is upgradedas a four lane divided carriageway. From this surveyit is clear that this indicated increase of 20% growth inthe traffic volume, making it highly viable for NHAI toaward this as an Annuity Project.

Thus, upgrading this highway will not only fuel economicgrowth but also provides for speedy and safe travelapart from reduction in accidents, diesel consumptionand wear and tear of the vehicles. Moreover, it willensure increase in comfort of the user and safety ofthe user.

As th i s h ighway passes th rough veryeconomically challenged areas of Rajasthanand Gujarat; right from its construction stage,till expiry of its operation and maintenancecontract, this will act as a growth engine forlocal employment.

There are many cement industries in thevicinity of this road project, such as RIICO,J .K . Cement , Laxmi Cement and B inan iCement e t c , who have i n f l uenced th i scorr idor . These industr ies wi l l a lso bebenefited to a great extent by virtue of fastermovement of the commodity.

Special Purpose Vehicle

This is L&T’s first annuity based road projectand this was bagged against internationalcompetitive bidding. L&T will design, engineer,finance, construct this 76 km long highway andmaintain it for a period of 17 years and six monthsthrough a special purpose company L&TInterstate Road Corridor Limited.

National Highway Authority of India are thepromoters. There are two consultants involvedin this project. ARRVEE Associates is assignedthe role of Independent Consultant reporting toNHAI and Scott Wilson Kirk Patrric is theSupervision Consultant. Since the design isprovided by L&T’s in-house team, the design isentrusted to M/s SECON.

Highlights

♦ Contract value : Rs. 550 Crores♦ Contractual

commencement : September 2006♦ Project duration : 30 Months

Palanpur - Swaroopgunj Annuity Road Project

Preparation of subgrade in progress

33

♦ Reinforced earth wallconstruction of more than64000 Sqm♦ Construction of roaddrainage system for 76km♦ Construction ofmedians, intersections andaccess arrangements♦ Construction of TollPlazas♦ Provision of roadsigns, markings andfurniture

Logistics of theProject

As this road project spans over two states,proper care will be taken and due diligence isbeing applied for the efficient operation of theentire system to ensure that every road useris highly benefited by utilizing the resourcesto the fullest capacity.

Innovative Techniques to be used

♦ Modified bitumen for the top layer of thepavement

♦ Precasting elements for the box culvertsand drains

Major P&M mobilized for theproject

♦ Hot Mix Plant : 2♦ Batching Plant : 2♦ Pug Mills : 3♦ Lime Kilns & Hydrated

Lime Plant : 6♦ Motor Grader : 9♦ Vibratory Roller : 16♦ Tandem Roller : 6♦ Asphalt Sensor Paver : 2♦ WMM Plant : 2♦ WMM Sensor Paver : 2♦ Pneumatic Tyre Roller : 2♦ Kerb Casting Machine : 2♦ Screening Plant : 1♦ Crushing Plant : 3

Mohit VermaProject Manager

B.S. RathorePlanning Manager

A compactor in action

Kerb casting in progress

Scope of work

♦ Site clearance including maintenance ofexisting road

♦ Traffic management and diversions♦ Widening of existing 2 lanes to 4 lane

highway with service road constructionon either side for 40km

♦ Construction of new flyovers, ROBs, bridgesand culverts

♦ Construction of under passes (14Nos)

34

ational Highways Authority of India(NHAI), under Ministry of Road Trans-port & Highways (MoRTH), is implement-

ing the construction of six laning of Vadodara-Bharuch road project on NH-8. This is apart of the ambitious National highway devel-opment programme (NHDP) of Governmentof India, connecting four metros of the coun-try. Considered as one of the major high-den-sity traffic highways in India, NH 8 connectsnational capital of Delhi and the financial hub

Mumbai.

Construction of this 84 km long project ofnational importance has been awarded to L&TVadodara-Bharuch Tollway Limited, a SpecialPurpose Veh i c le p romoted by L&TInfrastructure Development Projects Limited,with a negative grant of about Rs.450 crore(Rs.4500 million). The total construction costof the project is around Rs.750crore (Rs.7500million) and construction period is 30 months.The concession period including constructionperiod is 15 years.

The agreement was signed on July 12, 2006and the const ruc t ion commenced f romJanuary 2007 and is expected to be completedby March 2009 and the commercial operationswould commence thereafter.

Construction of this highway commences at108/700 km and ends at 192/000km, on NH-8 in the state of Gujarat. The highway whileconnecting the two cities of Vadodara andBharuch, passes through many semi urbancenters and intersects a number of statehighways, MDR (Major District Roads) andODR (Other District Roads) in these twodistricts. As a part of the continuous stretchof Ahmedabad-Vadodara expressway, thisserves as the main arterial road for the trafficemerging from eastern and western sides ofthe highway.

Moreover, it is one of the busiest highwaysof India and it has immense potential to attractincreasing traffic as it serves various industrialestates especial ly in Mumbai, Surat andAhmedabad and nearby areas. Upgradingthis section to 6 lanes will not only developthe main industrial and commercial hubsenroute but this will also give a direct boostto the economy and business as well as peoplein its neighbourhood. Apart from widening ofthe existing 83.3 km of 4 lane carriageway to 6lanes, the scope of work includes rehabilitationof the existing carriageway, widening andrenovation of 10 major bridges, 36 minorbridges and 70 culverts. Construction of 11new f l yovers , 20 new pedes t r i anunderpasses, 2 railway over bridges, 8 cattle

c ross ings , 1 veh i cu la r underpass ,improvements to 44 minor intersections. Inaddition, the scope also includes constructionof 8 m wide service roads 22 km (11 km oneach side) along with 11 bus bays, 21 busshelters, 2 truck lay byes, 2 rest areas, onetoll plaza and one base camp.

ECC, L&T’s Construction Division is executingthis project to the design of SAI, Ahmedabad,the Design consultants - Artifect ProjectsPr i va te L im i ted a re the i ndependen tconsu l tan ts appo in ted by NHAI fo rsupervision.

As a part of the contract L&T will also provideHighway Traffic Management System (HTMS),which consists of emergency communicationsystem, mobi le communicat ion system,variable message sign system, meteorologicaldata system, automatic traffic counter–cum-classifier system, CCTV surveillance system,power supply system to collect/disseminateinformation about the traffic and incidentmanagement and for the safety of the highwayusers.

For execution and logistic purpose, the projectis divided into four sections of 20 km each.Carrying out the entire construction activityamidst continuous and uninterrupted flow oftraffic is a major challenge in this project.For th i s purpose , an e labora te t ra f f i cmanagement p lan has been p reparedenvisaging the complete risks and problemsinvolved in traffic movements. The trafficmanagement plan prepared is expected to take

Six Laning of Vadodara-Bharuch BOT Road Project

Grading and watering in progress

35

care of total safety of all staff and workmenand minimize the accident rate to zero in spiteof the heavy traffic flow of speeding vehiclesplying along the work site. The safety planincludes providing proper barricades usingconcrete safety barriers along the road,installation of sufficient numbers of warningsigns and signals at entry and exit locations,bifurcation of the existing road traffic toservice roads and diversions etc. apart frommany other elaborate traffic managementsystems to take care of the safety of everyroad user and as well construction crews.

In order to meet the enormous quantum ofaggregates required for executing the project(27 lakh tons of aggregates and 13 lakh tons ofGranular Sub base), L&T has established three

quarry sites with crushing plants of differentcapacity with state of the art crushing technologies.The next challenge during construction is mobilizingapproximately 60000 tons of lime stone which isneeded for the construction of the stabilized sub-grade.

Major Plant and machinery required for theconstruction includes 3-Hot Mix Plants, 4 -Pugmills,3 -Batching plants, 1-Hume pipe Manufacturing Unit,2-Pre cast yards, two 35m long trailers for shiftingof the girders, two 100t Hydraulic Cranes, 20 EarthCompactors, 14-Motor Graders.

The massive scope of structural work demandsefficient and cost effective shuttering solutions,which is expected to be around 2.5lakh Sqm.L&T Formwork, with in house design and

sys tem componen ts wou ld meet th i srequirement.

During the course of construction specialattention will be devoted for safety and qualityassurance. In order to ach ieve th is aseparate quality plan has been prepared,giving details of work procedures, guidelinesto be followed for material management, sitequality control tests, etc.

This will ensure full-fledged compliance ofspecification and reduce the cost of re-works.To achieve highest standards in quality ofwork, a site lab is established with wellequipped testing machinery, instruments andtes t p rocedures to meet the qua l i t yrequirement.

In order to achieve various other objectivesof the company, diverse cost saving devices,techniques and methodology are proposed andthey will be implemented at the site. Some ofthese techniques include execution of RiskManagement , Con t rac ts Management ,Quantity Survey/Mark Number Concept, WBSbased integrated planning execution strategy,Earned Va lue Methodo logy , Execu t i onPlanning, Modified JCR, Productivity Norms/Measurement , Was tage Norms/Measurement, Cost Sheet Based Negotiationsetc.The construction of the entire project isexpected to be completed well ahead of June2009.

Ravi PrakashProject Manager

K.V. MahadevPlanning ManagerCompaction in progress

Grading work in progress

36

undra Port is located in Navinal Island in theGulf of Kutch, Gujarat, on the west coast ofIndia. Currently the port has one multi-purpose

berth and a container terminal. Initially MundraPort proposed to develop a Dry Bulk Terminal butwith a view to meet the anticipated rise in traffic ofcontainer vessels, they decided to go in for ContainerTerminal #2 (CT 2) measuring 618 m long and and48.5 m wide.

M/s. Mundra Port and SEZ Ltd. awarded the designand construction of CT 2 to ECC amidst competitionfrom Simplex, AFCONS, Skanska, HCC, etc. Theexisting multi-purpose berth at this port wasconstructed by ECC in 1997.

The terminal is designed to facilitate berthing ofbulk carrier vessels varying from 150,000 dwt to10,000 dwt as well as container carriers of 8,000TEUs to 100 TEUs. The clients chose M/s. StupConsultants Ltd. as their consultants while ECCchose M/s, L&T Ramboll Consulting EngineersLimited.

The contract value of the project is Rs.46.25 cr.excluding cement, steel and berth fixtures like

fenders, CR 120 rails, etc. The projected is to becompleted in 19 months from 19th September, 2005and has one of the shortest duration considering itslong berthing face. However, the client has addedto ECC’s scope by extending the length of theterminal by 13 metres and revised the completiondate as 30th June, 2007.

The broad scope involved in this projectincludes:

♦ Construction of 475 bored-in-situ piles of diavarying from 1300mm to 1000mm to be drivenin marine mode method using piling gantries

♦ 95 nos. of 50m long transverse in-situ beamsintegrated with 6.5m long crane and rear enddeep beams

♦ 2,000 nos. of precast planks to be placedover in-situ beams

♦ 50,500 Cum of concrete♦ Placing rock in rock bund at rear of the berth

to a tune of 600,000 t♦ Placing of geo-textiles and sand filling to a

tune of 150,000 Cum behind rock bund fordevelopment of back-up area

Salient features of the project

Design

♦ The berth needed to be designed to followingberthing requirements:a) Bulk carrier vessels varying from

150,000 dwt to 10,000 dwtb) Container carriers ranging from

8,000 TEUs to 100 TEUs.♦ The draft required at berth face is -18.50 m for

which dredging is done by others.

♦ The berth deck is to be designed for an udl of3t/Sqm

♦ The back up area is to be designed for stackingof 5 loaded containers high and 6 emptycontainer high.

♦ The design life of berth is 50 years.♦ The total berth area is 29,530 Sqm

The client’s design proposal was for diaphragmwall construction for retaining weak soil mass behindthe berth. As the diaphragm proposal was found tobe expensive, ECC considered several options andproposed as follows:

♦ Strengthen the weak soil mass behind berth byway of dredging

♦ Protect the slopes with rock bund behind berth♦ Sand filling behind berth for back-up area

development♦ Tie the berth in transverse direction with SAIL

MA tie rods of 100mm dia between rear pileand dead-man anchor wall in sand filling area.

Construction Methodology

The job has been a challenging task as theconstruction is on marine waters having springtidal variation of 5m.♦ Two fronts were opened for operations – one

from middle of the berth and another from farend.

♦ The five grid piles were executed using onethree-pile gantry and one two pile gantry fromeach front.

♦ The in-situ cross beams trail the piling gantries.♦ Rock bund behind the berth will be placed by

end-on method using long excavators in pacewith the two-pile gantry’s speed

Construction of Container Terminal #2 at Mundra Port

Deck slab and marine piling works in progress

37

♦ Balance rock placement and profilingunderneath the berth was done by 75 t cranesfitted with 1 Cum orange peel rock grabs fromcompleted deck slab

♦ Once the above rock placement was completedthe pre-cast slab placement was done usingthe same crane, followed by 250mm thick in-situ deck slab

♦ Further marching of crane on the completeddeck slab was done after the in-situ slabconcrete attains M-20 strength which isachieved after 72 hours

♦ To avoid idling of work for 72 hours, the berthwidth was taken up in two halves

♦ Once rock bund was completed for substantiallength, geo-textile laying and sand filling wastaken up

♦ The dead-man anchor wall was done in partpre-cast and part in-situ mode. The pre-castpart was placed in the trenches followed by in-situ portion and tie rod fixed

Major Equipments Deployed

♦ Three-pile gantry with7.5 T winches : 2 Nos

♦ Two-pile gantry with7.5 T winches : 2 Nos

♦ 75 t crawler cranes : 2 Nos♦ 40 t hydraulic crane : 1 No♦ Concrete batching

plant 30 Cum/hr : 1 No♦ Concrete batching

plant 15 Cum/hr : 1 No

♦ Transit mixers6 cum/4 Cum : 4 Nos

♦ Concrete pump : 2 Nos♦ Long stick excavators : 2 Nos♦ 1 Cum Orange peel

rock grabs : 2 Nos♦ 6 cylinder boat : 1 No

Troubleshooting

♦ Initially the winches broke down at frequentintervals as they had not been in use for quitesome time. These were replaced with newones, after which the piling cycles stabilized at6-7days per bent

♦ Material feeding to gantries/fronts wascentralized by synchronizing/networking allresources, thus avoiding delays

♦ The height of the goosenecks was increasedby 1m resulting in a big ease in reinforcementcage handling, which gave rise to considerabletime reduction in cage lowering

Staff

The project team is led by Mr. A.K. Jayaprakashwith three section-in-charges, viz., piling, in-situ,and rock bund, and supporting staff. The total staffincluding accounts and administration is 33.

Awards

Client has awarded ECC a certificate for achieving1 million safe man hours.

Project Monitoring

The project is monitored on fortnightly basis usingMS Project and variance statements.

A. K. JayaprakashProject Manager

Deck slab work in progress

Central part of Jetty piling works in progress

38

CC executed a unique infrastructure project forGujarat Industrial Development Corporation atDahej to cater to the safe disposal of treated

effluent collected from various industries in Dahej &Vilayat Industrial Estates into the Gulf of KhambattValued at Rs. 176 crores, this is the first project ofits kind and perhaps the longest effluent disposalpipeline in the country.

Moreover, this involved several challenges like layinglarge diameter HDPE onshore pipeline ( 710mm &1000mm dia) and hydro testing the same in longstretches of 3-5 km length as well as laying 4.5kmlong marine pipeline, under huge tidal variations with

high currents in the Gulf of Khambatt (rated as secondhighest in the world for tidal currents).The basic infrastructure facility under constructioninvolved:♦ Pumping Station of 25 MLD capacity at Vilayat,

solely to cater to new industries, with fourEffluent Transfer Pumps (2W+2S) powered with135 KW induction motors for a discharge of 525Cum/hr

♦ 40 km of 710 mm dia HDPE pipeline for conveyingthe treated effluent from Vilayat to Dahej

♦ Pumping Station of 90MLD capacity at Dahej(including 25 MLD for future requirement), withfour Effluent Transfer Pumps (2W+2S) poweredwith 415 KW induction motors for a dischargeof 1875 Cum/hr

♦ 9 km of 1000mm dia HDPE pipeline for conveyingthe treated effluent from Dahej to landfall point(Starting point of the Long Sea Outfall)

♦ 4.5 km of marine pipeline for conveying thetreated effluent from landfall point to diffuserpoint in the Gulf of Khambatt

Salient Features

♦ Supply & installation of 40 km onshore HDPEpipeline with 641mm ID, 710mm OD - PE100.SDR21 PN 8, at 20° C, conforming to DIN8074:1999. Testing of the pipeline was done instretches exceeding 5.00 km in length

♦ Supply & installation of 9 km onshore HDPEpipeline with 922mm ID, 1000mm OD PE 100,SDR 26, PN 6.3 at 20° C, conforming to DIN8074: 1999. Testing of the pipeline was done instretches of 3.00 km length

♦ Laying of the critical 4.5 km ‘Long Sea Outfall’CS pipes of grade API 5L X60 comprising:

♦ 2700m of 1000mm ID CS pipe, 17.6mmthick with 12mm thick cement mortarlining, 2mm outside bitumen wrap and65mm thick concrete weight coating

♦ 1800 m of 1000mm ID CS pipe, 11.7mmthick with 12mm thick cement mortarlining, 2mm outside bitumen wrap and90mm thick concrete weight coating

Offshore pipeline laying in progress for the disposal of treated effluents from Vilayat to Gulf of Khambatt

39

Methodology for Long Sea Outfallexecution

Execution of the 4.5 km Long Sea Outfall was the mostcritical activity, especially due to the extraordinarilyhigh tidal variations and the enormous length ofthe Inter-tidal zone (2.0 km). The pipe for conveyingtreated effluent weighed 1.25 t/m in air against itssubmerged weight of approximately 135 kg/ m. Thepipeline was to be installed using the “Bottom Pull”method using pull force generated from a barge in thedeep sea.

However, the major problem was to take the pipelinethrough the inter-tidal zone, where the weight of thepipe increased 10 folds during the low tide, making the‘Bottom Pull’ process next to impossible sincecontinuous pulling was a necessity for countering thehigh currents.

To overcome this problem, an innovative scheme wasdeveloped, by which a 2. 70 km long railway trackfrom land, extending 1.75 km into the sea was speciallylaid for conveying the pipeline in the inter-tidal zone.

Structural system for the rail track involved driving640 marine piles and 2750 tons of structural fabricationand erection. This was made ready within a short timeof 4 months.

