Heaviest portal beam installed in Maninagar for Mumbai-Ahmedabad bullet train project

In a major achievement, one of the heaviest precast-prestressed portal beams, weighing about 1360 metric tonnes was successfully installed over the Amdavad–Vadodara railway line at Maninagar. It is a part of Mumbai–Ahmedabad bullet train project. Beam is 34 metres long and has a cross-section of 5.5 metres by 4.5 metres. Five such beams will be installed near Maninagar railway station.

Installation was completed in 3.5 hours during a full traffic and power block coordinated with Indian Railways. Earlier the same operation was expected to take up to nine hours and required caution orders for nearly six months.

A 2200 MT crawler crane was used as main lifting machine. It was supported by a 260 tonne standby crane, an 80 tonne crane, man lifters, and a special lifting beam system with anchoring frames. Prestressed macalloy bars of 75 mm diameter, heavy-duty slings, and lifting beams were used to safely handle the heavy structure.

Operation involved several engineering challenges. Team had to lift a very heavy beam of around 1,360 tonnes within limited time, working space was restricted, and overhead railway equipment and multiple active railway lines made the task more complex. Beam had to be placed at a height of about 15 metres with high precision.

Engineers also carried out continuous wind speed monitoring due to large size of beam, they ensured proper coordination with railway authorities, used backup lifting systems, and conducted strict safety checks. Accurate survey and alignment control helped in safe and successful installation of the beam.