Providing Cost effective and Environment friendly Multi-Layer

Transportation System for Metro Rail and Highway (Double

Decker at Nagpur

I. Introduction about the Initiative:

Four years ago, Maha-Metro Rail Corporation Ltd. along with NHAI envisaged
the need of the Railroad Bridge consisting of Multiple utilities sharing the same Right
of Way in the city of Nagpur. With the administrative approval of the same, Govt of
Maharashtra gave green nod to the combined double decker system which is not
only cost effective but also a unique blend of modern and innovative civil
engineering marvel. The 3-layered transport system is coming up for the first time in
the country along Metro corridors including stations for a total length of 3.14kM.

Maha-Metro is executing a 3.14kM 3-layer Transport system (Double-Decker)

including metro stations on existing National Highway on Wardha Road in Nagpur
city using a unique design and adding to the aesthetics of the city. This 3-layer
transportation system comprises of:
a. Existing Road at Ground Level
b. Elevated National Highway at the First Level
c. Metro Corridor at the Second Level

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II. Objectives of the Initiative:

The double decker and the road beneath, once completed, will have a three-tier
structure in place, which would cater to the dual transportation needs of the people.
While the existing Hyderabad-Varanasi National Highway and the bridge would cater
to two-wheeler and four-wheeler vehicles, the top-most structure would be used for
movement of Metro trains.

i) Improvement in Road Capacity and Level of Service (LOS):

Wardha Road, as is NH-7 road called, has always been crowded because of its
location. The road is gateway to South India and connects Nagpur to major cities
like Hyderabad and Kanyakumari. Airport, Butibori Industrial Estate, MIHAN – Multi-
Modal Cargo Hub, Cricket Stadium are located along this road, leading to higher
volume of traffic there. The volume of traffic thus generated on this route, demands
alternate measures for vehicles to commute from city to other places.

Before the construction of double decker flyover, the traffic on the existing NH road
was 3165PCU at peak hour. The level of service of the existing NH road was ‘E’ i.e.
“Represents operating conditions when traffic volumes are at or close to the
capacity level. The speeds are reduced to a low, but relatively uniform value,
average value being one third the free flow speed. Freedom to maneuver within the
traffic stream is extremely difficult and is generally accomplished by forcing a vehicle
to give way to accommodate such maneuvers. Comfort and convenience are
extremely poor, and driver frustration is generally high. Operations at this level are
usually unstable, because small increases in flow or minor disturbance within the
traffic stream will cause breakdowns”.
In other words – a system that is capable of construction without
disturbing existing traffic and environment was needed here, and hence
Double Decker. The double decker, with two-tier transportation facility is
ideally suited to meet National Highway No 7 or Wardha Road which
would improve, as per the traffic survey and estimates, the Level of
service to ‘A’ i.e. “Represents a condition of free, flow with average travel speed
usually about 90 per cent of the free flow speed for the arterial class. Individual
users are virtually unaffected by the presence of others in the traffic stream.
Freedom to select desired speeds and to maneuver within the traffic stream is high.
The general level of comfort and convenience provided to the road users is
excellent.”
Additionally, the NHAI flyover also provides connectivity with the ROB with
intersection at the first level of the double decker arrangement to facilitate and
provide convenience from the regular traffic across the railway Level crossing
towards the highly populated area of Manish Nagar.

ii) Achieving Economical Design by providing Common Sub-Structure for

Metro Rail Viaduct and NHAI Flyover:

National Highway Authority of India (NHAI) had decided to take up construction of

one flyover of 3.14kM length within Nagpur City, for better connectivity catering
future traffic, efficient commercial transportation, and decongestion of traffic in the
city areas and to reduce pollution and travel time. The proposed alignment of the
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NHAI flyover is concurrent with the Metro alignment along the NH-44 having 3-
metro stations in this stretch. In order to avoid construction conflicts and timeline
mismatch, the initial proposal of NHAI envisaged that the Metro alignment & NHAI
flyover shall have common alignment with independent foundation & supporting
structures with alternate pier arrangements for Metro and NHAI flyover. Later, it
was jointly decided that as Metro Rail & Flyover are in same alignment
metro viaduct and flyover should be constructed on common pier so as to
ensure cost saving as well as better aesthetics from economical design,
savings in land acquisitions and reduced traffic congestions on existing
road level during construction. It was also deliberated that since both the
facilities are planned on same piers, then the whole project should be
executed/implemented by single agency to ensure better effectiveness in project
coordination and overall savings. As Maha Metro had already started the task of
constructing Metro project along the same route, Maha-Metro was entrusted with
the construction of Fly-Over as well as Metro Rail project.

III. Implementation of the Initiative

The Double Decker starts from Ajni Square, on National Highway 7 and stretches
almost upto Nagpur Airport. The Piling work was launched on June 2016 and NHAI
cast its first segment in May 2017. The erection process started in September 2017.
However, major works of casting and erection of both spine and wings has been
carried out in 2018-2019. The whole erection process has been completed in
December 2019. Wearing coarse work of the flyover was also on the verge of
completion till March-2020.

i) General description of Double decker bridge:

The length (including approaches), span, width (upper deck), width (lower deck),
approach length on either side and average vertical elevation is 3.14km, 105, 8.5m,
19.5m, 12.31m,18.21m, 5.5m respectively. Bridge design includes a post-tensioned
segmental-precast box girder superstructure at two different levels one being
exclusively to be utilized for metro rail and other for road traffic. The upper metro
rail superstructure is segmental box girder with 8.5m, 3m, 2m in width, length, and
depth respectively.
The lower superstructure is segmental precast prestressed spine and wing system,
with its spine (four lane carriageway) 7.5m, 3m, 2m in width, length and depth
respectively & spine (six lane carriageway) 9.5, 3m, 2m in width, length and depth
respectively.

ii) The salient features of the Double decker bridge are following:
 Start Point: Near Ajni Square
 End Point: Before Pride Hotel
 Total Length of Structure: 3.14kms
 Length of Approaches: 300m (including both sides)
 Technology Utilized: Precast Segmental construction
 Type of Superstructure: Spine and Ribs (Wings)
 Erection Method: Launching Girder
 Wings Erection method: Wings Lifter
 Type of Foundation: Pile Foundation

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  Road Width Available: 19m (4-Lane), 26m (6-Lane)
iii) Other Technical Specifications of the Bridge are as follows:
 Total No of Spans = 105 Spans
 6 Lane Spans = 17 Spans
 4 Lane Spans = 88 Spans
 Type of Bearing utilized = Spherical Bearing (As per IRC 83 Part 4)
 Total no of bearing required = 420 Nos of bearing
 Approach Length = Airport Side - 125m, Ajni Side - 184m
 Height of Fly-Over from Ground – 5.5m
 Height of Metro Track from Ground – 20-22m

High yield strength steel of grade Fe 500D is considered for use as reinforcement
bars conforming to IS:1786. Prestressing steel in the form of stress relieved multiply
strands of low relaxation conforming to IS:14268 has been used for construction of
the Double Decker. Concrete of High grades (M60 & M70) has been used for the
construction of the NHAI superstructure.

IV. Challenges & Perceptible Innovations:

Though the decision to construct Double Decker was taken, planning the
construction was not an easy job. Because first the work had to be undertaken
without disturbing traffic on that Road, and secondly, heavy vehicular movement on
that road had to be taken into consideration, while preparing design of Fly-Over. It
was after brain—storming sessions and planning process involving Maha Metro
officials that the design was finalized, and Double Decker work launched.

i) Demolition of Chatrapati Square Bridge:

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A flyover of approx. 400m length (excluding 100m approach on either side) was
already there at Chatrapati Square of NH-7. For the construction of Metro Viaduct as
well as NHAI flyover with double decker system, the existing Chatrapati bridge had
to be demolished. The work of demolition was to be carried out in such a
way that it should not affect the adjoining/nearby structures and must be
completed in a very minimal time so to have least effect on existing NH
traffic. Considering above, a specialized agency in demolition work was
engaged and the work of demolition was completed in a record-breaking
time of just 8-days including the removal of debris etc.