Specially designed saddles for carrying the pipe,mounted on bogies to run on the rail track, were shopfabricated, supplied and installed at site for use in theinter-tidal zone. The co-efficient of friction using thissystem was found to be within 1.5%.

The entire strings were kept ready in lengths of 500m-800m, at the stringing yard near the Landfall Point forsequential launching and pulling.

Using this pipe conveyance system, the pipeline wassequentially launched, with the pull generated using10t capacity winches and the pipeline taken toCh.1650m, from where our Offshore Partner, SSSSSMITInternational, Singapore took over the pipe pullingactivities using a 750t pull force capacity barge.

The main pipeline pull was completed as scheduled onMarch 3, 2004, to the entire satisfaction of the clientand consultants - Frischmann Prabhu, India Pvt. Ltd.

The system designed was so efficient that the ultimatepull experienced was only 250t against the anticipated600t. Probably, this is a breakthrough for systemsbeing used all over the world for marine pipelineinstallation, doing away with the requirement of highcost barges, with measured investments in theinfrastructure for pipe conveyance.

E.P. SajitConstruction Manager

G. BalasubramanianDesigns Manager (Civil)

Pipes entering deep sea

A Pumping station

40

nkleshwar is a major industrial town ofGujarat, situated on the bank of river Narmada.Many chemical, pharmaceutical and pigments

industries are located in nearby industrial zones ofAnkleshwar, Jhagadia and Panoli. All theseindustries were discahging their effluents into thenearby open drain (Amala khadi). To comply withthe orders of the Hon’ble Gujarat High court, itwas considered necessary to construct a FinalEffluent Treatment Plant (FETP) and pipeline throughwhich the effluents can be discharged into the seaabout 40 km away. This will protect the surroundingagricultural land and the open drain from pollution.

The site selected was near the Amala khadi whereeffluents from all the three industrial estates aredeposited. Raw effluents, once lifted, would passthrough different units by gravity flow before beingpumped into the sea. This is one of the biggestplants of its kind in India. A common Final EffluentTreatment Plant of 60MLD with two batteries (each

of 20 MLD Capacity) was constructed andcommissioned for its full capacity of 40 MLD.

The plant’s common facilities were designed for 60MLD capacity, providing for future expansion. Thefinal treatment consists of three levels - primary,secondary and tertiary. The effluents from threeindustrial estates are pumped into the inlet chamberof the plant. All interconnecting and pumping linesare of HDPE up to 900 mm diameter while all theequipment are of stainless steel to withstandcorrosive effect of the effluent.

The primary treatment system consists of unitslike equalization tanks for mixing effluent from thethree industrials estates to ensure homogenization.For mixing, 24 mixers (imported from Italy) areinstalled. Effluents are treated further forneutralization by lime slacker unit and its dosingsystem. Removal of solids is to be done in theclarifier, in preparation for secondary treatment.The sludge generated from clarifiers is thickenedthrough thickener and converted into sludge cakeby two centrifuges of 15 Cum per hour capacityeach, procured from Germany. The sludge cakestorage platform is provided for further drying anddispatch to a hazardous landfill area 15 km fromthe site.

The secondary treatment is an aerobic processthat entails an activated sludge system with extendedaeration and de-nitrification by anoxic process. Theaeration tank is divided into two batteries of 20MLD

flow, each consisting of three ponds in series havingtwo days retention time for aeration. A dedicatedintermediate tank with a retention time of 12hoursis provided for denitrification process. The air issupplied through eight 180HP twin lobe blowers tothe fine bubble diffusers in aeration tank. There areabout 9,000 silicon membrane diffusers importedfrom USA. The diffusers are fine bubble type forgood oxygen transfer efficiency of 35%. For onlinemaintenance, the diffusers are of retrieval typewhich can be removed from the tank withoutresorting to shutdown. For anoxic tanks there areeight aspirators (each of 22KW+3KW) providedfor the blower imported from Australia. The processof extended aeration is followed by biomassseparation in two secondary clarifiers, each of 55m dia. The sludge is re-circulated in the aerationtank and the excess to sludge thickener throughre-circulation pumps.

The tertiary treatment is a chemical coagulationand flocculation process to remove residualpollutants in conformity with the marine disposalstandards. Facilities are available to doze and storealum and lime. The tertiary clarifier for removal ofchemical sludge and thickener as well as twocentrifuges (20 Cum/hour capacity) are providedfor disposal of sludge. The final supernatant fromtertiary clarifier is discharged into guard pond ofone-day storage to check the marine standardsand provision for reprocessing of the effluent. Thetreated effluent is pumped through a 40-km-longonshore rising mains and 10 km inside the sea for

View of tertiary clarifier, thickener, guard pond, final sump and pump house for disposal to sea

41

final disposal as recommended bythe Gujarat Pollution ControlBoard.

The plant is equipped with an on-line SCADA system to monitortreatment parameters. A full-fledged laboratory is installed withatomic spectrophotometer(AAS203) and visiblespectrophotometer (UV2100)besides other analytical laboratoryinstruments. To check theincoming effluent parameteronline, TOC (Total Organic Carbon)analyzers along with a compositesampler are installed for all thethree streams. CCTV cameras areprovided at inlet chamber tomonitor the incoming effluentsright from the control room. Foruninterrupted operation of theplant two DG sets of 1275 kvacapacity are provided.

The clients for the project areBharuch Eco-Aqua InfrastructureLimited (BEAIL), a public limited company floatedjointly by industrial units in the Ankleshwar, Jhagadiaand Panoli along with GIDC. Multi MantechInternational Pvt Limited, Ahmedabad are the masterconsultants.

Total contract duration was 27 Months including 12months for operation and maintenance (O&M). Thefinal contract value stood at Rs.38.76 cr. The Plant

has been commissioned and the O&M part of thecontract will be in force up to November 30, 2007.Mr. Anupkumar V. Patel (Project Manger) took thelead role since beginning of the project for approvalof design and drawings, procurement of variousequipment, construction and commissioning of theplant. Mr. Sunil Kumar Singh (Planning Engineer)and Mr. S. Sarvanan (Acct & Admin) along with 12technical staff contributed to the successful

completion of the project. The major items of workinvolved in the construction of this plant are givenbelow:♦ Earth work excavation : 4,00,000 Cum♦ Disposal of surplus earth

up to 20 km radius : 1,75,000 Cum♦ Plain cement concrete : 6,000 Cum♦ Reinforced cement

concrete : 21,000 Cum♦ Corrosion resistant steel : 1,809 t♦ 3 mm thick FRP lining : 7,200 Sqm♦ Brick work : 3,200 Cum♦ Plaster : 27,000 Sqm♦ Piping network

(HDPE/PVC) : 11,500 Rmt

Construction of the Biological Reactor in the plantwas completed in December 2004 and taken up forhydro testing. During hydro testing, some leakageswere observed through the bottom slab from onecompartment to another.

Despite consultations with some experts, nosolution could be found for this problem. However,at the request of a Director of BEAIL, ECC took uprectification work as a challenge and successfullycompleted the job.

The Client appreciated ECC’s efforts for timelycompletion of Biological Reactor modification jobwith good quality and safety standards and awardedan incentive payment of Rs.15 lakh.

Anupkumar V. PatelProject Manager

Primary Treatment Units showing clarifier, thickner, neutralization tank, limeslaker unit, equalization pump house and chemical storage room

Mr. Anupkumar V. Patel, Project Manager, L&T (second from left), briefingMr. Narendra Modi Hon’ble Chief Minister of Gujarat on the effluent treatmentprocess during the inauguration of the plant

42

nder the ambitious Sujalam Sufalam Yojnavisualized by the Hon’ble Chief Minister ofGujarat, L&T bagged contracts worth Rs. 495

crores for laying 149 kms of bulk lines and 600 kmsof distribution lines. This scheme seeks to addressthe water problem in North Gujarat with aconcentration on drought-prone areas and also aimsto double the farmers’ income and improve therural economy of the Gujarat.

As a part of this project, L&T is executing about115 km of bulk lines of 2150 mm dia MS pipes toconnect Narmada Main Canal with Dharoi Dam,Hathmati and Guhai reservoirs. The scope alsoincludes 34 km of distribution pipelines of MS Pipe1600 mm-1750mm dia as extension work of canals.

L&T’s scope comprises works with♦ Gujarat Water Resources Development

Corporation Limited,♦ Narmada Water Resources, Water Supply

and Kalpasar Department (NWRWSKD)

♦ Gujarat Water Supply & Sewerage Board forthe Mehsana District Water Supply Scheme,which provides potable water to 239 villages

Modhera–Dharoi Pipeline(MDPL)

The Dharoi dam, constructed on river Sabarmati inMehsana District from 1972-78, caters to irrigationand potable water requirements of villages underMehsana and Sabarkantha districts of Gujarat. Inthe early days there was sufficient water in thedam to meet the total demand. Subsequentconstruction of water harvesting structures andstorage points limited the water supply to Dharoidam from the upstream catchment areas. Further,scanty and erratic rainfall ensured that the average

storage of Dharoi Dam from 1993 to 2003 was ameager 345.23 MCM against the total storage ofcapacity of 735.05 MCM (less than 45%).

The reduced availability of surface water resultedin alarming depletion of groundwater levels anddeterioration of water quality resulting in increaseof salinity, fluoride and nitrate levels. To augmentinflow of water to Dharoi dam, the Government ofGujarat decided to supply water from NarmadaMain Canal (NMC) for which it sanctioned 0.55 MAFTof water from Narmada. In North Gujarat, waterfrom the Narmada river flows through the NMC,which is a contour canal; hence flow/gravityirrigation is only possible to the left side of thecanal, whereas on the right side, the contour/elevations are higher than the NMC water level,

Dharoi dam

Trenching work under progress

43

making it unsuitable to be fed through gravity flow.To achieve this, three lift irrigation schemes areearmarked at different chainages of NMC. MDPLis one of these.

This project, valued at about Rs. 260 Crores,comprised supply and installation of pipes, valvesand allied civil works. Gujarat Water ResourcesDevelopment Corporation Limited (GWRDCL)monitored the execution of the project and the roleof the third party inspecting agency (TPI) wasentrusted by client with M/s SGS, Ahmedabad.

L&T’s scope involved manufacture, supply and layingof the 2150mm dia MS pipeline from Narmada WaterCanal to Dharoi dam through 88 Km of agriculturalland, strata varying from soft murrum to sandy viathe pumping stations located at Modhera, Motidauand Rasulpur. With the pumping stations scheduledfor completion by February 2007, the project isexpected to go on stream during March 2007.

Scope of Work

♦ Total Length of Pipeline : 88.75 km♦ Diameter : 2150 mm x 12

thick♦ Total Weight of Pipes : 60000 t♦ Outside Tape Coating : 6.07 lakh Sqm♦ Inside Epoxy Painting : 5.99 lakh Sqm♦ Excavation : 10-lakh Cum♦ Sand Bedding : 0. 8 lakh Cum♦ Backfilling : 6 lakhs Cum♦ 12mm thick HR coil

conforming to IS 10748 : 58000 t♦ Manufacturing and supply

of 2150mm dia ID pipewith inside epoxy paintingand outside coal tar taping: 88750 Rmt

♦ Supplying and Fixing of1800mm dia Butterfly Valve: 18 Nos

♦ Supplying and Fixing of300mm dia Scour Valve : 29 Nos

♦ Supplying and Fixing of200mm dia Air Valve : 299 Nos

♦ Fixing of 2150mm dia ZeroVelocity Valve : 9 Nos

♦ Fixing of 300mm dia AirCushion Valves : 29 Nos

E.P. SajitProject Manager

Narmada Main Canalpipeline to Guhai - HathmatiReservoirs

Narmada Water Resources DevelopmentScheme (NWRDS) contributes to Bhujwa and

Hathmati reservoirs and caters to therequirement of Guhai Dam. The project is locatedin the Sabarkantha district of North Gujarat andis being executed by the Narmada WaterResources, Water Supply & Kalpsar Department.M/s. Harmony Associates, Baroda, is the designconsultant, M/s. SGS India Pvt Ltd., is thenominated third party inspection agency.

L&T’s scope of work involved laying 64.45 km ofvarious diameters pipes (2174mm OD/1920mm,OD/1770mm OD/1614mm, OD/1214mm, OD/1164mm) from Talod pumping station from wherethe canal water is lifted and pumped after fillingvarious reservoirs enroute.

The pipeline is externally coated with coal tarwrapping of 2.5mm thick and internally lined with110 micron Epoxy comprising of spirally weldedSAW pipes.

The pipeline traverses through different terrainslike rocky, marshy, water logged, loose soil etc.Around 12 Km of the pipeline is laid under heavyground water conditions, 2 Km of the pipeline islaid across the Fatherpur reservior in waterstagnant conditions.

The pipeline crosses the Chiloda Udaipur NationalHighway no – 8, for which 2150mm of ID casingpipe is done beneath the highway. In additionthere is a railway crossing and Hatmathi maincanal crossing at two locations.The complexitiesinvolved arrangement of Right Of Works for thetransportation of huge pipes, pipe laying in waterlogged areas, executing the 19 major roadcrossings including one railway and NH. Meetingthe challenges head-on, the project teamcompleted the entire job with right planning andsupports from the departments and the regionaloffice. The site clocked 908779 safe man-hours.

Project Highlights

♦ Section - 2 : S S S Canal To Fathepur -14.867Km

♦ Section - 3 : Fathepur To Khed-20.773 KmFathepur To Bhujwa-8.750Km

♦ Section - 4 : Khed To Hathmati - 3.172 KmKhed To Guhai - 16.890 Km

♦ Total length : 64.452 Km

Quantum of work

MS Pipeline Length

♦ 2174mm OD x 12mm : 26027 Rmt♦ 1920mm OD x 10mm : 7440 Rmt♦ 1770mm OD x 10mm : 7953 Rmt♦ 1720mm OD x 10mm : 1660 Rmt♦ 1616mm OD x 8mm : 16890 Rmt♦ 1214mm OD x 7mm : 1310 Rmt♦ 1164mm OD x 7mm : 3172 Rmt

♦ Butter Fly Valves(1800/1500/1200)mm Dia : 10 Nos

♦ Scour Valves(300mm Dia) : 23 Nos

♦ Air Valves withIsolation Valves : 212 Nos

♦ Construction Of RCCValve Chambers : 54 Nos

Productivity ♦ Hard Rock Excavation

(Average) : 1500 Cum/day♦ Excavation (capacity) : 84 Cum per Hour♦ Crane : 4.2 Pipes per day♦ Pipe Laying per day : 62 Pipes (756 Rmt)

M.K. MishraConstruction Manager

Pipe installation work in progress

44

Mehsana District WaterSupply Scheme on DesignBuild Operate basis

The people of North Gujarat are dependent on deepbore wells for drinking and irrigation water supply.Due to extensive use of such bore wells coupledwith poor rain fall, the water table has gone downdrastically, in addition to high concentration ofFluoride in these areas.

To put an end this problem, the Government ofGujarat came out with the plan for the constructionof Narmada Main Canal Based Regional WaterSupply Scheme to provide potable water to 12 subgroups of Mehsana and Patan districts of Gujaratcovering 239 villages/habitations of Mehsana,Becharaji and Chanasma taluks. Under this schemewater is drawn from the Narmada Canal at villageModhera in Chanasama taluka and after filtrationand treatment, it is supplied to various towns andvillages by pumping main, gravity main andintermediate head works with sumps, ESRs andPump Houses.

The 12 areas covered under this scheme includeMehsana, Nanidau, Sametra, Jotana, Kherwa,

Ambliyasan, Modhera, Kalari, Pimpal, Lanva,Dharmodoa and Islampura. For this purpose, twofiltration plants are constructed – (a) at Modhera(45 mld capacity) located two km away and (b) atDediyasan (91 mld capacity) located about 25 kmaway from the tapping source.

ECC, L&T’s Construction Division executed thisproject for Gujarat Water Supply & Sewerage Boardand the work involved construction of pipelines,ESRs, underground RCC storage reservoirs/sumps, pump houses, water treatment plants etc..Certification Engineers International Limited,Mumbai were the Consultants for the project.

The work on the project began in March 2004 andthe entire work was completed in December 2006and it is now under Operation and Maintenance byECC for the next two years.

Apart from building two water treatment plants,the work involved construction of:

♦ 160 km of MS pipeline in dia ranging from322mm to 914 mm

♦ 40 km of DI pipeline in dia ranging from 300mm to 450 mm

♦ 490 km of PVC pipeline, dia ranging from 90mm to 315 mm

♦ 10 elevated storage Reservoirs of 5 lakh litreto 20 lakh litre capacity

♦ 58 sumps of 5 lakh litre to 20 lakh litre capacity♦ 4 intermediate pump houses

This also involved installation of pumps, valves,water hammers, water meters, pressure gaugesand associated civil works including supply,erection, testing and commissioning of electro-mechancial equipments for various services.

At peak of works ECC deployed 28 staff, 43 skilledand 280 unskilled workmen including five 8t capHydra cranes, one crawler type and three tyremounted excavators, two 40 kVA DG sets, eighteen10/7 Cum mixer machines and three 40 feet trailors.

The entire work was completed in December 2006and 200 out of 239 villages have been supplied withtreated water. Moreover, ECC has been entrustedwith the O&M contract for 24 months from January2007.

E.P. SajitConstruction Manager

View of Clariflocculator for Water Treatment Plant

45

ujarat is the leading onshore producer of crudeoil and natural gas in India contributing 17.9per cent of the total oil production and 10.4

per cent share in total gas production in the country.The major players in the upstream oil & gas sectorin the state include ONGC, GSPC, Niko Resources,Cairn and GAIL.

Currently, crude oil is transported from domesticoil fields and ports/jetties (for imported crude) tothe refineries, and oil products are transportedfrom refineries to the marketing networks, by rail,road and transmission pipelines. Understandably,pipelines are far more advantageous consideringthe fact that transportation cost accounts forroughly 25 per cent of the product cost.

Extensive network of gas pipe-lines

Gujarat State has an extensive network of gaspipelines. Gujarat State Petroleum CorporationLimited (GSPC) a vertically integrated energycompany set up in 1979 is a force to reckon with inthe sector with its wide range of hydrocarbonactivities. Gujarat State Petronet Limited (GSPL), asubsidiary of GSPC is a pioneer in developing energytransportation infrastructure and connecting naturalgas supply basins and LNG terminals to growingmarkets. In order to meet the increasing demandfor gas supply, GSPL is continuously expanding itspipeline network in Gujarat, connecting the demandcenters with various gas grids.

