Total Surface Area
Aluminium Bio & PMMA
Project Case Study
PROJECT NAME / SITE
Mankhurd–Ghatkopar Flyover (GMLR)
EXECUTING AGENCY
Technocrats Kohlhauer / Technocrats Security
TOTAL SURFACE AREA
11,000+ SQ.M (Acoustic Shielding)
EXECUTION TIMELINE
100 Days Flat (PO to Full Handover)
PANEL TECHNOLOGY
Aluminium Bio Panels + Continuous PMMA Glazing
OPERATING WINDOW
COVID-19 Pandemic (Mission-Critical Fast-Track)
ACOUSTIC RATING
EN 14388 Compliant (15–25 dB(A) Insertion Loss)
HEALTH & SAFETY
100% Bio-Bubble & Dual-Site Worker Camps
1. Executive Summary & Infrastructure Context
The Mankhurd–Ghatkopar Link Road (GMLR) Flyover is a vital elevated arterial corridor connecting the Eastern Suburbs with Central Mumbai, accommodating massive daily vehicular volumes. To shield surrounding high-density residential colonies, healthcare facilities, and educational institutions from severe traffic acoustic pollution, municipal authorities sanctioned a mega-scale noise barrier installation spanning over 11,000+ square meters.
Technocrats Kohlhauer Infrastructure Pvt. Ltd. (TKIPL) and Technocrats Security Systems Pvt. Ltd. were awarded the comprehensive turnkey contract encompassing structural engineering, raw material sourcing, automated factory manufacturing, and elevated bridge mounting. Despite being executed in the midst of the COVID-19 pandemic under severe movement restrictions and stringent health mandates, TKIPL completed the entire 11,000+ sq.m manufacturing and installation program in 100 days flat from the date of Purchase Order (PO) receipt, establishing a benchmark for crisis-resilient infrastructure delivery.
2. Technical Architecture & Composite Panel Specifications
| System Component | Configuration | Engineering Specifications & Material Details | Acoustic & Structural Role |
|---|---|---|---|
| Aluminium Bio Panels (Alumna Bio) | Modular Opaque | Dual-skin 3005/3105 H14/H24 aluminium; 1.25 mm perforated front skin + 1.00 mm solid back; 500×3000×125 mm; hydrophobic Rockwool infill (50–100 kg/m³); 60–80µ powder coated. | Provides primary acoustic energy absorption (DLa ≥ 10–13 dB, Cat A4) and blocks direct sound transmission (DLr ≥ 25 dB). |
| Continuous Transparent Panels (Scorsa PMMA) | Vision Glazing | 10–15 mm high-impact, UV-stabilized Polymethyl Methacrylate (PMMA) clear sheets; heavy-duty extruded aluminium retaining frames with internal EPDM cushioning. | Delivers >90% daylight transmission, preserves open urban vistas, prevents driver tunnel vision, and maintains airborne acoustic reflection. |
| Structural Steel Posts & Fasteners | Superstructure | Jindal Universal Beams / ISMB 150×75 uprights; 60–80 micron Hot-Dip Galvanizing (HDG); reinforced base plates; high-tensile Grade 8.8 structural anchors & bolts. | Engineered to withstand extreme cyclic wind shear forces (up to 150+ km/h) and dynamic vehicle gust loads across elevated spans. |
| Acoustic & Vibration Seals | EPDM Gaskets | Fire-Retardant (FR) continuous extruded P-type EPDM rubber gaskets fitted along vertical post channels and horizontal inter-panel joints. | Eliminates acoustic bridge leakage, dampens structural flyover vibration, and prevents panel rattling under traffic resonance. |
3. COVID-19 Crisis Management & Bio-Bubble Logistics
Executing a mega-scale 11,000+ sq.m industrial project amidst lockdown conditions demanded exceptional regulatory coordination and rigorous workforce protection protocols:
- Special Priority Permissions: Liaised with municipal corporations, state infrastructure bodies, and police authorities to secure essential-service transit passes for heavy material carriers, factory operating permits, and elevated road occupancy clearances.
