Coastal road project from NH- 4B near Navghar to Sector- 63 at Dronagiri, Navi Mumbai with TechSpan® for Bridge Structures – 3, 3A & 4.

P R O J E C T  D E T A I L S

TECHSPAN® STR SPAN Owner Contractor Construction Year Designer + Consultant
340 m City and Industrial
Development Corp.
J. Kumar Infra
Projects Ltd.
2017-18 Terre Armée (Reinforced Earth India Pvt. Ltd.)


City and Industrial Development Corp. (CIDCO) of Maharashtra (CIDCO) is building a 34 m wide road from Nh-4B near Navghar to Bokadvira adjoining NMSEZ at Dronagiri, Navi Mumbai. CIDCO develops all the new suburbs around Mumbai and is an undertaking of Govt.of Maharashtra. The project has been contracted to J. Kumar Infra Projects Ltd.Mumbai.

The road is of prime importance since it forms a parallel link from NH-4B to JNPT in its final stretch and would cater to heavy traffic projected in the coming years.


In the stretch of 4.8 km there are three  holding ponds along the proposed coastal road alignment where CIDCO needed to  provide bridge so that the water movement to holding ponds during tidal variation is not affected. CIDCO was also looking for cost effective and aesthetically good structures for these bridges.

The foundation at these three locations has brown marine clay with high plasticity.  The thickness of the strata ranges from
4.0 m to 14.0 m.


REIPL came up with the solution of TechSpan® structures for the ponds no 3A, 3 & 4:
• For Bridge no 1 (Holding pond no 3A) & Bridge no 2 (Holding pond no 3): REIPL proposed two pin TechSpan® structure with 3 arch spans with Reinforced Earth Head walls.
• For Bridge no 3 (Holding pond no 4): REIPL proposed two pin TechSpan® structure with 4 arch spans with Reinforced Earth
Head walls.

Based on the hydraulic cross section requirements and proposed coastal road formation levels, the Span of the 2 Pin TechSpan® arch structure is 9m and Rise is 4.5m.

In view of the marine clay and tidal effects the TechSpan® structures are being built on pile foundations. 

Total length of each TechSpan® structure is 340 m and the carriageway width is 32.5m. The spandrel walls and wing walls are formed from reinforced soil retaining walls using EcoStrap®.



Construction of Yard at Kalamboli in Navi Mumbai in Maharashtra, India.

P R O J E C T  D E T A I L S

System Owner Contractor Construction Year Designer + Consultant
RE Wall Type: TerraTee®
with High Adherence
GeoStrap® and GeoMega®
Central Railways GOI MVR Constructions 03/2017 to 11/2017 • Terre Armée (Reinforced
Earth India Pvt. Ltd.)
• IIT Mumbai/
Central Railways


Kalamboli is a railway station on the Vasai Road – Diva – Panvel route of the Central Line, of the Mumbai Suburban Railway network. The yard is being developed at this station for the goods train carrying heavy loads.

The railway line was planned on embankment height varying from 3 mt to 6 mt in height and of 550 mt long. The central railways had approached Terre Armée India to provide an innovative and sustainable solution to build the embankment to support railway loading.


The most challenging part was to convince the railway authorities to use Geosynthetic soil reinforcement.

The central railways wanted to finish this project in a duration of 6 months, the total length of RE wall to be completed was 550m.

Central railways were concerned about the drainage system which would be adopted for construction of RE wall.

Economy was a major concern, the system had to be cost effective when compared to conventional retaining system.

The surcharge loading on the RE wall was approximately 48kN/m2.

Since this was the first time, central railways was using Reinforced Earth® wall techniques for supporting railway tracks there were many apprehension from the client on the use of this technique.