The gas grid project promoted by GSPL, envisagestransporting indigenously produced natural gas fromproduction centres and LNG terminals to demandcentres all over Gujarat through a high-pressuretrunk pipeline transmission project to deliver gasto end users and for local distribution.

Gujarat State Petronet Ltd, which owns the secondlargest gas transmission network in India afterGAIL India Ltd, is expanding its pipeline network inGujarat from 433 km at present to 742 km. Gujaratis the largest consumer of gas in the country,accounting for one-third of the national gasconsumption.

ECC, L&T’s Construction Division takes pride inhaving been associated with GSPL in laying andcommissioning more than 430 km of gastransmission pipelines at various sections in theState from Bhadbhut – Paguthan, Petronet Dahej,Paguthan – Baroda, Mora – Sajod operating in theHazira-Vadodara-Ahmedabad-Kalol area. And thesepipelines transports more than 13 MMSCMD of gascurrently, including more than 5 MMSCMD of R-LNG.

Out of the 742-km gas pipeline expansion plan ofGSPL, ECC has already constructed andcommissioned 542 km comprising of major sectionsof gas transmission pipelines from Anand-Rajkot,Mora-Vapi, on EPC basis.

Project Highlights

Following are some of the major pipeline projectsexecuted by ECC for GSPL

Anand-Rajkot

Engineering, procurement and construction of 123kmlong 24" dia x 11.1/14.3 mm thick API 5LX65 pipelinesystem from Anand to Rajkot, including HDD for 1river crossing, cathodic protection work, fiber opticcable network, sectionalizing valve stations includingassociated civil, mechanical, electrical andinstrumentation works and commissioning of theentire system on EPC basis.

Mora-Vapi

Engineering, Procurement and construction of 128km long 30" dia x 14.3/17.5/20.6 mm thick API 5LX65 pipeline system from Mora to Vapi, includingHDD for 12 river crossings, cathodic protectionwork, fiber optic cable network, sectioning valvestations including associated civil, mechanical,

electrical and instrumentations works andcommissioning of the entire system on EPC basis.

Mora-Sajod

Laying of 24" dia pipeline to a distance of 15 km forMora – Sajod section.

Paguthan-Baroda

EPC contract of residual process design, detailedengineering, procurement, construction,commissioning and mechanical guarantee includingtemporary/permanent cathodic protection system& OFC work for Paguthan – Baroda Gas Pipelineproject (24" dia x 80 km) including construction ofsectionalized valve station and river crossing byHDD works.

Petronet Dahej

Turnkey contract including residual engineering,procurement, laying of 24" dia 8.5 km long gaspipeline including TCP/PCP and OFC works alongwith metering station form Petronet Dahej to GujaratAlkali Limited of Gujarat State Petronet Limited.

Bhagbhut-Paguthan

Residual process design, detailed engineering,procurement, construction, commissioning of 24"dia pipeline x 24.88 km long and 12" dia pipeline x 5km long including installation of OFC and temporary/permanent cathodic production.

GAIL (India) Ltd

GAIL India Ltd. (earlier Gas Authority of India Ltd),India’s principal gas transmission and marketingcompany, was set up by the Government of Indiain August 1984 to create gas sector infrastructure

Anand-Rajkot Gas terminal

46

for sustained development of gas market in thecountry comprising of Jamnagar-Loni, Kalol-RamolPipeline Projects constructed and commissionedby ECC. Highlights of these projects include:

Kalol-Ramol

Laying of 40 km long 12" pipeline and compositeworks along with optic fiber cables and completedesign, engineering, supply, installation testing andcommissioning of receipt terminals, SV station forKalol–Ramol Pipeline project including civil,mechanical and associated works for the terminalstations at Kalol and Ramol terminals.

Jamnagar-Loni

Laying of LPG pipelines for a distance of 755 kmusing 16"/14"/12" dia pipes including optic fibercables and complete design, engineering, supply,installation testing and commissioning of receiptterminals, SV station for Jamnagar–Loni Pipeline(JLPL) project of Gas Authority of India Limited(GAIL). This also involved construction of terminal/intermediate pumping station at JamnagarSamakhiali, Abu Road, Ajmer and Loni including civil,mechanical and associated works for the terminalstations at Ajmer.

ECC Division undertakes turnkey & EPCconstruction of Oil & Gas, Refinery & Petro –chemical, Cross country pipelines projects coveringcivil, structural, piping, equipment, heavy lifts,electrical & instrumentation works. ECC has In-house design engineering capabilities for cross –country pipelines, terminals, offsite facilities,floating/fixed roof tanks, cooling towers/coolingwater system, electrical & instrumentation system,fire protection system, etc.

Oil & Gas Terminals and Cross-country Pipelines

♦ Execution of cross-country pipeline projectsinvolving laying including OFC, HorizontalDirectional Drilling, testing, pre-commissioningand commissioning of pipelines. Expertiseincludes design, engineering, procuremeantand construction of civil, mechanical, electricaland instrumentation for composite stationworks, cathodic protection system forpipelines/stations

♦ Construction of LNG terminals and LPG storagefacilities

♦ Design, procurement & construction andcommissioning of facilities for undergroundcavern storage system for LPG

♦ Erection of high capacity gas compressors andassociated facilities

Refineries and Petrochemicals

♦ Design and Construction of civil works, viz.cooling tower, equipment/pipe racksfoundation, sub station/control buildingsincluding geo technical studies

♦ Design, procurement & construction of the civilstructure for the plant

♦ Design, procurement & construction of storagetanks

♦ Design, procurement & construction ofelectrical systems, project electrification,control and automation systems

♦ Procurement & construction of fired heaters,structural and process plant piping includinginconel, hastalloy, titanium, etc.

♦ Procurement & construction of mounded bulletsand Horton-spheres

♦ Erection of static and rotary equipmentincluding heavy lifts of reactors, re-generators,columns, etc.

♦ Shutdown maintenance and revamping works

Rajiv KumarSPM – HCP

Control panel installed at the Anand-Rajkot gas terminal

Pipe laying work in progress

47

ndian Oil and its subsidiaries account for 47%petroleum products market share among publicsector oil companies, 41% national refining

capacity and 74% petroleum products pipelinecapacity.

The Company’s cross-country crude oil and productpipelines network spanning over 9,000 km meetsthe vital energy needs of the country. L&T hasplayed a vital role in developing major projects ofIOCL across the country and Gujarat in particular.Following are some projects executed by L&T forIOCL.

Koyali-Viramgam-Sidhpur-Sanganer Pipeline (KVSSPL)

The 249 km long Koyali-Viramgam-Sidhpurpetroleum product pipeline was extended with a518 km long pipeline of 18" dia from Sidhpur toSanganer connecting it with the Kot-Salawas branchpipeline at Kot and delivery facilities at Sanganerterminal. Apart from laying the pipeline, this involvedcathodic protection and civil, mechanical, electrical

and instrumentation works at stations en route. Thiswas commissioned by ECC in 2004.

Vadinar Kandla Pipeline Project

Installation, testing and pre-commissioning of 60 km24" dia on-shore product pipeline (API-5L Gr X-60)from Vadinar to Kandla, including composite works ofinter-mediate works involving civil, mechanical,

electrical and instrumentation works for PetronetV. K. Limited/IOCL.

Crude Oil Pipelines

Kandla-Bhatinda Pipeline (KBPL)

Commissioned in 1996, the 1443 km long Kandla-Bhatinda Pipeline, with a capacity of 8.8 MMTPA, pumpscrude oil from Mundra Port to the 12 MMTPA PanipatRefinery. It has recently been converted to crudeservice. It was a Petroleum Products Pipeline earlier,pumping petroleum products from Gujarat coast tothe heartland of Punjab.

Pertronet LNG, Dahej

Petronet LNG Ltd is a company promoted by fourhydrocarbon majors in India viz. IOCL, GAIL, ONGC,BPCL, Gaz de France, Ras Gas, GOG, and the restfrom banks and financial institutions to develop theinfrastructure required for imports to bridge thedemand-supply gap primarily through imports of LNG.

Petronet LNG Ltd constructed and commissioned in2004 India’s first LNG Terminal at Dahej, Gujarat of5MMTPA capacity. ECC executed construction andtesting of trestle & jetty area piping; terminal areapiping (30" cryogenic lines – 5.631 km & 56 km utilityand process pipelines of various diameters) andequipment erection for LNG Regassification Plant forPetronet LNG Limited at Dahej in 14 months.

Dhiraj GidwaniBU Co-ordinator, HCP

Petroleum Product Pipelines for IOCL

Reactor erection for FCCU shutdown work

A section of the FCCU

48

ujarat State Petronet Ltd. (GSPL) is currentlyimplementing a high-pressure pipeline projectcovering various industrial belts and cities of

Gujarat. Considering the importance of such apipeline network and realizing Gujarat's aim ofemerging as the 'Petro Capital' of the Country, theState Government has accorded 'InfrastructureProject' status to GSPL's project.

In a bid to establish a systematic, integrated andseamless infrastructure for gas transmission fromsupply points to various demand centers in thestate, GSPL has been laying underground gastransmission network across Gujarat.

At present around 742 Km of gas pipeline is underconstruction. The EPC contract for the 123Km long 24” Natural Gas Pipeline fromAnand (Gana) to Chuda, awarded to L&T, isthe first section (Section A)of the Anand-Rajkot pipeline laying programme of GSPL.

Project overview

The project envisages setting up of a high-pressurenatural gas pipeline system. The pipeline systembroadly consists of the following:

♦ ARPL is originating from the existingSectionalizing Valve Station No. 2 of Baroda-Ahmedabad-Kalol Pipeline (BAKPL) situated atGana Village of Anand District in Gujarat.

♦ The Pipeline will transport natural gas fromAnand to Rajkot for domestic, automobile,commercial and industrial consumers.

L&T's scope as an EPC contractor in this projectincludes design and detailed Engineering, supplyand laying of 123 Km pipeline, construction andinstallation of launching facilities at Gana, six nos.

of intermediate sectionalized valve stations and anintermediate pigging station at Chuda.

Peep hole

The Anand Rajkot Gas Pipeline Project Section A(ARPL-A) was awarded on 7th July 2005 with atight completion target of 13 months includingcommissioning and one-month operationalacceptance. This being a full-fledged high-pressurepipeline, all parameters right from procurement ofall specialized materials and equipment to delivery,execution including pipeline laying and HDD atSabarmati river, testing and commissioning of thepipeline needed to be meticulously planned andexecuted. With excellent coordination between sitemanagement, HCP BU at HQ, North Zonal andAhmedabad Regional Office, the project has seensmooth and steady progress till date, which hasearned profound appreciation of the client.

This project had set tough challenges for the SiteManagement which rose to the occasion by evolvingeffective strategies and implementing the same.Following are some of the strategies the siteadopted. This not only yielded the desired resultbut also resulted in achieving the targets as perschedule.

Strategies adopted

The contract required approved work proceduresfor almost all activities. Hence the first thing thesite did was to draw up procedures and submitthem to client for approval. This helped in obtaining

Trenching and laying of pipes

Welding in progress

The Anand - Rajkot Pipeline

49

approved procedures much before the actual startof job, which gave the frontline engineersenough time to study and understand theprocedures. This in turn guaranteed executionwith absolute conformity wi th contractspecifications and saved time and cost ofrework and repairs.

The approved procedures required 'procedurequalification'. This meant the sequence ofact iv i t ies for pre-and post-weld ing areperformed on actual mainline pipes and testedfor viability of the procedure.

However, the pipes were to reach site threemonths later. So, waiting till then meant ade lay o f a t least one week in s tar t o fproduction because actual job could be startedonly after Procedure Qualification.

To overcome this situation, the clients werepersuaded to arrange for a small quantity ofpipes immediately, on which we could carryout procedure qualification and return themat a later stage. Thus a lot of time was savedand procedure qualification obtained muchbefore arrival of mainline pipes.

The third and most important achievement waswelder selection and their qualification at site.The sub-contractors were called and instructedto mobilize welders immediately. On arrival ofwelders, they were interviewed and screened.The welder qualification activity followed

immediately and the site was ready with weldersbefore the mainline pipes arrived.

Similarly it was ensured that welding machinesand other equipment were received, inspectedand made ready before the mainline pipeswere received at site. All efforts were madefor early import of electrodes. Electrodequalification tests were also successfullycompleted before the mainline pipes arrived.

Unloading and stringing of pipes

It was decided that pipes be directly unloadedat site and stringing be done simultaneouslyduring unloading. Keeping in view the hundredsof trailer loads of pipes to be received, thistask needed c lose and met i cuo louscoordination between pipe manufacturer andthe frontline team.

To ensure accurate del ivery at desiredlocations, it was decided to depute one of oursenior personnel at the manufacturer's worksto coordinate with site and the transporter,to monitor progress and expedite third partyinspection.

As part of this effort, a meeting was held betweenthe manufacturer, the front line team and pipedelivery coordinator. This helped everyoneconcerned to clearly understand their role in theactivity and facilitated smooth delivery of pipesat site. The whole exercise was so well-planned

that the actual mainline welding started the verynext morning on receipt of the first pipe withzero loss of time.

Effective resource management

A project of this magnitude with an askingrate of 120 joints per day would generallyrequire mobilisation of ample resources.Keeping in view the limited resources allocatedto this project, a detai led and effect iveresource allocation was worked out at site.

Low-priced and easily available alternatives(12t Hydras ) to unava i lab le resources(Pipelayers/Tata320) were mobilised at sitefor stringing activities.

Similarly resources in other activities wereallocated in such a manner that the availabilityof equipment would help and complement thesmooth progress of work. This resulted inachieving 120 to 150 welded joints per day.

Quality assurance

The site management made it a policy to keepweld joint repair percentage below 2%. Toachieve this target, a strategy was establishedto analyse and find out the root causes ofrepair.

Once the root cause was found out, thef ron t l i ne eng ineers , sub -con t rac to rsupervisors and welders were given feedbackand advised of the preventive action to betaken to stop further recurrence of repair.

This was quite educative for the front lineteam and helped them achieve a repairpercentage of as low as 1.2%, which is oneof the most commendable achievements ofthe project.

ECC's success in the project proves that astrategy can work only when it is worked outwith a vision at the back of everyone's mind.The site team worked with diligence in turningthe strategies into concrete results.

The relentless efforts of the whole team withfirm commitment to achieve targets bothquantitatively and qualitatively have beencommendable.

V. ThirumalaisamyProject Manager

Dev Nandan DasPlanning EngineerComposite civil, mechanical, electrical and instrumentation works done at the gas

terminal

50

our Indian states, namely Jammu & Kashmir,Punjab, Rajasthan and Gujarat lie on India’sborder with Pakistan. Recently India started

fencing large sections of its border with Pakistanwhich is vulnerable to infiltrators and terrorists.The total length of India’s border with Pakistan is3310 km. Gujarat’s share in this is 512 km.

In view of reports of misuse of Gujarat border byanti-national elements, top priority was accordedto the work of erection of fencing on India-Pakistanborders with a view to contain infiltration, smugglingand other anti-India activities from across theborder. Border Security Force (BSF) is controllingand managing the entire operation of this fencingand flood lighting works.

No Man’s Land

In this no man’s land, L&T is entrusted withinstallation and stringing of 11kV HT Lines forGujarat Electricity Board (GEB). The workinvolves supply, erect ion, test ing &commissioning of 281 km of HT Lines consistingof 55 nos. of 100kVA distribution transformers,2300 tons of galvanized RSJ girders, 450 km ofACSR Panther Conductor, 400 km of ACSR Dogconductor, 3920 nos. stay sets and 28000 nos.of Disc insulators. Though this project is locatedin the Rann of Kutch along the sea shore, itremains dry for nearly six to seven months in ayear and there is no habitation for almost 50 to100 km along the border.

Executing the project in this no man’s land is areal challenge in view of the adverse weatherconditions and restriction on free movement ofmen, materials and vehicles, in addition tofollowing reasons:

♦ Entire work is coordinated from the main siteoffice located at Khavada, 120-200 km awayfrom the work-site

♦ While staff used to commute in jeeps to and frofrom office to site, workers are allowed tostay in tents near the existing BSF camps and

food materials are transported from Khavada♦ Entry permits to be obtained on daily basis for

all workmen and vehicles. Without a validpermit, no one can move beyond BSF checkposts

♦ Workmen are transported in trucks to variousoperation points along the border.

♦ Because of the restricted working hours, BSFdoesn’t permit workmen to move around aftersunset and overnight stay is not allowed. Duringworking hours in the day, workmen have tocommute almost 200km, resulting in loss ofeffective man hours.

♦ During summer, no work can be done due toheavy sand storms

♦ Moreover, there is threat of scorpions bitemostly in the Rann area

Gujarat Electricity Board awarded this contract toECC in February 2005 and the work commenced inApril 2005. It is scheduled for completion by March2008.

This is an interesting project from the point of viewof safeguarding and building the Nation.

Ramchandra YadavAsst. Construction Manager

51

enpact is the largest business services andtechnology solutions company in India witha global presence operating out of 10 sites

in Gurgaon, Delhi, Hyderabad, Bangalore, andKolkata. The latest addition to list of theiroperating offices in India is the IT processingfacility at JLN Marg, Jaipur. A green field projectand the first IT/ITES project in the state ofRajasthan, Genpact awarded the contract to L&Tduring February 2005 with a stringent scheduleof 12 months to build a state of the art ITprocessing facility. The contract period was laterextended to September 2006 after an increase inthe scope of civil and service works.

M/s Design Plus, New Delhi, was nominated asthe main consultants assisted by specialisedservices consultants - M/s. MKG Consultant,Pioneer consulting engineers Pvt Ltd, Guptaconsultants, Electrical consulting engineers,Khote landscape and horticulture services.

L&T’s major scope of work comprised civil,structural, architectural and finishing works of theentire area which included the IT building, serviceblocks, compound wall, Sewage Treatment Plant,Water Treatment Plant, plumbing and sanitaryworks, external development with internal RCCroad, landscaping and horticulture, fixed and looseinteriors and PMC for services package such asHVAC and VRV system, fire fighting, electricalsystem, DG sets, fire alarm system, PA system,CCTV, Access control system, BMS, Elevators, STP,WTP, modular furniture, sinages, chairs, carpets,blinds, kitchen equipments.