- Factory Bio-Bubble Camps (Vasai / Goregaon Works): Established self-contained on-premise residential camps for 80+ fabrication welders, machine operators, and assembly crews, totally isolating personnel from external contagion risks.
- On-Site Installation Camps: Set up secure, sanitized base camps adjacent to the Mankhurd–Ghatkopar corridor with dedicated transport shuttles, hygienic catering, medical isolation units, and PPE provisions.
- Comprehensive Health & Social Distancing: Implemented mandatory daily thermal scanning, pulse oximetry checks, scheduled antigen screenings, and staggered shift patterns across fabrication lines and site installation bays, resulting in zero infection outbreaks.
- Raw Material Supply Chain Resilience: Pre-procured critical buffers of aluminium coils, rockwool, PMMA sheets, and HDG steel sections ahead of transit curfews to guarantee uninterrupted, round-the-clock factory throughput.
4. 100-Day Fast-Track Delivery & Parallel Workflow
To achieve 11,000+ sq.m of completed fabrication and installation within the 100-day deadline, TKIPL orchestrated a synchronized parallel manufacturing and erection schedule:
| Timeline Phase | Execution Scope & Operational Milestones | Key Output & Throughput Metrics |
|---|---|---|
|
Days 01 – 15 Setup & Procurement |
PO formalization, structural design vetting, municipal permit clearances, raw material batch ordering, and establishment of factory and site bio-bubble labor camps. | 100% material supply lines locked; labor camps fully commissioned. |
|
Days 16 – 45 High-Volume Fabrication |
Automated CNC punching, shearing, roll-forming, acoustic rockwool infill insertion, and automated powder coating of Aluminium Bio Panels at Vasai facility. | Peak fabrication throughput of 150–200 sq.m / day across 2 shifts. |
|
Days 40 – 85 Parallel Site Erection |
Night-time ISMB structural post alignment, base plate chemical anchoring, vertical EPDM gasket channel insertion, and panel sliding using mobile boom cranes. | Concurrent erection of opaque and continuous PMMA vision panels. |
|
Days 80 – 100 Alignment & Handover |
Top cap fastening, structural torque verification, acoustic joint sealing, night-time illumination checks, site demobilization, and formal client handover. | 100% project completion in exactly 100 days flat. |
5. Quantifiable Project Outcomes & Operational Highlights
Record Execution
PO to Final Handover
Zero COVID Cases
Dual-Site Labor Camps
Noise Attenuation
EN 14388 Compliant
Unprecedented Turnkey Speed: Successfully compressed what is traditionally a 6-to-8 month manufacturing and erection cycle into 100 days flat without sacrificing quality or structural integrity.
Significant Acoustic Mitigation: Reduced ambient highway noise levels by up to 25 dB(A), transforming the acoustic environment for residential communities and public institutions bordering the Mankhurd–Ghatkopar link.
Architectural Aesthetics & Visibility: The integration of continuous PMMA vision panels provided uninterrupted natural light and horizon visibility for motorists while preventing visual barrier monotony.
Zero Lost-Time Incidents: Maintained flawless occupational health and structural safety standards despite high-elevation night-time crane lifts and pandemic constraints.
EXECUTING ORGANIZATION & MANUFACTURING WORKS
Technocrats Kohlhauer Infrastructure Pvt. Ltd. (TKIPL)
Noise Mitigation & Mass Transit Infrastructure Division
C-2, Model Ind. Estate, Vishweshwar Nagar Rd, Goregaon (E), Mumbai - 400 063
Tel: +91 22 4248 0406 / +91 98219 12262 | Web: www.automaticdoorsandgates.in
PROJECT SUMMARY & INFRASTRUCTURE CREDENTIALS
Mankhurd–Ghatkopar Link Road (GMLR) Flyover Noise Barrier
11,000+ SQ.M Turnkey Fast-Track Pandemic Delivery
Scope: Aluminium Bio Absorptive Panels, Continuous PMMA Glazing & Steel Substructure
Execution Benchmark: Completed within 100 Days Flat