Know Your Project Series – 3


The third Talk in the Series was delivered by Mr. Rahul Kumar, Sr. Manager-EPC Division, on Saturday, 4th September 2010. In his Talk, he simplified the complex subject of plant and machinery that we have to help us understand them better. The following summary covers some of the topics covered in the Talk.


Recall the scene when about 100 workers hurriedly pass on a small open disc heaped with concrete up the scaffolding to lay the slab of a house under construction. In a whole day’s effort, they would have moved about 50 to 100 of concrete. Imagine pouring 4,000 of concrete in a day! Mind blowing? That’s the benefit of mechanization. That’s exactly what the ROTEC Mixing Plant is capable of delivering. A champion by any standard, the Plant churns out huge volumes because of its creative, but simplistic design. A highly mechanized system, fully automatic, the speed of the conveyor decides the mixing proportions and the quantity produced. A massive tower belt carries the concrete and drops it several metres away exactly just where it is required. The men at work have to gasp keeping pace with the machine!


The 160 BP of Schwing Stetter is not too far behind. It deploys a twin shaft mixer that ensures homogenous blending of the ingredients. Fully microprocessor controlled, the Plant is operated just through a keyboard! A few commands of the fingers determine the quantity of various inputs and a batch of concrete pours out in a processing time of just 30 seconds – shorter than preparing a cup of tea!


To produce aggregate, crushers are used. They are capable of generating over 200 MT of aggregate an hour. In comparison, our meek neighbourhood stone cutter can do, at best, 3 to 4 MT in a whole day!


Another special feature of the project is the use of Creter Cranes. These are specially designed equipment for pouring of concrete. It has unique features like a telescopic rotatable boom that can pour concrete over a large radius and distance and feeding belts that carry concrete at a very rapid pace thus augmenting speed of work.


Boom Placers are much smaller versions of the crater crane concept. They are mobile, have the ability to reach narrow spaces and pour concrete that is pumped through their hydraulic & concrete piping system. Concrete Pumps, on the other hand, are stationary but have the advantage of serving concrete as far as 500 mtrs away.


In the Power Channel, Inclined Pavers are used to spread the concrete uniformly over the sloping surface.


In the Head Race Tunnel (HRT), a specially designed Floating Gantry Concreting Machine is used to build and pave the inner circular lining all through the 1 Km tunnel drilled under the mountain.


Movement of materials is done through transit mixers and dumpers. While usage of transit mixers is commonly known, using dumpers for concrete movement is a special innovation in our project. The idea has helped in moving larger than normal quantities in a speedy manner.


Other equipment includes silo feeding blowers through which bulk cement is carried through blown wind force through a pipe to be dropped into cement storage silos. A number of Tower Cranes help is movement of heavy materials within the sites. Transportation of loose cement in specially built containers on truck chassis (We call them Bulkers) makes it more economical to use and faster to feed the silos. This is possibly the only project in the hydro power sector in the country using bulkers.


In his Vote of Thanks, Mr. Sanjay Srivastava reflected on how Materials and Machines are like two sides of a coin. He said a lump of metal that could just be worthless as scrap, when modified and reworked by an engineer to form a component, could be worth hundreds or even thousands. He said that value addition, whether to material or to the mind is essential to enhance growth as could be seen in Mr. Rahul Kumar’s career.


Rahul is a Mechanical Engineer from Regional Engineering College, Trichy. He worked with Gammon India for about 7 years after being selected in the campus interview in 1996. He was actively involved in the Delhi Metro Railway, the Golden Quadrilateral and the famous Signature Bridge over the Yamuna- the second of its kind in the world. He was also involved in the construction of Delhi’s tallest building- MCD Civic Centre – 31 levels, 112 mtrs tall, over 3.5 lakh sq ft of covered area, 4 helipads, parking for 2500 cars and what not! In June this year, GVK invited him to join in the EPC Division as Sr. Manager. He is a disciplined professional who values time management, honesty and in looking ahead in a positive way. He is an active sportsman, sometimes a workaholic and a loving parent of two little boys 3 yrs and 9 yrs old. His wife too is highly qualified and is an MA, BEd.