Salient Features

The building 28 m tall and 80 m x 35 m wide, is aground plus four floors structure with twobasements with an overall built up area of around 3lakhs Sqft. L&T’s scope of work involvedconstruction of RCC framed structure with brickmasonry walls and involved architectural andsophisticated finishing works such as false ceilingmade of gypsum and metal tiles with acoustic layerof high NRC value, high ACP canopy, semi unitizedcurtain glazing, Al. door/window , special whitebeach wood doors, fire proof doors, tiling works,marble and granite design flooring, false flooring,red sand stone cladding, external texture paintsfinishes, and all services related to IT building.

The amphitheatre is designed traditionally with sandstone cladding, wood Pergola and wall paintings

surrounded by attractive landscaping. The recreationfacilities included a 312 seater state of the artcafeteria at two floors, 2 break out areas withrefreshment facilities and house phones in eachfloors, a full fledged Gym, lawn of more than 27000Sqft area, party terrace adjacent to lawn.

Employee services like ATMs, departmental store,Information and reservation booth, phone payingmachine and a hospital are available inside thecampus.

Green building

Being a green field project, the latest energyconservation systems are adopted to economizethe cost of operation and conserve the energy. TheHVAC systems (Variable refrigerant volume,variable frequency drive, Thermo fusers, energyefficient chillers), Electrical system (Compactfluorescent lamps and dimmer systems) monitorand control the power usages at various areas.Other special features included hot water generationthrough solar panels, hydro pneumatic pumpingsystem, RO water system and 3X synchronizationfor elevators.

Power and Utility features incorporated are in linewith the latest technology with highest efficiencyplus 100 percent redundancy. A 33-kVA electricalsub station with 2000 kVA transformer throughexclusive cables is installed. Special CFL lamps areused for power savings. Technology for earthing is

GENPACT Jaipur - A green field IT/ITES processing facility in Rajasthan

52

maintenance free and has life span for 25 years.Advanced technology is used for lightening arrestor.Silent power generators with Euro III engine designedfor zero noise level, 4 DG sets in N+1 redundancy(2x750 + 2X500 KVA) and fueled through 30KL UGDSTwhich is monitored by ultrasonic level sensor, PLCpanel for auto power management, UPS N+1redundancy (2x200 + 5X120 KVA) are installed. Allservices are automatically controlled through BuildingManagement System.

Security System

A foolproof intelligent security system with closed circuittelevision monitoring, intelligent perimeter protection,and access control with biometric/keypad readersmonitors the man movement in critical areas such asdata centre, hub rooms and all entry/exit doors. Cagesare provided in the server room for external customerracks for privacy and high security. A guard toursystem ensures effectiveness of security guards anda full-fledged badging station is established for ID cardprinting.

Fire & Safety System

The fire alarm system provided is an addressable typefor smoke detection all over the building. An automaticfire extinguishing system (Inergen) is installed to reducedown time in server and all UPS rooms. The overallbuilding is protected with fire sprinkler, internal andexternal hydrant systems as per NFPA Standard.

Environment Protection – Bearing in mind thegreen field objectives, the project is equipped with rainwater harvesting, a sewage treatment plant thatensures that there is no disposal let into the city sewage.A full-fledged laboratory, water treatment and softeningplant ensure on the quality of water used.

Telecommunication - A full range of voice, dataand internet services are provided via CAT 5 wiring,multi-mode and single-mode fiber for connectivitywith all sites.

Features of GENPACT

♦ Plot area : 11487 Sqm♦ Permissible Ground

coverage : 3967 Sqm

♦ Ground Coverage : 2597 Sqm♦ Super Built up area : 17339 Sqm♦ Landscaped Area : 8600 Sqm♦ Area under road and

Car park : 3985 Sqm♦ Basement Car parks : 165 PCU♦ External car Parks : 167 PCU♦ Two level Cafeteria : 312 seater

Major items of work include:

♦ Excavation : 45665 Cum♦ Concreting : 17290 Cum♦ Shuttering : 51395 Sqm♦ Reinforcement : 1500 t♦ Brick work : 4516 Cum♦ Plastering : 40629 Sqm♦ Painting : 55615 Sqm♦ Stone cladding : 3257 Sqm♦ Flooring : 20895 Sqm♦ Al. glazing : 2287 Sqm♦ False ceiling : 20600 Sqm♦ Water proofing : 15460 Sqm♦ Structural steel : 82 t♦ Doors/ window : 2280 Sqm♦ Expansion joint treatment : 2889 RM♦ Vacuum dewatering : 8245 Sqm

Design Complexities

Services such as wiring, conduiting, duct, piping,cable tray etc had to laid above false ceiling and inexternal development area by following a complexdesign pattern.

Initially Sewage treatment plant design had 2 tiersin 11 m depth which was modified to single tier in7 m depth where the space between the intercompartment is limited and tedious to build.

30 m high DG exhaust structure was designed forerection in close proximity to the temple wall, whichwas later relocated and redesigned with reducedheight.

Construction Challenges

Considering the open office environment in ITprocess, installation of glass partition with

East side elevation of GENPACT

Beautiful view of the landscaped garden

53

accommodation of data cabling and other wiringwas a challenge.

As per client requirement, second floor includingserver room was to handed over first and hencethe finishing works from top could not be started.

Executing the second phase works in theoperational building was a highly sensitive andcritical activity.

Deep excavations done during the constructionof UG diesel oil storage tank and STP requiredprecise planning and continuous monitoring sincethe area was very close to adjacent temple walland service road.

The labour colony had to be relocated duringexecution of the project since the existing placewas sold to private party. The relocation wasestablished without affecting the progress of thejob.

Innovations

Instead of the conventional chemical mixedconcrete for RCC road work, Tremix flooringtechnique was used which was of higherdurability and gave a smoother aesthetic finishand facilitated speedy execution.

The RCC road was cast in one go and grooveswere cut in set concrete instead of providingconstruction joints in panels. This helped in speedyconstruction without affecting the technicalrequirement.

Deep excavation slopes were cut in steps insteadof one slope with more clearance, which madeexecution easy and safe.

Since there was a constraint in getting browngravels (as per specification) of uniform colourand quality, it was decided to make use of factorymade round shaped white marble pebbles for fillingat entrance which has greatly enhanced theaesthetic appearance of the outdoor landscape.

Fabrication & Welding

Fabricating the chiller steel structural foundationsat heights and huge ducting for HVAC was a majorconcern. Hence shop fabricated ducts were usedand fabricated the chiller structural foundationsin small segments at positions. Using LPG forwelding or cutting was strictly prohibited as per

EHS (Environment Health and safety) Standard.Getting acetylene and O2 gas was one of theconstraints.

Fabrication of tubular steel structure was done intruss form to suit the desired shape of ACP canopy.

Erection

Erection of shop fabricated diesel oil tank was acritical activity due to space constraint near thetemple and surrounding filled soil. This wassuccessfully executed using heavy crane.

Lifting of chillers to 30 m high terrace was anothermajor challenge as the lifting crane had limitedspace within boundary. This was negotiated with80 tones capacity tyre mounted crane with longboom.

Erection of structural beams for chillersfoundation at terrace level was done by certifiedchain pulley block system with utmost care.Lifting of UPS panel through window at third floorlevel was complicated task executed skillfully asthe building structure and external finishes wasalready completed.

Safety

To meet the tight construction schedule andensure a safe working environment the projectteam had taken the following safety measures:

♦ Issue of personal protection equipmentfor all labourers, vendors, supervisorsand staff working in the project

Two level cafeteria

Inside view of the workstations in the BPO

54

♦ Induction and screening of workmenworking at site

♦ Secur i t y sys tem a t a l l co rners o fconstruction premises

♦ Work permit system before start of anywork

♦ Checking of staging, working platform,hand rails and issuing the green tag foruse

♦ Checking and issu ing ‘safe for use’certificate to all construction eqipments,tools and tackles, vehicle etc.

♦ Keeping centralized house keeping crewon daily basis

♦ Keeping an emergency vehicle 24x7 hrs♦ 100%hard barricading of the construction

zone from surrounding public prone zone

The stringent safety measures adopted paid richdividends when the project was awarded a safetyappreciation certificate for achieving one millionman-hours of incident and injury free work by theclient.

Formwork

L&T formwork was used for the entire structuralwork of the building. Concreting work was doneusing 2 nos RM-800, 5 nos 10/7 mixer machinesand builder hoist.

Logistics

The project is located in the heart of city and comesunder no entry zone during day for goods vehicle.

Hence an alternative route was found for goodsreceived during day and planning had to be doneaccordingly during night.

Workspace constraint was a major challenge,which was effectively handled through meticulousmaterial management on daily basis. Coordinationamong different services vendors, respectiveconsultants and establishing their work sequencewas brainstorming exercise through out the project.

Due to transporters strike the flow of cement andother long lead materials were delayed. Procuringfrom the local market and rearranging the sequenceof activities according to the materials availabilitynegotiated the problem. Since the supply ofreinforcement steel from Kolkatta was timeconsuming, a delivery schedule was prepared andphysical reconciliation was done on weekly basisand suggestion was given to transport in truckinstead of trailers. Also coordination with vendorand monitoring the vehicle from loading point to sitehelped in materials reaching site at the earliest.

Quality of Works

Only client/consultant approved materials was usedfor the project. Method statement for all major andimportant activities was made and followed.Approved and reputed manufacturers weredeployed for materials supply. Besides quality ofcivil and structural works was monitored by testingand inspection procedures as per Project Qualityplan requirement. Samples, mock-ups werepresented to clients for approval and thereafterworks were carried out. Quality checks wereprepared and corrective action taken for theshortcomings if any.

Being Rajsthan’s first IT building, the project hasdrawn the special attention of the government andduring its inauguration, the client as well as theHon’ able chief minister of Rajsthan appreciatedL&T for creating a landmark building in Jaipur in avery short duration.

Ashok KumarResident Engineer

A section of the basement showing the utility services

A part of the control systems for the water treatment

55

he North South - East West Corridor (NS-EW)being implemented by the National HighwaysAuthority of India (NHAI) under the Ministry

of Road, Transport and Highways (MoRTH) is thelargest ongoing expressway project in India. It isthe second phase of the National HighwaysDevelopment Project (NHDP), and consists ofbuilding 7300 km of four/six lane expresswaysconnecting Srinagar, Kanyakumari, Porbandar andSilchar, at a cost of US$ 12.317 billion and theentire project is expected to be completed byDecember 2009.

As a part of this East- West Corridor Project, ECCis executing the rehabilitation and upgradation byfour laning of 70 km road (from 509.000 to km.579.000 km Package RJ-11) on NH-76 in the stateof Rajasthan. ECC bagged this contract in theteeth of stiff domestic competition.

Funded by the Asian Development Bank (ADB), thePackage begins approximately 109 km from Kotacity and ends in the Rajasthan - MP border andconnects Porbandar in the West with Silchar in theEast. The Project has a great importance as it formsa part of the East-west corridor, which whencompleted will significantly improve the connectivitybetween the Western India with the East in terms

of reducing distance, improving the riding quality,saving time and fuel cost thereby directly benefitingall road users. This apart, it will benefit the localpeople through new business opportunities, bettermarketability of local agricultural produce,appreciation of immovable properties through betterconnectivity.

The Project is being executed by L&T for NHAIunder the supervision of Wilbur Smith and Associateswho have been appointed by the client as SupervisionConsultants.

The Architectural and structural design are providedby Span Consultants Pvt. Ltd., New Delhi.Commencing the project in September 2005 L&T isexpected to complete the same in 30 months (March2008).

The Scope of work involves:

♦ Construction of new flexible 2 lane carriagewayon one side of existing single lane pavement

♦ Widening and strengthening/ reconstruction ofthe existing road

♦ Construction of New 4-lane dual carriagewayin bypasses, detours

♦ Construction of service roads♦ Construction of junctions, intersections

including grade separators♦ Construction of bus stops, truck lay byes♦ Construction of new bridges, underpasses and

box culverts♦ Providing road markings, road signs, protective

works, metallic crash barriers, guard rails,etc.

♦ Construction of reinforced earth retainingstructures in underpass approaches

♦ Maintenance of existing road and trafficmanagement during construction period

Salient features of the contract

♦ Contract Length : 67.225 km♦ Date of Acceptance : 31.05.2005♦ Contract Agreement

Signed on : 20.07.2005♦ Commencement Date : 30.09.2005♦ Completion date : 29.03.2008 ♦ Original Contract Period : 30 months♦ Major Bridge(4-Lane) : 4 Nos♦ Minor Bridge(4-Lane) : 9 Nos♦ Underpass(4-Lane) : 24 Nos♦ Box culverts(4-Lane) : 69 Nos

Major items of work:

♦ Roadway excavation : 339300 Cum♦ Earthwork in filling : 3648300 Cum♦ Granular Sub Base : 375900 Cum♦ Wet Mix Macadam : 355800 Cum♦ Primer and Tack Coat : 3933450 Sqm♦ Bituminous Courses : 187300 Cum♦ Concrete -All grades : 118770 Cum♦ Steel reinforcement : 4370 t♦ Prestressing strands : 925 t♦ Turfing : 592200 Sqm♦ Road Marking : 51000 Sqm♦ Metal crash barrier : 25600 RM♦ Crushed Aggregates : 1620214 t♦ Crushed GSB : 808185 t♦ River Sand : 61052 Cum♦ Cement : 50000 t♦ Bitumen (60/70and

PMB for BC) : 23500 t♦ Expansion joint : 770 RM♦ RE Facia Panel : 7350 Sqm♦ Spherical Bearings : 72 Nos♦ Elastomeric Bearings : 336 Nos♦ High Tension Strand : 925 t

Preparation of subgrade layer in progress with grader

Four Laning of Road Project on NH-76 in Rajasthan

56

Strategies for Project Execution

The project office, P&M workshop, site store,we igh b r idges , t ime o f f i ce , ca rpen t ryworkshop, bar bending yard, batching plant,wet mix plant, hot mix plant, quarry andcrusher for the project including the bacheloraccommodation and guest house and labourcamp have been set up at a strategic locationon km 532 spread over on a 80 acre landtaken on rental basis. This has resulted inbetter usage of resources through instantcommunication, immediate co-ordination andsharing of common resources in the event ofbreak-downs. Moreover, we could get rid ofadditional burden of aggregate transportation,double handling of aggregates, etc., resultingin substantial cost savings.

Quarry & Crushers

Road p ro jec ts genera l l y requ i re hugequantities of different grades of aggregatesand GSB. For this purpose, we mobilized anderected four crushers to meet the entireaggregate requirement of the project andtimely supply of the same. In fact we arecontemplating to make all supplies in time andthe total crushing is completed three monthsahead of completion date.♦ 2 x 150 tph Aggregate Crusher @ km. 532♦ 1 x 50 tphGSB Crusher @ km. 532♦ 1 x 50 tph GSB Crusher @ km. 548

The mining operations/maintenance of the abovecrushers are sub-contracted to the same agencyto avoid under utilization of crushing plants. Thecrushing plants are installed 500m away from quarryto reduce the cost of quarrying and feeding tocrusher keeping in view the minimum safe distance.

With these arrangements, till end of November 2006,we have been able to achieve an average monthlyproduction of 66000 t aggregates with an highestMonthly production of 94500 t in March 2006.

Survey

Soon after the site was handed over for carryingout the road construction work, site survey, themost critical pre-construction activity was takenup before the commencement of all other works.One after the other all other works are carriedout in a sequence as follows:

Excavation

This project involves a quantum of 339300 cumof excavation in soil and hard rock, on toughterrains in the ghat area, close to the forest

land. Hence the excavation in hard rock is beingcarried out by controlled blasting, to minimizethe impact on the wildlife, in the forest.

Earthwork

Around 3648300 cum of earthwork is to be doneincluding embankment and sub grade filling. Ofthis nearly 133000 cum of embankment filling isto be done with selected materials for theconstruction of reinforced earth wall at underpasslocations. 1228785 cum of earthwork have beenexecuted till date using 10 earthwork teams. Eachteam made use of one excavator, 4-5 dumpersof 20 t, one vibratory roller, one water tankerand one motor grader for two teams. Using theseresources, we were able to achieve a maximumquantity of 270000 cum of embankment filling injust one month.

Granular Sub base

Crusher GSB is used for construction of subbase course. The total scope involved in thisproject is around 375900 Cum. Transportationcontractors are engaged for transporting GSBmaterial and a total of 10 dumpers of 20 tcapacity have been used for this purpose. Tilldate 81500 Cum of GSB has been laid with 2GSB teams each making use of one grader,one roller and one water tanker.

Wet Mix Macadeam (WMM)

Two pug mills of 60 tph (L&T) and 200 tph (Subcontracted) have been commissioned to produce355800 Cum of WMM. Laying of WMM is beingdone by sensor pavers for maintaining the profileand cross fall as required. As of date 83636 Cum

Crusher in operation

View of shahbad Ghati

57

of WMM have been laid with a maximum quantityof 1100 Cum laid in one day. We have deployed 2WMM teams for laying. Each of this team isprovided with one vibratory roller, one water tankerand adequate lighting facility for laying at night.

Asphalt works

One Hot mix plant of 160 t/hr has beencommissioned for executing asphalt works to thetune of 187300 Cum. 15 km of two lane carriagewayhas been covered with asphalt layers till date withone asphalt team comprising one paver, onepneumatic tyre roller, two tandem rollers and onewater tanker. As the project is located in a semiarid zone, where the maximum pavementtemperature touches as high as 68 degree Celsius,we have been able to convince the Engineer forpermitting us to use polymer modified bitumen forthe wearing course, in order to avoid bleeding andrutting in the pavement.

Kerbs

One kerb casting team is being engaged for layingof kerbs. Kerb laying is done before the paving ofasphalt, as it confines to one end of the pavementlayer thereby reducing wastage due to confinement.

Finishing Items

Specialised agencies for construction of reinforcedearth structure, post tensioning mastic asphalt,

supplying of road signages, thermoplastic pavementmarking machines have been identified/mobilizedfor carrying out the specialized works.

