M Venkata Rao Infra Projects Private Limited

About Project

A significant Rail Under Bridge (RUB) has been constructed over the Mumbai-Pune Expressway near Chikhale station as part of the new Panvel-Karjat suburban rail corridor project.

Project Details

Purpose: The RUB is a crucial part of the Panvel-Karjat double-track suburban rail corridor, an initiative by the Mumbai Railway Vikas Corporation (MRVC) under the Mumbai Urban Transport Project (MUTP) III.

Structure: The underpass features four 61-meter long Open Web Girders (OWG) to accommodate both the Up and Down railway lines. Two girders span each direction of the expressway (Mumbai-Pune and Pune-Mumbai).

Impact: The new suburban corridor is projected to significantly cut travel time between CSMT (Chhatrapati Shivaji Maharaj Terminus) and Karjat by nearly half an hour for commuters.

Maharashtra
EPDM Rubber Pad
Cost - $820 million

Challenges

Heavy Load Transmission: Open Web Girders carry significant load from train operations. The bearings at the support points needed to withstand high compressive forces without deformation over time.

Constant Vibrations and Dynamic Stress: Train movement generates continuous vibration, impact forces, and structural oscillations. A suitable material was required to absorb these stresses safely.

Weather Exposure and Longevity Requirements: Bridge components are exposed to: Intense sunlight, Heavy monsoon conditions, Temperature variations, Dust and pollution from the expressway The elastomer must retain elasticity and strength for decades under these conditions.

Precision Seating for Girders: OWGs require stable and evenly distributed support at the bearing points to prevent misalignment, metal wear, or stress concentration.

Our Solutions

Excellent Load-Bearing Performance: The pads provided uniform load distribution under the massive OWG structures, ensuring stable seating and preventing stress concentration.

Superior Vibration & Shock Absorption: EPDM’s inherent resilience effectively absorbed vibrations from rail operations, protecting both the girders and substructure.

Outstanding Weather & Ozone Resistance: Ideal for long-term outdoor use, EPDM pads offered: UV resistance, Ozone resistance, Water and moisture tolerance, Temperature stability ensuring consistent performance throughout the lifespan of the bridge.

Reduced Noise Transmission: The pads minimized noise transfer from the bridge to the supporting structures, important for both structural longevity and commuter comfort.

Impact & Results

  • Ensuring safe and stable installation of the 61-meter Open Web Girders
  • Enhancing vibration control, reducing long-term structural stress
  • Supporting smooth commissioning of girder launching operations
  • Providing a durable, weather-resistant bearing solution suitable for expressway and rail environments

These pads will continue to play a vital role as the corridor becomes operational, helping maintain structural integrity for decades to come.