Delhi Faridabad Skyway

Delhi Faridabad Skyway
Route information
Length:	4.4 km (2.7 mi)
Major junctions
From:	Delhi
To:	Faridabad
Location
States:	Delhi, Haryana
Highway system
Indian Road Network National • Expressways • State State Highways in ¬

Delhi Faridabad Skyway (Badarpur Flyover) is an 4.4 km long Elevated highway connecting Delhi, India to Faridabad on NH 2, which opened in 2010, at Badarpur, Delhi at its junction with Mehrauli-Badarpur Road. ^[1][2] It has been awarded by National Highway Authority of India to the 'Concessionaire Badarpur Faridabad Tollway Limited'.

Project road begins at Km.16.100 of National Highways 2 (NH 2) near BTPS and ends at Km.20.500 near Sec37 crossing 3 lane dual elevated highway with interchange/ramps at Mehrauli Junction, up and down ramp near Delhi border.

Casting Yard

The construction work for the dfskyway™ was distributed across two locations. The first was the site of the actual road construction and the other was the Casting Yard at Mirzapur, Haryana, where the batching plant and concrete segments casting was located. The Badarpur Team was required to erect the spans using precast segments with the highly specific nomenclature given to them. A total 2,164 units of precast segment casting were completed in just 407 days. The activity was accomplished 2.5 months ahead of planned baseline schedule. The whole activity encompassed a main carriage way, and merging spans with seven different types of segments.

Innovative Engineering

During the construction of the dfskyway™, an innovative shutter design was implemented for both pier and pier cap, which made it possible to cast the pier and pier cap in one pour. This type of self supporting shutter decreased the cycle time from 15 days to 3 days, which in turn led to early completion of the project. This process left the cast piers with a slim design and provided for wonderful aesthetics.

Process of Segment Casting

Segmental construction was used in order to save time and expenditure. The Super-Structure was composed of 2,164 precast segments that were built at the Casting Yard with a Long Line method. Generally, the super structure of the elevated highway is casted keeping the bottom level parallel to the ground and the cross slope adjusted in the top deck. But in Badarpur, the soffit also had the same cross slope as the top, thereby giving the overall structure an elegant look while reducing the required concrete and steel. In order to achieve this, a special mould was designed by a Swiss designer which can be positioned in all three dimensions. This method also requires very precise detailing of each and every segment before casting.

Segment Launching

The precast segments were transported to the site and were erected with the help of the launching girder. For erection at curved locations, a Trestle arrangement was used.

Reinforced Earth Wall (RE Wall) erection

The RE Wall was designed and erected with precast panels of different sizes. The precast concrete panels were casted as per design based on the proposed height of the RE Wall. This requires limited construction space and occupies less space compared to a conventional wall system.

Construction of 40,000 m² of RE Wall would normally have required 3.1 lakh cu.m. of earthwork. However, in the dfskyway™ project, fly ash was used instead of earthwork with a view to preserve the environment. Fly ash is a waste product that is generated during the production of electricity in a Thermal Power plant. Fly ash, in its dry state, is very light and blows easily with the wind, resulting in respiratory problems and irritation to the eyes. Use of this fly ash in the embankment filling saved significant land area and precious soil. In Harmony with the Environment

Plantation

To ensure that no harm was caused to the natural environment during the dfskyway™ project, HCC, together with the NHAI, has undertaken a plantation drive along the roads in Delhi and Haryana, as well as at the Mirzapur casting yard. Significantly, the project undertook to replant, rather than cut down, some particularly valuable trees that are remarkable for their age and species. To date, as many as 52 such trees have been successfully replanted.

Water Positive project

To minimize the operational impact on the environment during construction of the project, HCC has undertaken initiatives for water recharge of the water table in the construction area, recycling of water used during construction and rooftop rainwater harvesting. This will result in recharging an excess of 0.6 million cubic meter of water over the consumption during the construction of dfskyway™.

Water Recharge

A pilot project was undertaken linked to the United Nations CEO Water Mandate involving business leaders, of which HCC is the only signatory from India. This includes recharge of the water table in the construction area with recharge wells at two locations to divert rain water to the ground water table through an appropriate mechanism. HCC has constructed an artificial pond of 1614 kl aiming to recharge 4.6 times the quantity of water consumed during construction. This ‘water consciousness’ effort is part of HCC’s commitment to the United Nations Global Compact.