Bridges, Underpasses, Culvertsand Retaining Walls

A separate team is formed for the constructionof cross drainage works and bridges, as it ismore important to complete these works to avoidgaps during paving during construction of theroad.

A total of 19834 cum of concrete have been laidtill date against the scope of 118770 Cum. Inaddition, we have till date completed around 37box culverts against 69 and 15 underpassesagainst 24. Sub structure works for almost allbridges have been completed with a few in theirfinal stages of completion.

Retaining wall to contain the embankment withits right of way is progressing in full swing sothat earthwork activity in these areas can startat the earliest.

L&T Formwork is being utilized for all structuralworks and a maximum quantity of 312 cum ofconcrete is poured in a single day with an averageof 190 Cum/per day for the month of November2006.

Plant & Machinery

A well equipped P&M department at site undertakesrepairs and maintenance of all plant & machineryitems at regular intervals as per schedule in orderto avoid major breakdowns.The following are the major machinery andequipment being used in this project.

♦ Excavators : 10♦ Wheel Loaders : 8♦ 10 t Vibratory Rollers : 15♦ Wheel loader : 4♦ 200 tph Wet Mix Plant : 1♦ 60 tph Wet Mix Plant : 1♦ Paver Finisher : 4♦ 160 TPH Hot Mix Plant : 1♦ Pneumatic Tyre Roller : 1♦ Tandem Vibratory Roller : 2♦ Bitumen Sprayer : 2♦ 30 Cum/Hr Concrete

Batching Plant : 1♦ 15 Cum/Hr Concrete

Batching Plant : 1♦ Excavator With Rock Breaker : 2♦ Transit Mixers : 11♦ Concrete Pump : 2♦ Cranes : 1♦ 40 T Trailors : 2♦ DG 62.5 kVA/125 kVA/

750 kVA (2 each) : 6

Asphalt paving in progress

58

Human Resource

Around 90 technical/non-technical staff have beenmobilized to execute the works with 350 departmentworkmen for carrying out various tasks. In addition,around 850 workmen have been engaged from thesubcontractors to execute the works under oursupervision. Some of the major sub contractorsare involved in crusher and quarry operation,earthwork filling, transportation of GSB, WMM andasphalt materials, paving of WMM layers, concretingworks, reinforcement cutting and bending worksand other special items of work. The field executionstaff have been grouped under five major groups,such as: structure works, earthwork and GSB,base courses (WMM), asphalt works and finishingworks for better execution, control andaccountability.

Challenges Faced

Poor availability of river sand

As the source for lifting the river sand (for allconcrete works) is located at a distance of 200 kmaway from site, we were not able to get sand atestimated prices on regular basis. Moreover, the

local agencies were paying better prices whencompared to us and hence, no agency was willingto supply the same to L&T on a regular basis.However, this problem was sorted by by convincingthe Engineer to use crushed sand produced by ourcrushers in partial replacement of natural sand,without sacrificing quality.

Conveyance

As the site is located 65 km away from the nearesttownship (Baran), which has basic facilities foreducation and healthcare, staff families chose tostay at Baran. Since the journey takes 4 hoursto and fro site, it was decided to put up thebachelor staff accommodation closer to site totake care of the early morning and late eveningworks. In addition, this is provided with completerecreation, sports & games facilities includingcommunication gadgets, vehicles for respite ofemployees and to meet any emergency that mayarise.

Ghat section

Since the excavation in the ghat section involvesa massive quantity of 339300 Cum of excavation

(both in soil/hard rock), a detailed work planhas been prepared by the site think tankcommittee. Accordingly, the entire ghat stretchhas been divided into 3 sections.

To begin with access roads are being made soas to commence the retaining wall activity.Initially concreting will be done with concretepumps, as transit mixers can’t access all locationsdue to the very steep terrain. Once the retainingwall is built-up, in the initial approaches, fillingwill be taken up in the valley side and this willserve as the approach for transit mixers to reachthe subsequent sections for concreting ofretaining walls.

Though the site team is continuously facingseveral such odds, kudos to our team who havebeen braving every such impediment andprogressing our way, achieving every milestonein the right earnest.

D.K. NandaProject Manager

T.R. PatnaikConstruction Manager

View of completed dense bituminous macadam work

59

edanta Resources plc, a London StockExchange listed and FTSE 100 metals andmining global major has interests in

aluminum, copper, Zinc, gold, silver and leadwith operations in India, Australia, Armenia andAfrica. Recently, Hindustan Zinc Limited (HZL)part of Vedanta Group, successfully completedthe phase I project of HZL at Chanderiya Unit,Rajasthan, where Larsen & Toubro Limited (ECCDivision) was associated with execution of thisprestigious project, in a record time of 24 months.

HZL has an installed capacity of 2,30,000 TPA Zincingots and 35,000 TAP Lead ingots across the country.In pursuit of its vision of becoming a World ClassGlobal Company, HZL has presently undertaken anotherexpansion for a 170,000 TPA Zinc Smelter at itsChanderiya Unit. L&T is once again proud to beassociated with this major project and inked the contractfor undertaking the construction of this project withSterlite Group, a flagship company of VedantaResources Plc., UK.

L&T successfully executed the following works ina record time for the Phase-I Project of HZL atChanderiya.

Detailed engineering, procurement, erection,commissioning of leaching purification & cadmiumplant (EPC-4). This involved supply and erection ofmechanical equipment, civil and structural worksfor the construction of tanks, silos, launders, utilities,process piping including complete electrical &instrumentation works.

Detailed engineering, procurement, erection,commissioning of tank house, zinc melting & castingplant and zinc dust plant (EPC-5), which involvedsupply and erection of mechanical equipment, civil& structural works for molten metal launders,utilities, process piping, including complete projectelectrification & instrumentation works.

Some of the salient features of structures executedunder phase-I includes:

The Cell House which has a length of 167m andwidth of 52m with a structural steel roof and coveredby 9600 Sqm of FRP sheet, accommodates 124RCC cells, two cathode stripping machines and oneanode washing machine.

A unique feature includes casting 124 RCC cells in-situ, as against pre-casting them in the yard,transporting and erecting them in position. Yetanother innovation included converting the concreteportal using structural steel, which resulted in timely

completion of Cell House, apart from eliminatingthe use of huge quantity of formwork systemcomponents.

The Casting and Melting furnace building isa 83m long and 45m wide structure. Thisaccommodates two zinc melting inductionfurnaces, one ingot casting machine, one jumbocasting machine all for melting zinc cathodesand casting zinc slabs.

Erection of two fully automatic cathode strippingmachines with PLC, each having a rated capacityof 300 cathodes per hour and weighing 55 t wassuccessfully erected for removing zinc depositionon the cathode plates during the electrolyticprocess. Erection of the 22t per hour capacityzinc slab casting machine (65m long and 75 theavy) which can cast 880 ingots each of 25kgweight in one hour including erection of the 30 tcapacity anode washing & flattening machinehaving a rated capacity of 100 anodes per hourwas a challenge.

The Leaching and Magnesium Removalarea has a dimension of 77m x 52m withstructural steel trusses covered by 4394 Sqm ofroof sheet. This houses five calcine feed hoppers,24 tanks made of MS/SS associated with relatedpumps and thickners for leaching.

The Purification process area which has adimension of 45.75m x 60m, houses 15 tanks ofMS/SS along with associated pumps and piping.

View of Casting and Melting area

Hindustan Zinc Limited Poised to become the leader in Zinc & Lead

60

In addition, two MCC buildings one for Roasterand the other for Leaching and purification housesthe motor control centers with connectedelectrical and instrumentation works. This alsoinvolved finishing items/specialized items ofworks like, floor tile fixing, aluminium doors &windows, acid resistant brick lining, PVC lining,mastic lining, FRP sheet roofing & grating, epoxypainting on RCC structures including painting ofbuildings.

More than 150 staff and approximately 3000workmen were employed round the clock tocomplete the project in a world record time of 24months. Fixing the 16 paraliners in 10 hours isyet another world record (previous record -14hours in Australia). In addition, ECC completedthe refractory lining works in the inductionfurnace and commissioned two fully automaticEOT cranes for handling of anodes and cathodesin the Cell House in a record time. And achieved11 million accident free man-hours by maintaininghigh standards of safety throughout the projectconstruction period.

In recognition of its speedier completion of thePhase-I project and in appreciation of its teamleadership, HZL awarded ECC Projectmanagement a bonus of Rs.3.0 crore.

Phase-II

Currently, ECC is actively involved in the Phase-II expansion plant which will have a capacity of1,70,000 TPA Zinc Smelter Plant. This is comingup close to the existing production unit (Phase Ibuilt by ECC) at Chanderiya near Chittorgarh inthe state of Rajasthan.

Though Phase-II is a separate capacityexpansion, it has practically all elements of a

grass-root level plant except sharing of certainutilities with the existing production plant.

ECC’s scope of works in this project involvesfour major packages as follows and this includescivil and structural works, fabrication of tanksand silos, mechanical erection and process pipingworks as per details below:

EPC 4 - Leaching and Purifica-tion Package

This involves design, detailed engineering, projectmanagement, procurement, supply, fabrication,inspection, transportation, unloading includingfree issue i tems, storage, construct ion,instal lat ion, testing, pre-commissioning,assistance in commissioning and handing overthe plant.

EPC 5 - Cell House, Melting andCasting Plant

This package involves design, detailed engineering,project management, procurement, supply,fabrication, inspection, transportation, unloadingincluding free issue items, storage, construction,installation, testing, pre-commissioning, assistancein commissioning and handing over the plant.

EPC 10 – Civil and structural worksfor the above plants including raw material storageand handling, roaster and waste heat recoverysection, gas cleaning section and sulphuric acidplants.

EPC 12 – Tanks and Silos Packageinvolves construction of MS tanks including supply,fabrication and erection in the leaching andpurification area as well as calcine silos.

UHDE India Limited (UIL) have been appointed byHZL as Detail Engineering and Project ManagementConsultant (PMC) for Civil and Structural Package.The detail civil engineering and PMC for tankpackage is also done by UIL.

ECC is executing the EPC 12, EPC 4 & EPC 5packages as lump-sum turnkey contracts, hencethe detailed engineering are provided by ECC.However, the PMC for the entire package restswith UIL. As Project Management Consultants,UIL are responsible for the project executionand to ensure the handing over of plant as percontractual terms to the complete satisfactionof HZL.

Process technology for both Phase I and II aresourced from Outokumpu, USA by Hydro-metallurgical route.

Over view of Cell house

Over view of Leaching area

61

ECC’s work in this project involves civil andstructural, mechanical equipment erection andpiping, testing and commissioning of equipmentincluding electrical installation and instrumentationwork as well as testing and ommissioning of thesame.

Tanks and Silos Package (EPC 12)

The tanks and silo package for Phase II involvedfabrication and erection of two silos for the calcinestorage apart from 42 tanks in the leaching andpurification area. This is estimated to consume atotal quantity of 1035. 42 t of steel for fabrication -367.42 tonne for the two silos and 668 tonne forfabrication of 42 tanks.

Fabrication challenges

The structural fabrication and erection was a realchallenge as it involved plate bending of eachsegments of shell in the yard, transporting these

segments to the actual site incluting erection andwelding of the same.

This involves a whopping quantity of 6272 t. Out ofthis total quantiy, fabrication and erection of tankand silo package alone touches a quantity of 1035.42t. Moreover, the two silos fabricated here are oneof the tallest structures having a height of 19m andinternal dia of 13m. 20mm thick MS plates wereused for the fabrication of the silos and this involveda total quantity of 183.71 t for each silo. In all therewere 8 shells – 7 of 2.5m height and the top one of1.5m height.

Leaching and Purification Pack-age (EPC 4)

This EPC package which covered the leaching,purification and jarofix areas involved mechanicalequipment erection including erection of free issueitems, piping, SS tank fabrication and erection, acidresistant brick lining etc. The detailed scope of thepackage is as follows:

♦ Equipment erection : 1280 t♦ Plates and structural

steel (MS) : 900 t♦ Plates (SS) : 400 t♦ Piping (CS,SS & PPH) : 24700 m♦ Fittings (CS, SS & PPH) : 23565 Nos♦ Valves (diaphragm, plug,

butterfly, gate, globe,ball and check valves) : 2219 Nos

♦ Steam traps : 71 Nos♦ Grating (MS & FRP) : 29 t♦ SS904L – Coils and

Injectors : 130 Nos♦ Rubber lining : 1655 Sqm♦ A R Brick lining : 14984 Sqm

Construction schedule

Approximately Rs.430 crore worth of orders areunder execution by ECC for phase-II expansionof HZL and the completion schedule for theseprojects are as follows:

EPC-10 which began in February 2006 is expectedto be completed by May 2007EPC-12 which began in May 2006 is expected tobe completed by January 2007EPC-4 & 5, which began in August 2006 are expectedto be completed by June 2007

The major items of work involved in the Civil andstructural Package (EPC 10) are given below:

Major quantities of work

♦ Excavation : 172862 Cum♦ Backfilling / Disposal : 250150 Cum♦ Concrete : 92341 Cum♦ Formwork : 139512 Sqm♦ Brickwork : 4456 Cum♦ Plaster : 36600 Sqm♦ Reinforcement : 4967 t♦ Miscellaneous Flooring : 27609 Sqm♦ Doors & Windows : 1055 Sqm♦ Structural Fabrication : 6272 t♦ Structural Erection : 6272 t♦ Grating : 8390 Sqm♦ Sheeting : 40248 Sqm♦ Sand blasting &

Painting : 6155 t♦ Water Proofing : 4432 Sqm♦ Sanitary & Plumbing : 72 Nos♦ Mastic Lining : 21040 Sqm♦ PVC Lining : 25750 Sqm♦ AR Brick Lining : 26250 Sqm♦ Cell Casting &

Alignment : 132 Nos

Structural erection of acid plant

View of control room

62

The EPC 5 package covers the gypsum removalarea, cell house, melting and casting areas and themajor items of work are given below:

♦ Equipment Erection : 6362 t♦ Piping (including

CS, SS & PPH) : 14080 m♦ Fittings (including

CS, SS & PPH) : 13492 Nos♦ Valves (Including diaphragm,

plug, butterfly, gate, globe,ball and knife gate valves) : 808 Nos

♦ SS Plates : 27 t♦ CS Plates & sections : 371 t♦ Grating (MS & FRP) : 6.9 t♦ Rubber ling : 6986 Sqm♦ A R Brick lining : 5483 Sqm

The electrical and instrumentation packages forma major part of the project as most of the mechanicalequipments are fully automated. The major itemsof E&I work involved:

♦ Motor control panels(15x3 m) : 11 Nos

♦ Marshalling junctionbox (5x3 m) : 8 Nos

♦ Emergency power distributionboard (10x3 m) : 12 Nos

♦ VFD panels (1x3 m) : 98 Nos♦ Cables (Power control

& Signal) : 648 km♦ FRP cable trays : 22 km♦ Illumination system : 2378 Nos♦ FIM – E&I related (For

Anode washing/ cathodestripping, filter press, slabcast, furnace etc) : 36 Nos

♦ Analyzers ( pH, conductivity& density) : 28 Nos

♦ DB/SLDB/ESLDB : 65 Nos

In addition, ECC’s scope of work also involvesfinishing items, such as:

♦ Tiles : 1348 Sqm♦ Aluminium doors and

windows : 873 Sqm♦ FRP Sheet : 9150 Sqm♦ Epoxy paint (RCC) : 20000 Sqm♦ A R Brick lining : 26250 Sqm♦ PVC Lining : 25750 Sqm♦ Mastic lining : 21040 Sqm♦ FRP grating : 6860 Sqm♦ Painting of buildings : 50900 Sqm

With an exponential growth rate of Indian marketthe scope for infrastructure and construction workis increasing. The use of galvanized steel inconstruction field is increasing which leads to asignificant demand for Zinc in India. Though therequirement of Zinc is increasing in other fieldsalso, including export, the present expansion willbridge the gap between demand and supply. Theemployment opportunities generated by the plantrequires no mention, as it will definitely help toincrease the job openings for large number of peoplein and around the place.

The Zinc Smelter complex consists of the followingprocess units:

♦ Raw Material Storage and Handling♦ Roaster & Waste Heat recovery section♦ Gas cleaning section♦ Sulphuric acid plant♦ Leaching, purification and Cadmium section♦ Cell House, Melting & casting section♦ Off sites & Utilities section

The Zinc concentrate is received on road trucksand directly unloaded into raw material storageshed. The concentrate is reclaimed by pay-loadersand transferred to roaster section throughcrushers, screens, and conveyors. The concentrateis roasted in the fluidized bed roaster at hightemperature to yield calcine (Zinc oxide) and Sulphurdioxide gas.

The sulphur dioxide gas is cooled by passing throughwaste-heat boiler. The gas undergoes furthercleaning in the Hot gas precipitators scrubbers andwet gas precipitators. The cooled gases are thensent to the Sulphuric acid plant.

The calcined material from the roaster is cooledand sent to the leaching and purification sectionwherein further processing takes place to produceZinc Sulphate electrolyte with various impurities.The impurities are precipitated and pure electrolyteis produced. The purified zinc sulphate is sent tothe Electrolytic cell house. In the cell house the zincis deposited on the cathode.

The zinc sheets are removed from the cathode andmelted in Induction furnace. The molten metal iscast in to ingots by casting machines. Lumpy drossgenerated in the induction furnace is ground in drosstreatment plant. The fine dross is recycled toroaster by mixing with concentrate.

J. SureshConstruction manager

A.K. MallikSPM – IPU Sector

View of thickener formwork

Cell house cooling tower

63

aipur, the Pink city of India, is located innorthwest part of Rajasthan surroundedby the Aravalli mountains. The population

of Jaipur, which is close to around 2,50,000,depends almost entirely (97%) on groundwater resources for its potable water supply,as a result of which over the years the watertable has fallen dramatically and continues todecline at an alarming rate. Four consecutiveyears of drought conditions have exacerbatedthe problems, and it is felt that the groundwater resources within many parts of the citymay not be adequate in the future.

Bisalpur dam is the only nearby water source,which is located over the river Banas nearDevoli. It has the potential to cater to thec i t y ’ s requ i rement and i nc ludescomplementary provisions for supplying waterto other areas. The long-term strategy is todevelop the Bisalpur water source to providetreated surface water to Jaipur City.

