The development of India’s first high-speed rail network is a milestone for the world’s most populous country. Sika has emerged as a preferred partner in creating the robust infrastructure needed to operate the bullet train technology made famous in Japan.
At first it was a vision: scores of people gliding above the treetops, congested roads and rivers, to reach faraway places at unprecedented speed. Now construction of India’s first bullet train line is well underway. The Mumbai-Ahmedabad high-speed rail (MAHSR) corridor will significantly improve the connection between India’s main financial center and the largest city in the Gujarat region. The journey will take just over two hours, rather than eight. It will also offer a greener alternative to road or air travel. This ambitious project highlights the spirit and scope of the government’s “Make in India” manufacturing initiative. And its success depends on construction partners that can deliver the right technical solutions anywhere along the 508-kilometer route.
A project of mega-projects
Over 90% of the MAHSR corridor runs above land, water, and existing infrastructure, apart from the subterranean and underwater tunnels in and around Mumbai. The elevated section consists of enormous interlocking full span girders. Saugata Biswas, National Mega Projects Director at Sika India, understood the stakes early on:
"Full span girders are iconic structures used to construct viaducts and bridges around the world, but they were never before used in India. It is no exaggeration to say they are considered game-changers because of their safer design and role in boosting the speed of construction."
For context, each MAHSR full span girder measures 40 meters long by 12.4 meters wide. Each must be precast and transported separately. Each also weighs around 1,000 metric tons. The 13 million cubic meters of concrete needed for casting are spread across 20 site locations and sourced from more than 50 batching plants. This explains why the corridor has been divided into multiple subsections, each a mega-project on its own.
Solutions on site, at every site
Sika-MBCC India reached out to colleagues in Japan, even before the tender stage, to tap into their expertise in bullet train infrastructure. The Research & Development teams in both countries worked closely together to adapt global product formulations to the local raw materials and climate – and continue to do so today. Sika-MBCC has in turn become a major supplier on this historic project. Keyur Shah, Regional Sales Manager at Sika India, believes the teams’ extensive collaboration has given them a competitive edge:
"We started preparing for this mammoth project before it even started. On day one, we were ready with a dedicated project team and technical service team providing hands-on training and application support in key locations. Because the client appreciated our swift response and ability to offer tailor-made solutions, they never hesitated to choose our high value-added products."
Sika-MBCC continues to support viaduct construction as the corridor grows, one long span girder at a time. The teams have more recently been awarded work on the underground tunnels and train stations, as well as the track-slab casting factories. As India’s high-speed rail network takes shape, Sika-MBCC is playing a growing role in bringing the prestigious project to life.
Sika-MBCC portfolio technologies delivered to date
Concrete admixture for full span girders
Proven formulation despite different raw materials (e.g., cement, sand, aggregates) and various mix designs to ensure consistent concrete quality and properties, and shorten the production cycle
Bearing pedestal grout
High-flow material – tested against Japanese standards for fluidity and compressive strength – to enable crucial contact between the full span girders and elastomeric bearing pads, and accelerate production
Cable duct grout
Aluminum-free and zero-bleed additive to avoid corrosion and extend the project’s life expectancy over 100 years
Form release agent
Demolding compound to ensure a blemish-free concrete structure and avoid long-term repair costs
Image: Keyur Shah (left), Regional Sales Manager, sees immense opportunities for infrastructure projects in India. Saugata Biswas (right), National Mega Projects Director, has more than 20 years of experience in civil engineering.