Water Recycling

The water utilized for the Batching Plant, Batching Plant Washing, Curing, Miller Washing, is stored and reused. A slope created in the work area where water is used for these activities is connected to a drain to drive the excess water to the existing main water channel which carries the water into the collection sump for reuse after processing.

Rainwater Harvesting

Rainwater harvesting was carried out at two locations to help increase the ground water levels in the vicinity. The water flows through the storm water drain into a filtration system and the filtered water then is discharged into a live bore well to improve the level of ground water table.

Two Toll Plazas

Faridabad Toll Plaza - 20 lanes

Delhi Toll Plaza - 15 Lanes

Client

National Highways Authority of India (NHAI)

Independent Consultant

The Louis Berger Group, Inc.

Concessionaire

Badarpur Faridabad Tollway Ltd. (BFTL) formed by HCC Infrastructure

EPC Contractor

Hindustan Construction Company Ltd. (HCC)

Design Consultant

Feedback Ventures Pvt. Ltd. (For road work) & Tandon Consultants Pvt. Ltd. (For structure work)

Background

It was a few years ago that the crucial need for an elevated flyover between Delhi and its satellite township of Faridabad was first realized. The traffic load on this stretch was more than sixty thousand vehicles per day and the existing infrastructure was incapable to cater to such a huge volume of traffic. As a result., the stretch faced frequent traffic jams delaying commuters by over 45 minutes. The NHAI proposed a 4.4 km long elevated six-lane road connecting in Delhi and Sector 37 in Faridabad as a solution to this problem. The dfskyway™ has been designed to provide uninterrupted travel past the four major crossings of MB Road, Jethpur, Sarai Bypass and Sector 37. The crossing is an important gateway to the capital city located on NH-2, which forms an important link between Delhi and Agra and even leads up to Maharashtra. For residents of Faridabad, it is the only direct link to the capital.

The project was awarded to HCC infrastructure Limited, a fully owned subsidiary of the HCC group. HCC began construction in Jan 2009 and the project was completed in under 24 months, significantly ahead of schedule. HCC’s construction team is very proud of this engineering feat despite the challenges posed by a highly congested work place and the unique downpours that Delhi witnessed in the summer of 2010.

Features

A safe and congestion free journey between Delhi and Haryana is the primary idea behind the creation of the dfskyway™ and the project boasts the following features:

• dfskyway™ is a direct link between Delhi & Faridabad
• The stretch will be covered in about 7 min even at an average speed of 40-km/h as compared to the present 45 min taken due to traffic jams
• Cloverleaf Mehrauli Junction: Totally congestion free drive
• State-of-the-art toll plazas and well established Facility Building for the road users
• Fully illuminated stretch and safe to drive at all times
• Well maintained Public Convenience Facilities
• 20-lanes toll plazas at the Faridabad side and 15-lanes toll plaza at the Delhi side
• Round the Clock (24x7) safety monitoring and emergency telephone line / help lines.

Toll rates till August 31, 2011

VEHICLE TYPE	SINGLE TRIP	MULTIPLE TRIPS IN 24 HOUR	MONTHLY PASS
CAR, JEEP, VAN	Rs. 20	Rs. 30	Rs. 600
LIGHT COMMERCIAL VEHICLE	Rs. 30	Rs. 45	Rs. 900
BUS, TRUCK ,MAV (>2 AXLE), EME & HCM	Rs. 60	Rs. 90	Rs. 1800

Reference

1. ^ "HCC bags Rs.340 crore BOT project of NHAI for Badarpur elevated highway". Financial Express. Jul 01, 2008. http://www.financialexpress.com/news/hcc-bags-rs.340-crore-bot-project-of-nhai-for-badarpur-elevated-highway/329877/0. 
2. ^ "Badarpur flyover to open today". The Times of India. Oct 5, 2010. http://articles.timesofindia.indiatimes.com/2010-10-05/delhi/28253226_1_badarpur-flyover-second-carriageway-hcc. 

External links

• Road Map reference at National Highway Authority of India
• Project reference