The government of Rajasthan conceived theBisalpur Water Supply Project and requestedthe Asian Development Bank (ADB) to take up

the first Phase of the project as a part of theongoing Rajasthan Urban InfrastructureDevelopment Project (RUIDP).

The contract valued at Rs 481 crore wasawarded to L&T during July 2006 and involvesdesign, procurement and construction of thetransmission system for phase I works. Thescope of work comprises water supply ,treatment and transmission system from theBisalpur dam to the Balawala reservoir siteon the outer edge of Jaipur City and includesoperation and maintenance for a five-yearper iod . The p ro jec t i s schedu led fo rcommissioning by December 31, 2008.

The project is divided in 6 units

Intake Pump House: The scope of workinvolves supply and installation of 9 verticalturbine pumps in the existing intake pumpingstation at the Bisalpur dam, renovation andstrengthening of the existing structures,construction of new hostel building and a 33/3.3 kV substation.

Pipeline: The pipeline works comprise layingof the 2400 mm diameter mild steel raw waterpipeline of 8400 m length from Bisalpur intaketo water treatment plant at Surajpura and 2300mm diameter mild steel clear water pipelineof 97400 m from clear water reservoir atSurajpura to Balawala reservoir. The pipelinesare external ly coated with cold appl iedpolyolef in to be imported from USA andinternally lined with cement mortar. It willcomprise of spirally welded SAW pipes andhas to be provided with adequate cathodic

protection to increase the longevity of thepipes .It consists of both above ground andbelow ground portions with all auxiliary works.

Water treatment plant: The plant is of thepulsator type with technology from M/sDegremont, France and is being designed fora capacity of 400 mld (360 mld for Jaipur plus40 mld for the rural towns). It will be locatedat the village of Surajpura, 3.5 km from theTehsil town of Todaraisingh in the Tonk Districtof Rajasthan and will be connected to clearwater pumping station-having reservoir ofcapacity of 25 ml. 10 nos. of HSC Pumps willpump the treated water to Balawala reservoirnear Jaipur.

Roadwork: A four metre wide all weatherservice road will be constructed along thepipeline from Balawala to Bisalpur.

Renovation Work: The project also includesrenovat ion o f 21 quar ters and campusdevelopment for housing the operat ingpersonnel in 5 locations at Todaraisingh,Tordisagar, Diggi, Phagi and Balawala. Officespace and accommodation for line staff willbe provided by renovation of existing railwaystation buildings.

Electrical Works: Comprise constructionof a 33/3.3 kV substation at intake point andWTP sites and connecting the 33 KV powertransmissions. The 33kV existing line fromThadoli to Bisalpur will be upgraded to WolfACSR conductor from the existing Dog ACSRconductor.

The scope also includes construction of a new33kV overhead lattice tower single circuit linefrom Thadol i to Bisalpur. Simi larly, twoseparate 33kV overhead single circuit latticetower lines are to be executed from Thadolito Surajpura (WTP/CWPS).

Project execution is in the initial phase withplanning, design and mobilization underway.Survey and soil investigations have beencompleted. Location for setting of pipe millhas been finalized and the manufacture ofpipes will commence shortly.

HR Coil for the project is likely to be sourcedfrom China. The project execution task is beingmob i l i zed a long w i th o ther suppor t ingresources. Construction is likely to commencefrom January 2007.

Ajoy BhattacharyaProject Manager

Banas River

WTP - 400MLD

Existing Intake

ExistingReservoir

Bisalpur Water Supply Project

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ajasthan, one of the power starved states,in India is endowed with enormous windpower at its disposal. In order to harness

the wind power available in the state, Govt. ofRajasthan formulated a policy for promotinggeneration of power through Non-conventionalEnergy Sources and offered incentives tocompanies, putting up Wind Farms and supplyingpower to state’s power grid.

In response to this welcome move by thegovernment, Enercon (India) Limited, one of themajor wind power producer, made a feasibility studyof the wind speed, wind profile, wind power potentialand selected “Jaisalmer” in Rajasthan for puttingup its green field 2x50MW Wind Farm.

Enercon entrusted this EPC project to L&T-ECC forexecuting the complete Power Evacuation System.This involved two sections as follows, apart fromgetting ROW clearance and statutory approvals from

the state electricity board, Rajasthan Rajya VidhyutPrasaran Nigam Limited (RRVPNL):

♦ Design, detailed engineering, supply,erection, testing and commissioning of 132/33 kV switchyard at Gorera village inJaisalmer.

♦ Design, detailed engineering, supply,installation, testing and commissioning of a33km long 132 kV double circuit transmissionline of ACSR Panther conductor from Gorerato Amarsagar at Jaisalmer including bayextension at receiving end of grid sub-station.

Major items of work for the substation involvedsupply and installation of one 132 / 33 kV, 75MVA transformer, 5 Nos. 145 kV SF-6 circuitbreakers, 5 Nos. 36 kV vacuum circuit breakers,12 Nos. 132 kV isolators, 16 Nos. 33 kV isolators,15 Nos. 132 kV current transformers, 6 Nos.132 kV potential transformers, 15 Nos. 33 kVcurrent transformers, 3 Nos. 33 kV potentialtransformers, 12 Nos. 30 kV lightning arrestors,6 Nos. 120 kV lightning arrestors, 1 set of 132/33 kV control & relay panels, 1 No. ACDB, 1 No.33 kV/440 V auxiliary transformer, 1 set of110V, 150 AH battery & charger including layingof LT/Control cables, civil works for equipmentfoundation and cable trench, control room aswell as erection of gantry structure andequipment.

Construction of transmission line work involvedsupply and installation of 88 A type towerincluding extensions, excavation and concretingat 108 locations, supply and installation of 20angle towers and stringing of ACSR Pantherconductor for a distance of 33 km includinginsulators, f ixtures and other hardwareaccessories.

L&T commenced the work in August 2003 andcompleted the same by January 2004, takingprecisely 145 days, which is a record breakingachievement. Thus the switchyard wassuccessfully commissioned on February 27, 2004.

In a certificate received by L&T, Mr. T.R. Melroy,Assistant General Manager - Projects, Enercon(India) Limited mentioned that “ L&T maintainedgood standards of qual i ty and safetyrequirements. We are satisfied with their abilityto complete the project in the shortest possibleduration in difficult terrain and adverse weatherconditions”

Challenges

Since the site is located on a difficult terrain withhard rock, we found it very difficult carryoutexcavation for every foundation. Hence, it wasdecided to blast the entire switchyard area up toa depth of 1.5m. Thereafter, all foundations werecast in one go and then the entire area wasbackfilled.

The procurement of 50/63.5/75 MVA PowerTransformer was delayed due to frequentbreakdown of transport vehicle and finally whenit reached the site, we had just 3 days for thefinal testing and commissioning.

However, with excellent planning of all parallelactivities, transformer unloading, erection,assembly, oil filling, oil filteration and testing werecarried out successfully to the completesatisfaction of our clients.

Growing concern for the environmentaldegradation has led to the world’s interest inrenewable energy resources. Wind iscommercially and operationally the most viablerenewable energy resource and accordingly,emerging as one of the largest source in termsof the renewable energy sector.

Wind Energy will witness abundant opportunitiesin the developing economies, such as India,where the power supply s i tuat ion andinfrastructure development efforts provide a hugemarket for active investment.

Samir GuptaConstruction Manager - E&IPower Evacuation System for Enercon’s Wind Farm at Jaisalmer, Rajasthan

65

Manipal Academy of Higher Education (MAHE)located at Manipal, in Udupi District of Karnataka isthe Educational hub of South India. Situated on a500 acre plot on a hilly terrain, MAHE is home toseveral institutions in Medicine, Engineering,Business Management, Hotel Management,Nursing, Bio-technology and Allied Health Services.ECC was associated with this prestigious

educational institution for theconstruction of their Universityand Library Building including aLecture Hall. Having 2.50 lakhsft built up area, the Universityand Library Building presents abeautiful look with its strikinglyrich structural glazing. Moreover,this is the largest building withstructural glazing in the whole ofUdupi district. SundaramArchitects were the Structural andArchitectural Consultants.

Shaped in the form of thepunctuation mark “,,,,,” (comma),the University and Librarybuilding is divided into threesections as University, CentralHall and Library. The Universityblocks are located in thebasement, ground plus fourfloors. This houses the universityadministrative offices. The office

of the President, Vice President and Directors arelocated in the fourth floor with a terrace garden.The Central hall is meant for evaluation of answerpapers and the Board Room is located at the terracelevel.

The library is a six-storied structure with a carpark at the basement. The Library building, largestin Asia can accommodate more than 650 Studentsat a time. In addition to above, the University andLibrary accommodates Banks, ATMs, Food Courts/Coffee Shops, Creche, etc.

Hon’ble Sri P Chidambaram, Union Minister forFinance inaugurated the administrative block of theuniversity building on September 6, 2006 at Manipal.Dr Ramdas M Pai, Chancellor, Dr Ranjan R Pai,CEO, MEMG, Bangalore, Dr HS Ballal, ProChancellor, Brig (Dr) SS Pabla, Pro Vice-Chancellorand Dr H Vinod Bhat, Registrar of MAHE werepresent on the occasion. Sri Chidambaram alsolaunched the digital campus initiative of MAHE onthis occasion.

Manipal Academy of Higher Education (MAHE) Inaugurated

A part of the University and Librarybuilding at MAHE

A section of the building with its rich structural glazing

The plan showing the punctuation mark “,” (comma)

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The 425m long cable-stayed bridge built by ECC,L&T’s Construction Division, at Amman, the capitalcity of Jordan was opened to traffic at 11.00 a.m.on December 14, 2006. H.E. Dr. Ma’Rouf Al Bakhit,the Prime Minister of the Hashemite Kingdom ofJordan, inaugurated this in the presence of Eng.Omar Al Mani, the Mayor of Greater Amman, H.E.Rachakondu Dayakar, the Indian Ambassador, andSenior Executives of L&T.

Leaping across valleys and meandering with acomplex “S” curve horizontal alignment, this uniqueand seismically designed, dual two lane bridge isthe first of its kind in the world. This is the firstcable-stayed bridge built by L&T and also the firstone in Jordan.

The bridge has dual two lane carriageways, each7.28 m wide, and is supported on three toweringpylons rising to a maximum height of 71 m from thebottom of the valley bed (pile cap). It has becomean engineering marvel, a new landmark in the capitalof Jordan and a cynosure of all eyes. Gliding acrossthe Abdoun valley, the bridge presents a panoramicand strikingly beautiful view of Abdoun Townshipwith its beautiful residential and commercialbuildings.

Project Highlights

Client : The Municipalityof Greater Amman,Jordan

Consultant : Dar-Al-HandasahConsultants, Amman

Commencement : December 2002Completion : December 2006Type of Bridge : Curved Cable Stayed

BridgeLength of Bridge : 425m (1x63m+2x 32m+

1x63m+1x27m+2x4m)

Number of Lanes : Dual two lanesCarriageway : 7.28 m per laneTotal width : 22.5m to 29.39mSuperstructure : Built on 3 ‘Y’ shaped

pylonsDeck construction : Precast SegmentalMax radiusin the alignment : 180m

Wadi-Abdoun Bridge, Jordan, Opened to Traffic

Night view of Wadi-Abdoun cable stayed bridge, Jordan

A view of the bridge supported on “Y” shaped pylons

67

(from left to right) Mr. V.B. Gadgil, EVP & Head - B&UI and PT&D Sector Business (GCC Countries),Mr. K. Venkataraman, Senior Vice President (Hydrocarbon & Power Sector), Mr. K.V. Rangaswami, Member of the Board &Head-Construction, Mr. Shukri Saleh Yahya Al Braik, Member of the Board, Larsen & Toubro Readymix Concrete IndustriesLLC and Mr. S.R. Kumar, Vice President (Ready Mix Concrete) during the inauguration of L&T Concrete Plant in Dubai

L&T Concrete Launched in Dubai

L&T unveiled a Dh48 million ready mix concrete(RMC) plant with a capacity of 240 cubic metresper hour in Jebel Ali, in Dubai on January 24, 2007.This plant will meet the growing demand for ready-mix concrete in the UAE.

In India L&T manufactures and supplies about threemillion cubic metres of L&T Concrete per annumthrough 60 plants spread across the country andcommands 28 percent market share.

These plant operations are supported by a fleet of500 transit mixers, six mobile concrete pumps and100 static concrete pumps.

L&T plans to expand the total number of plants inIndia to 150 by the year 2009-10. In the Middle Eastthe company proposes to expand in other Emirates,specifically in Abu Dhabi and Ras Al Khaimah, andalso in Sohar and Muscat in Oman.Mr. K.V. Rangaswami, Member of the Board and

Head - Construction, L&T, said: “I am confidentthat L&T will establish itself as a major force in thissegment in Dubai and soon spread its wings toother parts of UAE as well as other countries in theGulf Region. With its increasing focus on the Gulfconstruction market, the company can leveragethe many advantages that L&T concrete offers andsupply this product for its own projects as well asto other contractors.”

Formwork is playing a major role in civilconstruction. Timber products also play a vital rolein construction of Concrete structures. Everyconstruction site needs thousands of running metersof Timber H-Beams.

In order to reduce the exploitation of timber andtimber products and maintain environmentalharmony, the Formwork Competency Cell of ECCConstruction Division has come up with a solution,an alternative to its own H-16 Timber Beam with I-160 Aluminum Beam.

This is basically aluminum extrusion of closedsection and carries high load carrying capacity forshort span. L&T obtained the copyright of theprofile from the Copyright Office of Govt. of Indiabearing Registration nos L-27038/2006.

This beam will be used as flextural member tosupport sheathing element for application of slab &Beam Formwork as well as Wall & ColumnFormwork. Polyethyl infill locked in the serrationof profile will also gives the comfort of nailing.

Copyright Obtained for Hollow I-160 Aluminium Beam

68

L&T’s Construction Skills Training Institute(CSTI) has added the welding trade to thecourses it has been offering over the pastten years. The new course was launched atChennai on December 16, 2006 by Mr. K.V.Rangaswami, Member of the Board & Head-Construction, L&T. Mr. K. Venkataraman, Sr.Vice President, L&T, released the coursecurriculum and skills standards for the weldingtrade . The f i rs t batch inc luded twe lvetrainees.

The training programmes already in place arecivil- and electrical-oriented and cater mainlyto the requirements of building projects. Withthe introduction of welding trade, CSTI meetsthe mechan i ca l - re la ted needs o f t heconstruction industry for industrial projectslike steel plants, petrochemical complexes and

On January 24, 2007, the state of Gujarat took itsfirst major step on the technology super-highwaywith the proposed L&T Knowledge City in Baroda.Mr. A. M. Naik, Chairman & Managing Director,L&T, Performed the ground breaking and foundationstone laying ceremony for this new facility.

In his address, Mr. A. M. Naik urged the employeesto leverage L&T Knowledge City to create value

for the country and build a strong nation with avibrant economy.

This new facility, the only one of its kind in Gujarat,is to be set up in an area of 112 acres between theAjwa and Waghodia crossings on Ahmedabad-Mumbai Highway (NH-8). It will entail an investmentof Rs.500 crores in infrastructure and building alonefrom L&T, spread over a period of 5 years.

Eleven buildings will be constructed in the firstphase which wil l house off ices of L&T’se-Engineering Solutions, EPC Businesses,L&T-Sargent & Lundy and L&T Chiyoda. Otherfacilities planned are Project ManagementInstitute, Convention Centre, EmployeesHostel, Residential Colony, Food Courts andEntertainment Facilities.

A trainee undergoing the weldingtraining

process plants. The eligibility criteria foradmission to the course are 18 to 24 vears ofage, tenth standard pass, experience of twoyears or ITI pass (desirable) together with anormal physique. The course duration is twomonths.

CSTI is situated on a 5-acre plot of land inManapakkam on the outskirts of Chennai in asetting conducive to vocational training.

The Institute, established by L&T in 1995, haspermanent infrastructure and training facilities

to provide structured training in the followingtrades: 1) Formwork Carpentry 2) Masonry(Brick work) 3) Bar Bending and Steel Fixing4) Plumbing & Sanitary 5) Electrical Wiremanand 6) Trade Assistant.

The structured training will enable both newentrants and workers with some experiencein the industry to progressively improve theirskills level and knowledge competency in therespective trades. The Institute has branchesin Ahmedabad, Bangalore, Delhi, Kolkata andMumbai.

CSTI Launches Training in Welding Trade

L&T Lays Foundation for Gujarat’s First Knowledge City

Mr. K.V.Rangaswami inaugurating the welding trade at CSTI, Chennai

69

Cognizant Technology Solutions, Chennai hasawarded a contract to ECC for the design andconstruction of Phase-1 works for SDB 1& 2,Canteen Building, External Works and Utilities attheir MEPZ campus, Tambaram, Chennai. Thecontract valued at 270.10 crores is to becompleted within a period of 550 days. The majorscope of work includes 73000 Cum of excavation,47954 Cum of concrete, 2,25000 Sqm ofshuttering, 6268 t of reinforcement and 68000Sqm of flooring works.

ECC has bagged a contract valued at 169.90crores from Hindustan Latex Limited, Noida. UP,for the design, construction, procurement,installation and commissioning for superspeciality block, trauma care center, nursingcollege at Jawaharlal Nehru Institute of PostMedical Education & Research (JIPMER),Pondicherry. The contract duration is for 20months from October 2006.The major quantumof work includes 55000 Cum of excavation, 61300Sqm of filling, 23150 Cum of concrete, 1,10,000Sqm of shuttering, 2610 t of reinforcement,35970 Sqm of flooring, 38400 Sqm of waterproofing and other medical equipments in general.

L&T (Oman) LLC, has secured orders valued atUS$ 120 mil l ion (Rs. 550 crore) for theconstruction of multi-storied apartments andvillas at Sohar in the Sultanate of Oman.

A prominent business group in the Sultanate isimplementing a greenfield township project atSohar, 300 km from Muscat, to meet theincreasing demand for residential properties. L&TOman has successfully bid for and securedcontracts for two packages in the township.

The packages are worth US$ 56.5 million (Rs.259 crore) and US$ 63.5 million (Rs. 291 crore)and are to be completed in 18 months fromOctober 2006.

Larsen & Toubro (Oman), a joint venture ofLarsen & Toubro Limited-India and the ZubairCorporation, has established a strong presencein Oman over the last ten years and is well set toconsolidate its position in the years to come.

