Bridge construction is one of the most demanding engineering disciplines, requiring meticulous planning, advanced technology and innovative solutions to tackle geographical, environmental and technical challenges. Afcons Infrastructure Limited has emerged as a global leader in delivering landmark bridge projects, pushing the boundaries of engineering and construction.
With over 195 bridges, flyovers and viaducts executed across the globe, Afcons has consistently demonstrated its capabilities in handling complex and technologically challenging bridge projects. As per the Engineering News-Record 2024 survey, Afcons is ranked twelfth globally in the bridge sector, being the only Indian company among the Top 25. It specialises in tackling challenges such as difficult geotechnical conditions, high seismic activity- and wind-prone zones; deep marine foundations; and innovative construction methodologies.
Delivering iconic bridge projects
Afcons has played a key role in delivering several iconic and first-of-their-kind bridge projects in India and across the world, showcasing India’s engineering excellence on a global stage. The Chenab Railway Bridge is a testament to India’s engineering excellence, standing as the world’s tallest single-arch railway bridge, 35 metres higher than the Eiffel Tower. This project posed unique challenges due to its geological conditions and engineering complexity. It is the first bridge in India designed to withstand blast loads – a design developed in collaboration with government authorities.
The arch erection and deck launching were among the most critical challenges of the project. “Climate was major hindrance to the erection of the arch. Winters brought cold winds, while summers meant dealing with extreme heat from the sun and steel structures. But we overcame all the hurdles and delivered a marvel of engineering with an unwavering focus on quality and safety,” says Giridhar R, Deputy Managing Director, Afcons Infrastructure.
“For the first time in Indian Railways, incremental launching was done on a transition curve and a longitudinal gradient, both occurring at the same location, for the deck launching of the viaduct portion of the Chenab Bridge. Typically, bridges have been constructed incrementally on a straight or curved platform with a uniform radius,” Giridhar says. Apart from the Chenab Bridge, Afcons has also constructed 16 bridges for the Udhampur-Srinagar-Baramulla Rail Link project in the harsh and rugged terrain of Jammu & Kashmir.
Another remarkable bridge project was the MG Setu in Patna, Bihar. It involved replacing an existing concrete superstructure with a new steel superstructure, a first-of-its-kind of engineering feat in India.
For the first time, a balanced cantilever bridge was converted into a simply supported superstructure. Managing a large-scale dismantling operation while ensuring the environmentally friendly disposal of waste materials posed a significant challenge. Strict environmental measures were implemented to prevent any debris falling into the river. The erection of the 120 metre-long steel truss spans over river Ganga was another formidable challenge, but meticulous planning and flawless execution ensured success.
On the global level, Afcons delivered Ghana’s largest railway project, a 97.68 km standard gauge Tema-Mpakadan railway line. The project included the longest railway bridge in Ghana, 300 metres over Lake Volta. This bridge was the first in Africa to feature raker pile foundations in unpredictable geological substratum conditions.
Building bridges in challenging terrains
One of the major ongoing projects being executed by Afcons is Package-II of the Mumbai-Pune Expressway Missing Link Project. It involves widening of the existing expressway from six lanes to eight lanes, and construction of two viaducts including India’s highest cable-stayed road bridge at a height of 132 metres along with approach roads, slip roads and others. While accessing the site in the Sahyadri ranges was challenging, it also required wind tunnel testing for both the pylons and the deck due to extreme wind loads at such heights.
Afcons is also executing the largest infrastructure project in the Maldives, the Greater Male Connectivity Project. The project involves construction of a 6.74 km-long bridge and causeway with others, connecting three islands with Male, the capital of Maldives. Numerous challenges are being faced by the project team, including a seabed filled with coral cavities, rough sea conditions and unpredictable weather. Despite these challenges, Afcons has achieved a major milestone by drilling the deepest undersea pile at 122 metre for the project. It has deployed multiple jack-up barges to provide stable working platforms, ensuring seamless execution while minimising ecological impact.
Way forward to bridging excellence
Afcons continues to push the frontiers of bridge construction through innovation, sustainability and strategic project execution. “We aim to further our global footprint by adopting cutting-edge construction techniques and enhancing sustainability measures. We remain committed to delivering world-class infrastructure that withstands the test of time and nature. Afcons is a leader in bridge construction and will continue to further its position in bridge engineering, ensuring safer, stronger and more efficient connectivity worldwide,” Giridhar says.