01 / Khodadad Circle Flyover, Mumbai
02 / Khodadad Circle Flyover, Mumbai
03 / Khodadad Circle Flyover, Mumbai
Execution Challenge
The right-of-way was exceptionally narrow and processed tens of thousands of commuter vehicles hourly, leaving zero spatial allowance for aggregate storage or onsite structural staging.
Deep substructural pile boring had to occur directly adjacent to century-old, fragile historic properties, strictly prohibiting traditional percussion impact piling.
Furthermore, the corridor was saturated with unmapped legacy municipal water mains and stormwater trunks that required real-time diversion without utility service disruptions.
Strategic Role
Mr. Avarrsekar directed the high-fidelity pre-bid positioning strategy, mapping the firm’s modular precast capabilities to meet MCGM’s strict technical and safety scoring parameters.
Upon acquiring the project, he established a centralized project governance framework providing rigid risk oversight across the supply chain.
Serving as the primary executive interface with MCGM committees and traffic regulators, he decoupled construction workflows from external pressures, fast-tracking nighttime road permissions to maintain critical path velocity.
Actions Taken
- Implemented a micro-phased timeline that separated foundation work from girder launching.
- Used low-vibration hydraulic rotary piling to protect flanking historic buildings.
- Moved girder fabrication to an off-site precasting facility to remove on-site space constraints.
- Launched multi-ton precast girders with mobile cranes inside restricted night traffic windows.
- Monitored equilibrium along adjacent property lines with real-time geodetic instrumentation.
Outcome
The successful commissioning of the flyover achieved immediate, absolute grade separation over three major intersections, dramatically accelerating north-south traffic throughput.
Utilizing prestressed concrete girder spans maximized load-bearing metrics while lowering the city's long-term infrastructure lifecycle maintenance costs.
For the sector leadership, this project validates how translating complex structural risks into precise, data-driven bid solutions secures landmark municipal contracts and ensures highly predictable project execution.
Technical Data of Record
Scope of Work
Turnkey design and construction of an elevated flyover over three arterial junctions, with earth-retained approaches and prestressed concrete girder spans.
Key Specifications & Challenges
PSC girders, monolithic RCC piers, reinforced earth retaining walls and durable bituminous surfacing. Piling beside fragile century-old buildings, girder launching in short night windows and unmapped municipal utilities.
Major Deliverables
An operational flyover corridor, junction traffic distribution, bridge deck drainage and improved surface intersections beneath the spans.
Result
Permanent grade separation, with tiltmeter monitoring of adjacent facades, third-party material certification and post-tensioning stress verification.
Client
Khodadad Circle (Dadar TT), Dr. Babasaheb Ambedkar Road, Mumbai.
Location
Municipal Corporation of Greater Mumbai (MCGM)
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