L&T in joint venture with Alpine Mayreder BauGmbH, Austria, has bagged an order valued atRs. 456 crores from NTPC Limited (a Governmentof India enterprise) for the execution of 4 x 130MW Tapovan Vishnugad hydropower project inUttaranchal.

The package includes construction of a concretelined head race tunnel of approx. 11.3 km lengthand 5.6 m finished diameter, using, partly by,tunnel boring machine and partly by roadheader/drill and blast. The project is located in districtChamoli on the Dhauliganga river, a majortributary of Alaknanda.

This is the second hydropower project L&T willexecute in Uttaranchal. The earlier project, SingoliBhatwari project being implemented through BOTroute, is located 125 km from Tapovan Vishnugad.

L&T has secured an order valued at Rs. 418crore (USD 94.33 million and AED 346. 68 million)from the Abu Dhabi Water & Electricity Authorityfor the construction of six major electricalsubstations in the Al Ain sector of Abu Dhabi.

According to the terms of the contract, L&T willsupply and install 33/11kV primary substationsto the specifications of the international consultantMott MacDonald. The project, which includesdesign and construction of civil building and over120 km of 33 kV cabling, will be completed within18 months.

The L&T-built substations will come up at AlMutaredh, Al Mezyad South, Al Dhaher South,New Al Qua’a, Al Qattara and Civic Centre toreinforce the region’s power distribution networkand help meet the increased demands for powerin the region.

Each substation consists of 33 kV gas insulatedswitchgear, 11 kV air insulated switchgear, 15MVA 33/11 kV transformers, substation controland monitoring system, protect ion andtelecommunication system, DC system andauxiliaries.

The contract also encompasses design andinstallation of utilities such as air conditioningand lighting systems.

L&T has won a contract valued over Rs 5400crores from the GMR-led Delhi InternationalAirport Private Limited for the expansion andmodernization of the Delhi International Airport.The order, secured against internationalcompetitive bidding, is an end-to-end contractthat involves design and construction of a stateof the art passenger terminal, and one of Asia’slongest runways. L&T will also carry outassociated work for the airport, scheduled to becommissioned in time for the prestigiousCommonwealth Games in 2010.

Commenting on the order, L&T’s Chairman andManaging Director, Mr A.M. Naik, said “L&T ishappy to participate in providing a world classairport for the country’s capital. We have anexcellent professional relationship with theproject developers led by the GMR Group, andlook forward to building a magnificent gatewayfor international visitors to India.

As the country’s leading company engaged inbuilding infrastructure for India, L&T’s strategicplan involves focusing increasingly on largemagnitude projects in critical sectors likeairports, ports, power and upstream oil andgas.”

The new terminal (Terminal 3) will come upadjacent to the existing international terminal,and will have a number of advanced features.Over 130 check-in counters and 70 emigrationdesks will cater to both domestic and internationaltraffic and will handle 37 million passengers perannum. This is more than twice the present traffic.The new terminal building will have a total builtarea of 4.8 million sq ft, and will include 74 aerobridges, 56 passenger travelators, IT andsecurity systems, E&M systems, etc. A new4.43 km runway will be one of the longest inAsia, and equipped with CAT III B – a landingsystem that enables landing with a visibility ofonly 50 meters - will be operational in 2008. Thecontract also involves connecting taxiways,satellite fire fighting facilities, etc.

The ‘airside’ work to be executed by L&T includesaprons, remainder taxiways, cargo terminals,aircraft maintenance facilities, utility services andother primary infrastructure support facilities. The‘landside’ works includes a six lane road connectingthe terminal and national highway NH-8, a newmulti-storey car park to accommodate 4300 cars,and a forecourt for the new terminal.

New Orders

Delhi International Airport Tapovan VishnugadHydropower Project

Substations in UAE

Software Park for CTS

JIPMER, Pondicherry

Orders from Oman

70

L&T participated in the Build Expo 2006-the largestconstruction expo organized by BAI (Kochi Chapter) inKochi. This took place at at Jawaharlal Nehru Stadiumat Kaloor, Kochi, during December 2-6, 2006. Nearly100 companies from construction equipment; buildingmaterials; and real estate participated in the event.

L&T took part in a 100 Sqm pavilion and depicted L&TFormwork components, L&T Concrete and majorprojects of ECC across all business units.

Mr. Raghava Reddy, National President, CII and Mr.Mani Sankar, Deputy Mayor of Kochi inaugurated theshow and visited L&T’s stall. Numerous visitors mainlyfrom builders fraternity appreciated L&T’s stall design,which was done up using formwork components. Amodel of Tejomaya IT Park - the state-of-the-art ITPark in Kochi promoted by L&T Tech Park was alsodisplayed. Salient features of L&T Formwork Systemand Tejomaya were briefed to visitors by marketingmanagers of L&T Formwork and L&T Tech Park .

Build Con Expo 2006 – the first of its kind in Ahmedabad– was organized by CII (Gujarat Chapter) and held atUniversity Grounds, Ahmedabad, during December15 – 17, 2006. This major construction expo ofAhmedabad had nearly 75 companies participating fromdifferent segments of the industry (constructionequipment; building materials; facilities and serviceproviders) in three halls.

ECC participated in the region for the first time anddisplayed its expertise in building materials (L&TFormwork and L&T Concrete) and turnkey constructioncapability in an area of 54 sqm through photo panels.Landmark projects executed in Ahmedabad regionacross all BUs were highlighted in our display.

Mr. Chetan Tamboli, Chariman-CII, Gujarat and Mr.Amol Sanghi, M.D, Sanghi Industries, inaugurated theexhibition. Other Indian Companies, who participatedin the exhibition include Kirloskar, Schwing Stetter,Ultratech, Essar, Godrej, Universal, SREIInfrastructure and few overseas companies.

The unique design and the attractive posters of ECC’sstall was cynosure of all eyes.

The response for the exhibition was very good andmany prospective clients thronged ECC’s stall Thelocal MLA Mr. Patel said that whatever projects L&T

has undertaken in Gujarat is a hallmark of high-classquality and wished that L&T should undertake moreA team of 18 members from ABRO and RMC plants

Build Expo 2006 at Kochi

Build Con Expo 2006, Ahmedabad

A view of L&T’s stall at Build Expo 2006, Kochi

A view of L&T’s stall depicting building materials and turnkey constructioncapabilities at Build Con Expo 2006, Ahmedabad

manned ECC’s stall. From planning to conduct of theexhibition the team displayed excellent involvement.

71

To create awareness and provide a wide range ofexposure to stakeholders on the latest developmentsin the construction sector, the Construction Expo2006 was conducted in the Land of Thunder Dragon(Bhutan). Jointly organised by Standard and QualityControl Authority, Ministry of Works and HumanSettlement, Royal government of Bhutan and NewWave Display Services Pvt. Ltd., Kolkata, this fourday event was held at the Changlimithang ground,Thimphu, the capital of the Royal Kingdom of Bhutanduring October 14 –17, 2006.

The exhibition was formally declared open by theHon’ble Prime Minister of Bhutan Lyonpo KhanduWangchuk and Hon’ble Health Minister LyonpoJigme Singye in the presence of Dr.Ketan Shukla,Deputy Chief of Mission, Embassy of India, Thimpu.This is the third such expo to be held in Bhutan andthe first one was held in December 2003.

More than 30 Indian companies including 5Bhutanese companies both from the governmentand private sector participated in the Expo. L&T,JP, HCC, and many other manufacturers, suppliersand dealers of construction related products andservices from India took part and set up their stallsat the expo demonstrating their capabilities andmodern technologies available in the field ofconstruction. Concurrent technical seminars werealso held during the expo for the benefit of the localengineers, builders and other young participantsfrom Bhutan.

During the closing ceremony, Hon’ble Secretary,Ministry of Works & Human Settlement, Dasho

Tshering Doprji thanked all participants andemphasised the need for organising such eventsperiodically to expose Bhutanese constructioncompanies to the latest technologies available inthe world.

During the course of the expo, the Royal Governmentof Bhutan invited L&T representatives to theSecretariat and made enquiries about its interest in

undertaking construction of certain importantprojects in the offing, such as:

♦ Construction of Stadiums at Thimphu♦ Expansion of Runway at Paro airport♦ New major hydel projects

In addition, Mr. Sangay Dorjee, Director of theDepartment of Occupational Standards, Ministry ofLabour & Human Resources, Thimphu, Bhutan,showed interest in knowing more about our CSTIoperations and construction trade certifications. Adelegation also visited L&T Chennai, in this context.L&T’s stall attracted huge crowds for its uniquedisplay as well as high pitched audio-visual filmsand videos. Thus, L&T has left an indelible mark inthe minds of the people and government of Bhutanthrough this four day event at Thimphu.

Construction Expo, Thimphu - Bhutan

Hon’ble Prime Minister of Bhutan,Lyonpo Khandu Wangchuk (middle)along with the Health Minister (left) atL&T’s stall

Top and bottom: Two views of L&T’s stall

72

Mr. P.K. Govindaswamy, Head-Quarry &Crushing and Mr. A. Ravikumar, Manager-Quarry & Construction Blasting, ECC HQ,Chennai, presented a technical paper titled “Construction Aggregates, Importance to Mankind”at a colloquium on “Mineral Potentialities of TamilNadu Nadu and Kerala-A macro level review witha thrust on XI five year plan” in Chennai on October13, 2006.

The presentation highlighted the amazing use ofaggregates in diverse areas such as construction,paints, glass, medicine etc. Drawing a parallelbetween the global and Indian aggregate scenario,the paper highlighted that countries like USA haveestablished super quarries producing over 5 milliontons of aggregates per annum with at least 150million tons of reserve and the industry as suchwas more organised with corporate playerswhereas the Indian sector is fragmented with miniquarries.

The presentation urged the need to organize andmeet the global demand of aggregates, which islikely to exceed 21.7 million metric tones in 2007

with an estimated annual riseof 4.7%. The total size of theIndian aggregates market isestimated at Rs 9000 – 10000crores. The high aggregateconsumption in the westerncountries and the diminishingavailability has resulted in thedevelopment and use ofaggregate substitutes whereasin India it is still in its infantstage. The paper highlighted thescope for large-scaleinvestment and scientific quarryoperations by major players.

Being a state controlled industry in India, issuessuch as short term policy decisions, unscientificexploitation of scarce resources are some of thefundamental problems faced by the Indianaggregate industry. The paper called for a strategicapproach with focus on forecast, demand andconsumption of aggregates, develop and understandresource constraints, government assistance inplanning of aggregate supply and demand to match

Mr. V.Sukumar Hebbar – Principal Architect, EDRC-HQ,Chennai, presented a technical paper on “Planning, Designing &Construction of Healthcare Facilities – L&T Experience” at theInternational Conference on Planning & Designing of Healthcare facilitiesorganised by AIIMS – New Delhi along with Ministry of Health &Family Welfare in Goa during September 15-17, 2006. More than 350dignitaries including architects and doctors of national and nternationalrepute attended the conference.

with urban development. Suggestive means ofapproach such as identification of major geologicalsources, location of quality aggregate resources,mandatory EIA for establishing new units, technicalexpertise, single window regulation of the sector,training facilities, safety procedures, change overfrom minor mineral to major mineral status werehighlighted in the presentation which was wellreceived among the participating industry experts.

At the National Award Competition for Professionals onStructural Steel Design and Construction –2005 organised byINSDAG, L&T was awarded the third prize for team work inthe project “ HITEX at Hyderabad” for innovative structuralsteel design of exhibition hall roof during the workshop on“Steel in construction” held at Mumbai on November 24,2006. Mrs. M.F. Febin, Engineering Manager, Civil, EDRC-B&F and her team guided by Mr. S. Kanappan – Head, EDRC-B&F carried out the design.

Mr. S. Kanappan, receiving the award from Mr. TanajiSatre, Joint CEO, MIDC. Mrs. M.F. Febin is at theextreme right.

Construction Aggregates, Importance to Mankind

Planning, Designing & Constructionof Healthcare Facilities

Innovative Structural SteelDesign Award for L&T

Mr. A. Ravikumar, delivering the presentation on“Construction Aggregates, Importance to Mankind”co-authored by Mr. P.K. Govindaswamy (extreme right)

Mr. V.Sukumar Hebbar presenting the technicalpaper on “Planning, Designing & Construction ofHealthcare Facilities”

73

Ms. M.F. Febin,E n g i n e e r i n gManager, EDRC-HQ, B&F, made apresentation on“Recent Trends inCivil Engineering”in the National leveltechnical symposium,F O C A L P S ’ 0 6

organised by the Civil Engineering Associationand the department of Civil Engineering ofPeriyar Maniammai College of Technologyfor Women, Thanjavur on 21st September,2006. The presentation focused on latest trendsin civil Engineering, buildings & factoriesconstructed by L&T - ECC including case studiesof HITEX and Convention Centre – Mauritius.

M.F. Febin

Mr. S . V i rapan , Eng ineer ingManger, Bu i ld ing Ut i l i t i e sCompetency Ce l l and Ms . M.Lavanaya, Design Engineer – EDRC,HQ, Chennai, presented a technical paper“Membrane Bioreactor (MBR) in SewageTreatment Plants” at the “International

S. Virapan M. Lavanaya

Conference On Cleaner Technologies andEnvironment Management” in PondicherryEngineering College campus.

Their paper was adjudged the best among these lec ted e igh t papers ou t o f t he 120presentations made at the conference.

Their paper highlighted the advantages MBRhad over the convent iona l wastewatertreatment systems and the potentialities formembrane application in treating industrialeffluents.

Exper ts and de lega tes f rom d i f f e ren tinstitutions from India and abroad participatedin the program and shared their experience.

International Technical Meet on Steel Industry at Ranchi

L&T and its technology partner Paul Wurth,Luxembourg jointly sponsored an International Meeton Steel Industry at Ranchi during 18-20 January2007. The meet was organized by the RanchiChapter of IIM; Centre for Engineering &Technololgy, SAIL; Research & Development Centrefor Iron & Steel, SAIL; and Mecon Limited and wasattended by over 200 delegates from across theworld.

The aim of the meet was to understand the fullimplications of the projected growth of the IndianSteel Industry from the present level of 42 MTPA to120 MTPA by 2020 and tackle the challenges inequipment manufacture and plant construction aswell as finding the right manpower to shoulder thisresponsibility in the face of the attraction that theIT sector holds for engineers.

At the first Technical Session L&T and Paul Wurthpresented papers on Steel Plant Construction andon the latest developments in BF BLT equipment.L&T’s paper was presented by Mr. R.P. Das, Sr.DGM (Business Development), Minerals & MetalsBU, and was well received, judging by the responseit evoked in the question & answer session. Thequestions touched upon L&T’s limited engagementin manufacture of steel plant equipment, thecompany’s strategy in not taking up projects belowa certain value and the scope for procurement ofequipment from China.

Mr. Peter Zoneveld, CEO, Danieli Corus, in hispresentation made a plea to SAIL and other buyersfor a tendering process that would give a fairopportunity to even those companies whose pricesare somewhat higher but who offer more advancedtechnologies. Stopinc, Switzerland made a pointthat technologists and end users should lead projectand technology selection and that purchase andcommercial departments should play more of a

complementary role. SSIT China said that Indianbuyers should study the quality grading system ofChinese manufacturers and take their advice tosource the best and economical products from China.

Some major organizations, which were representedat the meet, include Messrs. Bosch Rexroth, UCAR,Siemens VAI, IMS Maco, ZAO VTf, Mckeown andABB.

Mr. R. P. Das (right) receiving a memento from Mr. Rajesh Singh, General Manager,CET, SAIL

FOCALPS ’06 Membrane Bioreactor in Sewage Treatment Plants

74

Sales

Gross sales from operations of Larsen &Toubro Limited for October–December 2006stood at Rs. 4200 crore as against Rs.3742 crore for the corresponding quarterof the previous year. The share of revenuesfrom international operations constituted 19%of the gross revenues reported for thequarter.

For the period April–December 2006, theorder booking was higher at Rs. 22944crore, registering 41% increase over thecorresponding period of the previous year.

Profit after tax (PAT)

Prof i t a f ter tax [PAT ] fo r the quar terOctober–December 2006 at Rs.344 crore ish igher by 33% , when compared to thecorresponding period of the previous year.Excluding extra ordinary and non-recurringitems, the PAT grew by a healthy 84% overthe corresponding quarter of the previousyear.

PAT fo r the n ine -month per iod Apr i l–December 2006 at Rs. 702 crore is higher by29%, when compared to the correspondingperiod of the previous year. Excludingextra ordinary and non-recurring items, thePAT rose smar t l y by 69 % o ver thecorresponding previous period.

Group Financials

Group PAT for the quarter October-December 2006 at Rs 604 crore ishigher by 80% when compared to thecorresponding period of the previousyear. Excluding extra ordinary and non-recurring items, the PAT increased by 90%over the corresponding previous period.

Group PAT for the nine-month period April-December 2006 at Rs 1529 crore is higher by82% when compared to the correspondingprevious period. Excluding extra ordinaryand non- recurring items, the increase inPAT is 89% over the corresponding previousperiod.

The total income of the Group for the nine-month per iod Apr i l -December 2006increased to Rs. 14121 crore from Rs.11743 crore achieved in the correspondingperiod of the previous year. Most of the

businesses of Subsidiary and Associatecompanies have performed exceedingly wellduring the period, thereby boosting the Grouprevenue & profitability.

Engineering & ConstructionSegment (E&C)

The Company ’s E&C segment repor tedsignificant growth in order booking during thequarter, in line with the increased activityin the domestic & international marketsparticularly in the Infrastructure & Hydro-carbon sectors.

The E&C order booking at Rs.8172 crore forthe quarter ended December 31, 2006 postedan increase of 26% when compared to thecorresponding quarter of the previous year.The share of International orders bookedduring the quarter was around 12% of thetotal orders booked.

For the nine-month period, the E&C orderbooking was higher by 43% at Rs. 19127crore, over the corresponding previousper iod , wh i ch re f l ec ts the Company ’ssuperior competitive strength in the E&Csegment. The Company expects this growthtrend to continue in the last quarter of thecurrent fiscal year.

E&C segment revenue for the quarter endedDecember 31, 2006 was at Rs.3160 crore asagainst Rs. 2951 crore for the correspondingquarter of the previous year. The share ofexport revenue for the quarter at Rs.614 crorerepresents 19% of the segment revenue.

