FOREWORD HEAVY CIVIL INFRASTRUCTURE IC – MAHSR C4 HEAVY CIVIL INFRASTRUCTURE IC
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MINERALS & METALS SBG Celebrate Long Service Let’s connect, communicate, collaborate to excel!

Hailing from Kolkata, West Bengal, Bibek is still single and when he has played his role enthusiastically at work, he expends his energies on other things that thrill him like cycling, playing cricket and listening to music.

A memorable moment? “Joining L&T, a dream come true,” he says simply.

“Being the son of a farmer, my parents always wanted me to excel in life,” recalls Sandeep Saini, earnestly. “They were very happy when I got selected in NIT Hamirpur for my graduation and overjoyed when I got selected by L&T through campus placement. Those have been some of my life’s most memorable moments,” he grins.

A GET of batch 2017, he started at the Punatsangchhu Hydroelectric Project 1 (1200 MW), Bhutan after which for the last four-​and-​a-​half years, he has been at the RVNL Package 2 project, initially in the Planning Department and presently at ADIT‑2 site to execute the main & escape tunnels, laybys and cross passage lining activities. “I have supervised the erection of 2 main tunnels, 2 escape tunnels, 1 layby, and 1 cross passage gantry along with experts from M/​s. TFI, Italy, and now looking after the lining activities.”

There are 48 laybys in the escape tunnel at distances varying from 100 m to 375 m, but since the cross-​sectional area for the layby is more than that of the escape tunnel, it was not possible to shift the full-​length layby gantry to cast the laybys. Re-​erection and dismantling the gantry in each layby would have been costly & time-​consuming. “After many discussions with various gantry manufacturers, we decided to have 3 panels of 3 m each that could rotate 360° along its centre with individual power pack and hydraulic systems,” shares Sandeep. “This ploy saved us both time and cost and we have successfully completed casting for 3 laybys. Other packages are replicating the same design and implementing the same procedure to cast laybys at their package,” he winks.

Although only two and a half years old with L&T at the RVNL Package 2 Project, having joined in 2022 as an Engineer Trainee, young Acshat Joshi is thrilled about the trust he has already won from his site leadership. “They have given me the opportunity to be a Digital Ambassador, are always open to discussions, and have always supported and encouraged me, providing valuable feedback by discussing the pros and cons about my ideas.” This kind of support has strengthened him to grow into his challenging assignment in Contracts Management.

What he has found most rewarding is his success in implementing a comprehensive Project Information Management System (PIMS) across five different site locations for real-​time progress tracking, systematic documentation, and efficient communication among clients, engineers, and teams. It certainly was no walk in the park, as Acshat shares: “Initially, people were unaware of the benefits the platform could provide. It seemed to be an additional work for them and hence they were reluctant to adopt. But little did they know that this platform would help them to reduce redundancy. We organized training sessions to highlight its advantages, importance, and standard procedures of updating progress, communicating, monitoring, and analysing.”

He is equally delighted with the other digital initiatives implemented at site such as the tunnel communication system, video analytics, fuel management system and digitalization of key equipment like drill jumbos, shotcrete machines among others. “All these digital technological changes and initiatives have benefited the project in terms of productivity, cost, quality & safety,” he sums up with evident pride. Acshat’s responsibilities also include co-​ordinating with the corporate digital team and a third-​party developer to develop an app to optimise the use of explosives in tunnelling operations that should help future tunnelling projects using the NATM method.

He rues that had the employer been more flexible, the team could have adopted more digital technologies to streamline some of the processes such as billing, quality testing, etc. “However, we are still trying to hold the employer in confidence to introduce more digital initiatives with frequent meetings,” he grins.

A lateral thinker, bringing with him years of rich experience, Neeraj Kumar is making his mark at India’s longest tunnel project, the RVNL Package 4 and his recognition as a Tech Champ is hardly surprising, considering the various technology solutions he is implementing. “We use the VMT System to measure precast moulds and segments in 3D,” he ticks off, “SDS or Segment Documentation System to track the casted pre-​cast segments from casting to erection inside the tunnel eliminating paperwork, the ConEase App to track concrete production and control wastage, the Rebar Pro App to reconcile the reinforcements used in the different structures and the Equalizer (Quality Sanyog) App to improve project deliverables, raise QIRs, PIRs, site walk-​downs, and training.”

Having tasted the benefits of technology, Neeraj is a strong advocate of driving technology adoption more effectively across L&T. “To drive implementation, we need more structured training programmes that highlight the benefits and practical applications of new technologies, and by doing so, we can ensure a smoother transition and greater acceptance of new technologies within our organization,” he notes astutely.