In a detailed design process, Terre Armée India used the in-house technical know-how to design the Reinforced Earth® wall using High Adherence GeoStrap® with synthetic GeoMega® connection system. HA GeoStrap® as soil reinforcement having lateral ribs and made of high tenacity polyester yarns (PET) placed in tension and co-extruded with linear low density polyethylene (LLDPE) to form straps of 50 mm wide. System consists of connection system made of molded polypropylene  sleeve, a totally metallic free connection system. Project made use well graded fill material having angle of internal friction (Ф) > 32o and considering a 32 MT Axle loading as design as per RDSO guidelines.

Failure surfaces through reinforced soil block & extending beyond it or encompassing the foundation soil has been analyzed to ensure sufficient length & strength within the reinforced soil mass. In this project client had insisted on performing the hand calculations and graphical analysis, hence the calculations were performed with Swedish Circle Method.

As an additional safety for such important structure it was suggested to use Geocomposite Drain/Geomenbrane below the ballast on railway track to avoid seepage of water from the tracks.

Surface water runoff drainage system have been adopted near the coping beam on the top with proper gradient to facilitate the additional water coming on the railway tracks.

The foundation here was moderately weathered basalt at a depth of 3m. So the minimum foundation depth considered was 1.7m.



Construction of TechBox™ for Railway Underpass at ACC cement plant at Jamul, Chhattisgarh in India.

P R O J E C T  D E T A I L S

System Owner Contractor Construction Year Designer + Consultant
TechBox ™ 6mx3m ACC Limited ACC Limited. September 2017 Terre Armée (Reinforced Earth India Pvt Ltd) + Aarvee Associates


The railway tracks under South East Central Railway is the life line for the ACC cement plant located at Jamul in the state of Chhattisgarh, India for the logistics of supply of raw materials and to dispatch of cement/clinkers by wagons. Vehicular movement along the road was interrupted frequently due to the existing railway level crossing inside the plant. This access road along the outer periphery of ACC Jamul cement plant is one of the important connecting road for ACC staff colony and other adjoining residential areas.

To eliminate the obstruction of vehicular movement due to railway crossing, it was necessary to construct an underpass or a railway over bridge (ROB). However, due to shortage of available space, the ROB option was dropped.

ACC Ltd. then consulted Terre Armée In India regarding a viable solution for the above scenario. To ensure uninterrupted movement of the wagons during construction of Railway Underpass, Terre Armée in India proposed precast box structure TechBox™ system. ACC Ltd awarded this job to Terre Armée in India for construction of one Railway Underpass using TechBox® Technology.


The approach Road towards ACC Colony is intersected by three Rail Tracks which is the lifeline for Plant Logistics for raw material and dispatch of cement. Frequent obstruction to vehicular movement along the above approach road due to movement of Railway Wagons was causing difficulty for the residents.

Construction of conventional underpass was also not feasible as it would have shut the wagons dispatch system during the long construction period. This would have affected the operation of the plant.

Terre Armée in India initiated the for construction of one Railway Underpass using TechBox® Technology. The key challenges were to minimize the shutdown period of Rail Tracks, which was is indispensable for the plant operations. The execution had to be done in two parts, keeping at least one track operational to support plant logistics.

Time allotted for two phases of installation and of Box Structure and restoration of railway movement on at least one rail track was only 17 days.


Terre Armée in India used the in-house technical know-how to custom-design the requisite cross-sections for this project. Based on the design, the moulds were customized to meet the design specifications.

The barrel length of the underpass is 26.5m and the internal dimension of the underpass is 6m wide x 3.5m high. There are 3 parallel railway tracks and Terre Armée in India proposed part construction, in which one track always remained live for handling of plant logistics. This is indispensable for the plant operations.

The pre-casting of box segments was completed in the designated casting yard close to the installation site and was installed at the desired location by cut ‘n’ cover method. Lifting System was adopted with a combination of Fabricated Spreader Beam and H T Freyssibars was extremely effective while handling pre-cast segments weighing 54.50 MT (including weight of lifting system). Installation of seven (7) units in the first phase was completed in 8 Hrs. Installation of ten (10) units in the second phase took 16 hrs even after hindrances due to constricted approach of crane.