Segment profits [PBIT] at Rs. 325 crore forthe current quarter recorded a smart growthof 56% over the corresponding quarter ofthe previous year, largely due to betterselection of jobs, close monitoring andcontrol of contract execution costs throughappropriate risk management frameworkand economies of scale achieved throughlarger size of orders.

The segment order backlog as at December31, 2006 is robust at Rs.34142 crore.

Electrical & ElectronicsSegment

Electrical & Electronics segment reported arobust growth in sa les , re f lec t ing thesuperiority of the Company’s products and

its contemporary applications in a rapidlygrowing market. The segment revenue atRs.483 crore for the quarter ended December31, 2006 was significantly higher whencompared to Rs . 383 c rore fo r thecorresponding quarter of the previous year.

The increase reflects a sustained growth inthe Electrical Standard Products, ElectricalSys tems & Equ ipment , Con t ro l &Automation and Metering & ProtectionSystems businesses.

The Company continues to be a market leaderin Low Tension Switchgear products throughits cost efficient manufacturing, widespreaddistribution network, product innovation andquality.

Machinery & IndustrialProducts Segment

The segment revenue at Rs. 407 crore forthe quarter ended December 31, 2006 washigher when compared to Rs. 349 crore forthe corresponding quarter of the previousyear.

The growth in revenue was witnessed in mostof its product lines, both manufactured andtraded. Increased volumes, higher pricedifferentials and improved manufacturingefficiency contributed to better margins andprofitability over the corresponding quarterof the previous year.

Outlook

Indian economy is poised to sustain itsaccelerated growth momentum led by animpressive performance of the manufacturingand infrastructure sectors. The Company’sleadership position in these sectors holdsgood potential in terms of continued upsurgein order booking and sales.

The current economic buoyancy seen in theMiddle-East region, where the Company isbuilding up a significant presence, also offersseveral promising business opportunities forall business segments of the Company.

The revenue growth, which was modest inthe first nine months, is expected to be at ahigher level in the last quarter. The smartimprovement in margin is expected to bemaintained in the short and medium term.

Performance for the Quarter Ended December 31, 2006

75

The Sixth Brunel International Lecture wasorganized on October 25, 2006 jointly by theInstitution of Civil Engineers UK (ICE) and Larsen& Toubro Limited, ECC Division. The venue wasMortensen Block, Convention Centre, in ECC’sManapakkam Complex.

Prof. Paul W Jowitt, Vice President, ICE, deliveredhis International Lecture on ‘Engineering Civilisationfrom the Shadows’ as part of the Sixth BrunelInternational Lecture that is being taken acrossthe Globe. The Chennai lecture was the first of twoseries in India. Similar events were held earlier inEngland and other countries such as Tanzania, SouthAfrica and Sri Lanka.

Profiling great engineers and 19th Century heroes,Prof Jowitt highlighted the connection betweenEngineering, Technology and Economics. “Worksof great engineers have had great significance tothe extent that it did add over 2 decades to humanlife span. There are innumerable projects that couldtestify this,” he said.

He provided a ‘big picture and urged the engineersto view this in everything they do. Prof Paul saidthe climate change people talk of is real and thatnatural calamities such as hurricane, earthquakeand tsunami threaten the civil infrastructure. Healso reiterated that in the global context povertywas real and said that the creation of infrastructurewill be the key to sustainable development.

He also called for a change in human behaviour andadvocated a shift to appropriate technology,embarking on change in fuel and energy source -be it wind, wave, hydel, hydrogen, hydropower oreven nuclear. In effectively creating the requisiteinfrastructure, he stressed the need for goodgovernance and transparency.

ICE is a body, which facilitates ‘Engineering withoutFrontiers’ and shares knowledge across frontiers,beyond communities and nations. Prof. Jowitt calledupon engineers to evaluate their own work - as towhat it meant to them, their profession, theirorganization, and its consequences action andultimately, one’s own will to execute the work. Heurged the engineering community to ‘make povertyhistory’.

Mr. K.V Rangaswami, Member of the Board &Head-Construction, Larsen & Toubro Limited, wasbestowed the ICE Fellowship Certificate for hisnotable contribution to civil engineering.

In his presidential address, Mr. Rangaswamiexpressed that with the establishment of ICEChennai Chapter, there would be enormous impetusto Civil Engineering in India, particularly with theyounger generation who would gain by virtue ofparticipation and knowledge sharing with globalengineers.

Mr. G.D. Sharma, VP & Head-HR, L&T ECC Divisionreceived the certificate recognising L&T ECC Divisionas “Approved Employer” for training youngengineers preparing for professional review for theChartered Membership of ICE-UK. This is the firsttime in India that an organization has been accordedsuch status.

As many as 13 L&T Engineers were awarded theMembership of ICE-UK after a Professional Reviewconducted for the first time in India a few monthsago.

Mr. S. Ganguly, GM - Personnel & HRD, emphasisedthe need for association with such internationalprofessional _ bodies in view of L&T’s growingoperations internationally.

Mr. P.A.K. Murthy, Country Representative of ICE,Chennai introduced the Prof Jowitt and the ChennaiChapter of ICE.

Chartered Members of ICE-UK from L&T seen with Prof. Jowitt and Mr. K. V. Rangaswami

Mr. K. V. Rangaswami, Head Construction, L&T, & Member of the Board, deliveringhis presidential address

“Engineering Without Frontiers”

76

Bangalore International Airport Ltd. (BIAL)project site in association with the FamilyPlaning Association of India (FPAI), a leadingnational NGO working in the area of sexualand hea l th ca re , o rgan i sed an AIDSawareness campaign on December 1, 2006on the occasion of World AIDS Day.

Mr. G.D. Sharma, Vice President & Head -HR, L&T-ECC, and Mr. A.K. Monnappa, IASand Director, Dept. of Women’s and ChildDevelopment, Govt.of Karnataka, inauguratedthe function.

Others present on the occasion were Mr.G.V. Narasimha, SPM PT&D Sector, Mr. S.S r in i vasan , Reg iona l Acc ts . & Admin .Manager , Mr . Javeed Shak i l , P ro jec tManager, BIAL, staff members, employeesfrom BLRO and BIAL site and more than 300workmen.

The campaign aimed at generating awarenessamong the workmen and staff of BIAL projects i te on HIV/AIDS , r i sks i nvo l ved andpreventive measures.

In his welcome address GDS emphasized theimportance of healthy and active individualsin the process of nation-building. He pointedout that it is not just structures but the qualityof human resources which is vital for nationaldeve lopment . He re -a f f i rmed L&T ’s

commitment towards the society as part ofits corporate social responsibility.

Mr. Monnappa in his address said that it istime to intensify action to generate awarenessand work on the infected people. He also saidthat social ostracization of HIV/AIDS-affected

people needs to be addressed by changingpeople’s attitudes.

Mrs . Ra j Mathur , P res iden t o f FPAI ’ sBangalore branch, appreciated the initiativestaken up by L&T and the promptness of theirworkforce. She asserted that the spread ofHIV can be prevented by more aggressiveinformation sharing and appealed to theaudience to take a pledge to eradicate thedevastating disease.

Dr. Sheela Mane, Executive Member, FPAI,explained the difference between HIV andAIDS, and factors causing the disease, modesof transmission, indicators and preventivemethods.

A street play on AIDS was performed byartists from CARDS, Mangalore, which wasvery moving and had a profound impact onthe audience. Participants took a candlelightpledge to spread awareness of HIV/AIDSamong the people. An exhibition of posters,pamphlets and audio visual presntation on HIV/AIDS was organised.

Mr. Javeed Shakil proposed the vote of thanksand attributed the success of the campaign tothe dedicated team work of staff from projectsite, volunteers from NGOs and BLRO.

Mr. G. D. Sharma, Vice President & Head - HR, L&T - ECC, inaugurating the AIDSAwareness Campaign at Bangalore International Airport Ltd. (BIAL)

Participants taking a candle light pledge

AIDS Awareness Campaign at BIAL Project

77

A free medical camp was conducted by Konaseema Power project site at Deveapallivillage under East Godavari district, A.P. on January 7, 2007. Dr. SomasundraReddy, Ex-MLA inaugurated the camp. This was attended by more than 800 residentsfrom nearby villages. A team of doctors rendered the service. Free diagnosis andmedicines were distributed to the patients. A blood donation camp was alsoorganized on the same day and 30 persons donated blood. M/s Chiranjeevi CharityTrust extended all support and doctors/nurses from KIMS, Amalapuram came tosite for extending necessary assistance.

Appreciating the efforts of L&T as a goodcorporate citizen, and the yeoman servicerendered by ECC’s Construction Skills TrainingInstitute (CSTI), the Bombay Stock Exchange(BSE) awarded L&T the Best Corporate SocialResponsibility Award.

The award was received by Mr. S. Natarajan,Head-CSTI, ECC, Mr. G.D. Sharma, VicePresident-HR, ECC, and Ms. Sanyogta Raina,Manager-Corporate Social Initiatives, L&T, at aceremony held in Mumbai on December 15, 2006.

Mr. Natarajan made a passionate presentationto the contest jury on L&T and the role of CSTI increating employment opportunities, skillsugradation and social upliftment.

BSE in association with Times Now (a TimesGroup and Reuters Service Company) presentedthe ‘Business for Social Responsibility’ (BSR)Awards for Corporate Governance. Thecompetition hosted by ITM Business School,Mumbai had the theme: ‘Questioning Assumptions- Changing Framework’.

The panel of jury was headed by Mr. HaritNagpal, Operations Director, Hutchison EssarLtd., and Mr. Rajnikant Patel, MD & CEO, BSE,and comprised 14 heads of companies. The

award is part of a wide-ranging initiative topromote Business for Social Responsibility inIndia. This involves developing responsible

Mr. S. Natarajan, Head - CSTI, ECC, Mr. G.D. Sharma, Vice-President - HR, ECC,and Ms. Sanyogta Raina, Manager-Corporate Social Initiatives, L&T, are seen atright with the Best Corporate Social Responsibility Award

business policies and practices and making theman integral part of organisations’ mission, values,strategy and operations.

Mr. Y.M. Deosthalee,CFO, L&T, has beenconferred theprestigious CFO Awardin the Engineering &Capital Goods sector byIndia’s leadingbusiness TV channel,

CNBC-TV18. The awards ceremony was held inRas-al-Khaimah, the UAE, on November 26,2006.

Instituted by CNBCTV18 in 2006, the CFOAwards recognize the efforts of CFOs increating wealth for the organizations,stakeholders and customers.

This is the second such honour won by Mr.Deosthalee. Earlier, he had won the CFO of theYear Award instituted by the Economic Times,Economic Intelligence Unit and AmericanExpress.

Medical Camp at Konaseema Power Project CFO Award for YMD

Best Corporate Social Responsibility Award for L&T

Medical camp in progress

78

Continuing the tradition of honouring excellencein Quality in our projects, the Quality RollingTrophy for the year 2005-‘06 was presented tothe winners on January 2, 2007 at the ConventionCentre, ECC-HQ, Chennai. This year the Trophypresentation ceremony was held in conjunctionwith the customary New Year address by Headof ECC Mr. K.V. Rangaswami.

As in the earlier years there was enthusiasticparticipation in the competition, with thirty-sevensites getting short listed for the final rounds. Theentries were assessed on the basis of variousparameters such as product qual i ty ,housekeeping, customer satisfaction, projectschedule, project cost management, safety andadherence to the Company’s quality managementsystem. They were assessed in stages by theSite Quality team, Quality Management Committeeof the Region (QMC [R]), a board of examinersconsisting of QMC (R), internal auditors, and theQuality Management Committee-HQ.

The awards were presented by Mr. K.V.Rangaswami, Member of the Board & Head-Construction, Mr. K. Venkataraman, Sr. V.P.Hydrocarbon & Power, Mr. K.G. Hariharan, Sr.V.P. & Head-Industrial Projects & Utilities, Mr.V.B. Gadgil, EVP & Head-B&UI and PT&D SectorBU (GCC Countries), Mr. J. Ganguly, EVP &Head-Resources Support & Supply Chain, andMr. K. Venkatesh, EVP & Head-DevelopmentalProjects. The winners are :

Winners of the Quality Rolling Trophy seen with Mr. K.V. Rangaswami and other Senior Executives

Site Region Project/Construction Manager

Anand Rajkot Pipeline ABRO V. Thirumalaisamy

GWRDC - Ahmedabad ABRO E.P. Sajit

Wockhardt Hospital BLRO K. Nataraj

Kudankulam Nuclear Power Plant CNRO P. Paulraj

Kuttiyadi Hydel Power Project CNRO M.V. Ramachandran

Allahabad Bridge across River Ganga DLRO G. Vinod

DMRC Cut & Cover Tunnel DLRO Dharmendra KR Sharma

ASAHI Glass Factory DLRO B.M. Verma

SALPG-Underground LPG Storage Cavern HYRO K.S.R.K. Verma

Sri Satya Sai Water Supply Project -

O&M Anantpur HYRO P.R. Harikrishna

Coal Handling Package for Bakreswar TPP KKRO S. Raja

Tankage, Vessel and Piping Job at Lanjigarh KKRO P.K. Bandyopadhyay

Jharkand Road Project KKRO Chunduru Rajendra Prasad

400 kv D/C Maithon-Ranchi -

Transmission Line KKRO V. Mohana Sundaram

Durgapur Project Limited-Durgapur KKRO B. Paul

AWTF & SFSF BARC Tarapur MBRO B. Sundaramoorthy

G-1296 Project Al Ain V.V.V. Satyanarayana

Quality Rolling Trophy 2005-06

Quality Trophy Winners - 2005-06

79

ECC’s PTA Project Site - IOCL Panipat, has wonthe prestigious Silver Award of the Royal Societyfor the Prevention of Accidents (RoSPA), UK. Theaward is in apt recognition of ECC’s excellence inoccupational health and safety performanceachieved at site during a period of three years from2003 to 2005. This is the fifth RoSPA award won byECC.

Instituted in 1956, the RoSPA safety awards arecategorised into ‘Gold’, ‘Silver’, ‘Bronze’, and ‘Merit’Awards with additional accreditation for specificissues. In deciding on the winner, RoSPA’s focusis on total man-machine-environment system toassess accident potential and prevention ofaccidents. Greater emphasis is laid on engineeringtechniques in accident prevention than on merecorrection of unsafe practices.

The RoSPA Awards won earlier for excellent safetyperformance include the RoSPA Merit Award forOccupational Safety at ECUs Jawaharlal NehruStadium Site, Chennai, in 1993, the RoSPA GOLDAward for Occupational Safety at ECC’s CoalHandling Plant. Paradip Site in 2002, the RoSPAGOLD Award for Occupational Safety at ECC’sTISCO Jamshedpur Site in 2004, and the RoSPASilver Award for DHDT & HGU Site at IOCL Panipatin 2005.

Mr. P. L. N. Murthy, Project Manager, and Mr. Ravikant Dubey, Sr. Engineer (HSE),PTA Project, IOCL Panipat, seen with the RoSPA Award

Mr. K. Venkataramanan (KV), Member of theBoard and President (E&C Projects), was electedPresident of the Indian Institute of ChemicalEngineers (IIChE). He will hold office in the 60th

(diamond jubilee) year of the institute.

Established in 1947, the IIChE is the apexprofessional society of chemical engineers inIndia, with over 18,000 members on its rolls. Ithas emerged as a national platform overseeingthe interests of the academia as well as industryin the field of chemical engineering and alliedsciences.

KV said he would direct his efforts to build onthe historical traditions of the institute to expandits role and relevance in contemporary industryand society.

Making particular mention of the youth, he saidthe institute would enhance its engagements withyoung chemical engineers and provide avenuesto help them enhance their capabilities andexpertise.

K. Venkataramanan (left) receiving a memento from the outgoing President ofIIChE, Prof. S. Venkateshwar, Principal, University College of Technology,Osmania University, Hyderabad.

KV Elected President of Indian Institute of Chemical Engineers

ECC Wins its Fifth RoSPA Award

80

One of India’s largest circulated constructionbusiness magazines, Construction World, andNational Institute of Construction Managementand Research (NICMAR) honoured L&T with twoprestigious awards in Mumbai on December 01,2006.

Mr. K.V. Rangaswami, Member of the Board &Head-Construction, received the ‘Largest & MostProfitable Construction Company in India’ Awardfrom Mr. Rajiv Ratna Shah, Chief Guest andMember - Planning Commission, Government ofIndia, and ‘The Most Admired ConstructionCompany in the Industry’ Award from Mr. LalitSinghal , Director-General of SEZ units,Government of India.

Accepting the honour, Mr. Rangaswami said thathe would dedicate the award to the ECC team,customers and business associates. In amagnanimous gesture he further commended allthe prize winners and urged them to collectivelyenhance standards in the country’s constructionindustry.

Construction World-NICMAR Awards 2006

Mr. K. V. Rangaswami, Member of the Board & Head-Construction, receiving the‘Largest & Most Profitable Construction Company in India’ award from Mr. RajivRatna Shah, Member, Planning Commission, Government of India

Project Export Awards

L&T has won two Export Awards from TheProject Exports Promotion Council of India. Theawards are in recognition of export projectspromoted and executed by an Indian Companyfor the year 2005-2006.

Mr. V.B. Gadgil, EVP and Head-B&UI and PT&DSector Business (GCC Countries), received theaward from Mr. P.C. Chaturvedi, Member-Administration, NHAI, during the awardspresentat ion ceremony in New Delhi onDecember 16, 2006. The categories in whichL&T won the export awards are:

♦ Maximum turnover in overseas constructionand engineering projects

♦ Maximum value of overseas constructionand engineering projects

Mr. V.B. Gadgil, EVP and Head-B&UI and PT&D Sector Business (GCC Countries),receiving the Export Awards from Mr. P. C. Chaturvedi, Member - Administration,NHAI

Edited by Mr. V. S. Ramana for Larsen & Toubro Limited - ECC Division, from ECC - HQ., Manapakkam, Chennai - 600 089. The viewsexpressed in this magazine are not necessarily those of the management of Larsen & Toubro Limited. The contents of this magazineshould not be reproduced without the written permission of the Editor. Not for sale-only for circulation among the employees,business associates and customers of ECC - L&T’s Construction Division.