Working with TBM, using the NATM method and tunnelling in unforgiving Himalayan terrains, the team has been facing several uphill challenges like water seepage inside the tunnel which was addressed by introducing economical mix designs in backfill grouting for quicker setting to build the grout layer. “To measure moulds and segments, I arranged for the technicians to be trained to improve their competency levels to effectively use the 3D laser tracker,” he flags off. When the M‑60 grade mix design was inconsistent with the aggregate source, the team quickly experimented with various concrete mix trials with different proportions to establish the consistent and proven mix for segment casting.

Having joined L&T as a DET, Manu Prasad has had the opportunity to work at some key projects like the 520 MW Parbati Hydro Power Project, Himachal Pradesh; the 1,020 MW Punatsangchhu Hydro Power Project, Bhutan; and presently at the RVNL Package‑4, India’s longest railway tunnel project with NATM and TBM. With his overall experience, Manu has started to appreciate what imagineering is all about.

He is excited about the Korean-​made automatic carousel plant the team has installed at the casting yard for TBM tunnel segment production. “The Korean-​made automatic carousel plant has a PLC operated control system, and with its proximity sensors and limit switches, it helps to move moulds on the rail tracks to speed up segment casting,” he explains. Other tech interventions include IoTs (GPS, fuel level sensors, RFID tags) in P&M equipment, fuel level sensors for effective fuel management, operational efficiency, and cost savings. “With accurate real-​time data, we can prevent fuel theft, ensure timely refuelling, maintain smooth operations, and maximize productivity.”

GPS devices are acting as powerful tools to improve project management, improve security, and operational efficiency. “With GPS-​enabled IoT devices, we are easily tracking the location of assets, providing insights into equipment utilization, and ensuring that assets are not lost or stolen,” he adds with a thumbs up.

A tough project being executed in tough conditions call for innovations and Manu shares a few examples of the team’s clever thinking like installing a water treatment plant to supply pure water for the steam boilers and an automated polyfibre weighment system at the batching plants to show the quantities of polyfibres in the batch sheets. In his wish list, is AI powered predictive maintenance in plant and machinery and to drive tech adoption, he recommends training, resources, workshops, rewards & recognition.

Having started his innings with L&T in 2012 as an Assistant – ISD Systems at the CC-​27 Delhi Metro Project, Ankur Jain has since had several reasons to celebrate with a company that he prides for its dedication to exploring imagination and fostering innovation. “I have been recognized with several awards,” he says excitedly, “including the Best Project ISD – 2023, Best Digital Ambassador – 2023, and Best Digitally Savvy Project – 2023 in the MEGA category.” Currently at the prestigious RVNL PKG‑4 Project, he is involved in constructing Asia’s longest railway tunnel.

Implementing the advanced Tunnel Communication Technology is a tech innovation that Ankur is particularly proud of, which improves real-​time monitoring, ensures seamless connectivity, and enhances their ability to manage activities inside the tunnel. He proceeds to list out several other digital solutions deployed at site that include RFID systems to track assets; ConPro to manage concrete, reduce wastage, and improve tracking; Material NxT that streamlines material management; Weigh Bridge Systems (WBS) tamper-​proof with secure data storage to prevent unauthorized access; the Leaky Feeder solution to enable critical communications for emergency services in challenging environments.

“We deploy video analytics to increase security and gather operational insights, HK Connect that integrates site reporting and management reviews, VMT (Vehicle Monitoring Technology) to track and manage construction vehicles, and WAS (Workmen Attendance System) to digitally track attendance and monitor productivity,” he elaborates.

Operating in a hydel location, a major hurdle was the lack of data connectivity and mobility. “I implemented RF devices with an air distance of 5 km to create a single dashboard to monitor project progress across all locations,” Ankur shares his initiative. “This solution has greatly enhanced our ability to track and manage the project effectively.” He would like to improve the procurement process to track materials from Purchase Request Creation (PRC) to Material Receipt Note (MRN) at each location for better visibility and control over material management.

At the challenging RVNL Package 4 project, where the team is tunnelling into the Himalayas in entirely unchartered territory, it would help them greatly if they had some idea what is awaiting them as they dig deeper and geophysicists like Vishal Bhardwaj can help with techniques like the tunnel seismic predictor. “TSP is used in railways, highways and various types of hydro power underground tunnelling systems to anticipate the geological conditions that could be encountered during tunnel construction, relying on seismic methods to gather information about the subsurface conditions before and during the excavation of a tunnel,” he explains, sounding almost professorial.

