Maruti Rubber Group of Industries has successfully manufactured and supplied a comprehensive, integrated industrial kits featuring heavy-duty EPDM Pads (100mm x 85mm), Wooden Wedges, structural Tie Rods (with nuts & washers, 30” length), heavy-duty Clamps, and industrial Fevicol adhesives for a high-priority rail-overpass project in Alwar, Rajasthan.Executed by the leading infrastructure contractor Garg Builders, this strategic project involves the Construction of a 4-Lane Rail Over Bridge (ROB) at LC No. 11A Between Praisal (Railway Chainage KM 69/70-8). Maruti’s coordinated components were deployed to secure critical formwork, align heavy pre-cast concrete structures, and provide long-term elastomeric structural cushioning.
Challenges
Casting wide 4-lane bridge spans requires pouring immense volumes of heavy concrete. The resulting lateral pressure on the shuttering formwork is enormous; any failure or structural shifting of the formwork during a pour can cause catastrophic structural misalignments or fatal blowouts. Operating at a busy railway chainage (KM 69/70-8) means the under-construction overpass is constantly subjected to deep, low-frequency ground vibrations from high-speed trains below. Once opened, it will also face continuous dynamic impacts from 4 lanes of highway traffic. These forces can cause rigid concrete structures to experience micro-fractures, friction wear, and spalling.
Alwar, Rajasthan, experiences intense climatic extremes, with blistering dry summer heat that severely tests building materials. Inferior rubber pads can rapidly harden, ozone-crack, and degrade, while standard onsite bonding systems can fail or peel under extreme thermal expansion.
Solution
Maruti supplied high-tensile 30” Tie Rods equipped with heavy-duty Nuts, Washers, and Clamps. This robust hardware assembly mechanically locks the opposing formwork panels firmly in place, effortlessly absorbing the extreme hydrostatic forces of the wet concrete. Additionally, our precision-cut Wooden Wedges allowed the Garg Builders crew to make rapid, micro-level leveling adjustments on the fly, ensuring flawless structural geometry before the concrete cured. We engineered custom 100mm x 85mm EPDM Pads to serve as resilient structural dampening interfaces. Formulated from high-grade ethylene propylene diene monomer rubber, these pads absorb heavy shocks and distribute dynamic loads evenly. They allow the bridge segments to expand and contract smoothly without concrete-to-concrete grinding, significantly extending the service life of the ROB.
Maruti’s EPDM pads are highly resilient against ozone, UV radiation, and temperature spikes up to 130°C, ensuring they retain their elasticity for decades without embrittlement. Paired with high-strength industrial Fevicol bonding agents, the entire system creates an enduring, weather-proof assembly that anchors and cushions the bridge joints flawlessly despite Rajasthan's harsh environment.