ii) Connecting Bridge:

In Elevated metro station, access to metro platform is generally provided through

concourse level which is below the Metro viaduct and above the road level. But in
the case of double decker bridge, the same arrangement could not be provided as
the NHAI flyover is running parallelly below the Metro viaduct. For this, Maha-
Metro had come up with an innovative solution of providing a “Connecting
bridge” on the pier-arm just below the metro viaduct and above the NHAI
flyover. The connecting bridge acts like an over-hanged subway which provides
interconnectivity between the platforms of Metro station.

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iii) Launching of Spine and Ribs:
Bridge was to be constructed in extremely busiest airport link road (Wardha Road) in
the urbanized city of Nagpur. Under these conditions a system that is capable of
construction without disturbing the existing traffic and environment was needed. To
Counter this issue, Maha-Metro has devised a one of a kind “Launching Girder”
girder for the simultaneous erection of precast segmental girders of Metro viaduct as
well as the NHAI double decker Flyover. Special attention was paid to the additional
construction loads raised due to the self-weight of double decker launching girder.

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The schematic diagram of the Launching of the Elevated Road span is
shown below:

The schematic diagram of the Launching of the Elevated Metro span is

shown below:

The Principal advantage of double decker launcher girder system over the other
conventional erection system available in the country is its flexibility of accommodate
& erect the two super-structure of different level from a same position in the span.
Constructability enhancements are achieved in this method by eliminating the delays
in erecting and dismantling separate formwork for both the superstructures, it
further allows for higher construction progress rates with other available systems.
The critical attention to the constructability issues in the design phase itself was one
of the primary reasons for successful implementation of execution work at site.

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Salient Features of Launching Girder:
Segments are being lifted with the help of under-slung light movable hoist. The hoist
will move over monorails, each under webs of box girder. The Lower span is being
lifted under the span itself with the help of hoist, while the upper span is being lifted
later with hoist picking and lifting the segments from front span, in front of front
support. Initial lifting will be done through the hoist and final positioning will be done
via slider beams. Each segment has own slider beams.

In line of web flats will be welded. These flats act as runway for the sliders which in
turn supports the segment. In line of both webs bottom of box plate girder,
monorails is welded which permits the self-launch of the structure over the knuckle
bearing provided at top of middle support and rear support. In order to haul
launching girder, monorail is fixed underside of LG which takes the reaction from
middle/rear support by connecting it to monorail by hydraulic jacks.
The segments for each span in a particular stage will be hung from the launching
girder by means of high strength bars. These bars will be anchored at top by means
of cross trolleys which in turn rest at top of launching girder.

V. Executive Summary and Benefits of the Initiative:

Once completed, the Double Decker would help in decongesting traffic on National
Highway While on one hand, the Flyover would cater to vehicular traffic – especially
heavy vehicles plying on the Highway and on the other, metro route would help in
faster transportation of commuters, especially those travelling in hundreds to reach
their work place every day in the industrial estate ahead. The Double Decker would
serve the twin objectives of Maha Metro Nagpur – of providing easy and hassle-free
journey to Nagpurians and decongestion of one of the most crowded city roads.
Needless to say, the unique design and construction of the Double Decker would
also add to the aesthetic beauty of the city, especially that of the National Highway.
Also, it is a highly cost and space efficient structure as The Right of Way is being
shared by 4 Facilities, all integrated on a common pier. The structure is designed in
Rib & Spine manner which is sleek as well as aesthetically pleasing. The total project
cost of the NHAI Flyover is approx. 300 Crores out of which only 50 Crores for the
sub-structure of the Flyover against the initial projected cost of 384 Crores by NHAI.

Some of the notable advantages of the 3-layered transportation are

follows:
a. Savings in the Land acquisition.
b. Reduced construction time.
c. Reduced Construction Cost.
d. Reduced traffic congestions on existing road level during construction
e. The aesthetic look and state of art design.

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