The TechBox® technology has been proved to be far superior to the conventional in-situ Underpasses. It reduced the shutdown period of rail tracks to a great extent.



Construction of TechCulverts® for Kanpur-Kabrai Section on NH-86 from KM 7.430 to KM 130.0 in the state of Uttar Pradesh, India.

P R O J E C T  D E T A I L S

Size Owner Contractor Construction Year Designer + Consultant
TechCulvert® Size
2x2, 3x2, 4x2 and 6x2
National Highway Authority of India (NHAI) PNC Infratech Ltd. 2014 Terre Armée (Reinforced Earth India Pvt. Ltd.)


This project in the Kanpur-Kabrai section of the NH-86 included installation of precast TechCulvert® at 41 water crossing locations. TechCulvert® was selected over other conventional cast-in-place concrete culvert systems to expedite construction and maintain better quality control, which otherwise becomes an issues with conventional methods.

The TechCulvert® system was adopted based on Terre Armée’s extensive background and engineering knowledge of precast structures, which resulted in a commercially viable project that provided both superior quality and reduced construction time.


This project proved to be a breakthrough in the precast industry by providing a superior quality product and minimized time for installation. The system had to provide flexibility in terms of ease of construction without disturbing daily traffic. Terre Armée in India had to meet a construction period completion target of 7 months.


Terre Armée in India took advantage of the design customization of its shutter moulds to meet the requirements of the specifications. A single casting yard was set up at Moudha for precasting activity. To further economize the effort, a standard width of 1.75m for the TechCulvert® was accepted, which balanced the benefits of construction efficiency against the challenges posed by handling and transportation of precast units. The precast units were cast simultaneously, inclusive of side walls and slab. The raft was cast in-situ after installation of individual units at the site. This system provided the additional advantage whereby individual units are stitched on top and bottom, allowing the TechCulvert® system to behave monolithically.

The average time for site preparation and installation was 3 days from commencing of excavation to final installation.



Construction of TechBox™ for Chandikhole-Jagatpur-Bhubaneswar sections on NH-5 from KM 414.0 to KM 419.0 & KM 0.0 to KM 62.0 in the state of Odisha, India.

P R O J E C T  D E T A I L S

Size Owner Contractor Construction Year Designer + Consultant
TechBox® Size
10.5m x 5.5m
National Highway Authority of India (NHAI) RKD Construction Pvt. Ltd. 2012 • Terre Armée (Reinforced Earth India Pvt. Ltd.)
• Stup Consultants Pvt. Ltd.


TechBox™ structures were constructed in four locations of the Chandikhole-Jagatpur- Bhubaneswar section of NH-5 in the state of Odisha, India. The use of precast TechBox™ structures was chosen over conventional cast-in-place vehicular underpasses to expedite the construction schedule and obtain better quality control, which typically become issues in conventional systems.

This was a project undertaken by Terre Armée in India for their client, RKD Construction Pvt Ltd. The project took off after extensive technical discussions between the client, consultant and Terre Armée in India. Finally, TechBox™ was adopted as it proved to be a commercially viable solution and also promised savings in construction time under the given site constraints.


TechBox™ is an innovative solution to meet rapidly growing infrastructure demands. Availability of land was a constraint considering the tight project schedule. The idea was to construct the structure quickly as and when land was available for diversion of existing traffic. Therefore, time was a big challenge in this project. Lifting and installation of heavy precast units with all safety measures, besides running traffic, was also a notable challenge.


In a comprehensive design process, Terre Armée in India used its in-house technical know-how to custom-design the requisite cross-sections for the project. As part of the design, the moulds were customized to meet design specifications. The clear opening size of the box was kept the same as in tender specifications, which was 10.5m wide and 5.0m of clear height. The lifting system was also designed to ensure safety during demoulding, shifting and installation.

Design by:   Firefly Communications