TSP helps in geological mapping to predict the types of rock or soil that will be encountered, including their strength, weak zones, & water content and to manage risk by identifying potential hazards such as fault lines, water-​bearing strata, or unstable rock formations. He explains that work at RVNL involves both acquisition & processing work. “As part of acquisition work, we measure the seismic waves generated by the impact hammer inside a tunnel, acquire accurate data without disturbance, marking the position for testing and coordination with the tunnel team, check the quality of the raw data, edit the geometry of the layout, if required, and perform tests with the good quality data,” he explains.

Processing work involves getting & processing the raw data either from the Cloud or file, generating results in about 6–8 hours, computing the geo-​mechanical parameters like P & S‑wave velocities, Poisson, Young’s, shear, bulk modulus, and submitting reports.

“We have encountered some major challenges at site,” he says gravely, “like a sudden change in lithological variations in the lesser Himalayan terrain while encountering weak zones and changes in water seepage happen almost daily. This is where TSP helps,” he smiles tightly, “by continuing to analyse rock mass conditions and taking remedial measures before proceeding.”

In terms of improvements, Vishal recommends the introduction of seismic and well data software QA/​Testing/​Scrum MASTERLandmark decision space Geoscience for seismic analysis, velocity modelling, lithology interpretation, AWS & Azure DevOps.

“Having successfully assembled 18 TBMs and achieved 13 successful TBM breakthroughs, I am able to guide and lead my team through the ups and downs encountered during TBM operations,” shares Tajinder Singh, referring to his previous experience with other companies before joining L&T, that includes overseas stints in Singapore & Qatar.

Presently Tajinder is busy at the RVNL Package 4, constructing a twin tube tunnel with hard rock single shield TBM in the Himalayas, and considers himself fortunate to be working with some “great and innovative minds” helping him to develop critical thinking, evolve strategies for unforeseen circumstances and find definitive approaches to minimise/​ alleviate such events. “My seniors and team members are highly skilled and qualified, creating an environment of zeal towards work and challenges to keep us motivated as a united working front,” he says passionately. “Their support invigorates me to pursue excellence,” adding that being entrusted with the responsibility and freedom to execute ideas at site, is helping him build excellence in learning and development.

TBMs are at the centre of Tajinder’s life. His initial challenge was to transport the two overweight and over dimensional TBM parts & equipment through the narrow & challenging Himalayan terrain, for which special self-​propelled modular vehicles were used. “We transported them using 8/​12 hydraulic axles trailers with the cargo laid horizontally and at the orientation change point, a tower stand jack system was set up,” he explains. Their next challenge was to assemble the TBM machine in 8 weeks.

“Throughout my experience, I have worked with 4 Slurry, 1 EPB, and 2 Hard Rock TBMs, as well as in a manufacturing unit and this diverse experience has equipped me to guide and lead my team through the challenges encountered during TBM operations and manufacturing, successfully navigating any issues that may arise,” says a confident Anuj Taneja, from his RVNL Package 4 project. Although his first with L&T, Anuj brings with him the experience of having worked at other challenging projects for other construction companies.

Being a TBM expert, TBM is Anuj’s favourite subject. “We used a SKID system to push the 1,450 MT TBMs to their launching positions, 600 m and 700 m away from the assembly point respectively, to set a new ‘pushing’ record of 135 m per day, which is almost four times the conventional distance,” he shares proudly. “We utilize HK Connect to monitor all the working equipment established in the TBM, to ensure optimal working parameters and conditions.” A 10 km long tunnel conveyor belt (Make H+E Power 315 X 3 KW) and booster for the tunnel belt are connected to the TBM via an optical fiber cable, he notes too.

Referring to the team’s initial challenges of transporting the overweight and over-​dimensioned TBM parts and equipment through the narrow and challenging Himalayan terrain, Anuj mentions using Self-​Propelled Modular Transporters (SPMT), after conducting prior route surveys and live testing the bridges, and 8/​12 hydraulic axle trailers, with the cargo laid horizontally. A tower stand jack system was set up at the orientation change points. Faced with the challenge to assemble the TBM machine in 8 weeks, the team did in 6 weeks handling some major heavy-​weight consignments, such as the Main Drive, Cutter Head, TBM Shield, Tail Skin, and Erector. “Our technical team brainstormed to come up with a solution involving a 1000 MT gantry, a method never before attempted in India, particularly in the challenging Himalayan region,” highlights Anuj.

She is at her first assignment with L&T at the RVNL Package 4 Project, but Mahima Rajput is focussed to ensure 100% implementation of all the digital Apps deployed at site, address and overcome user resistance, and maintain accurate data tracking. “Ours is a very digitally active site,” she smiles, “implementing various digital initiatives such as Rebar Pro, ConPro, the Workmen Management App, HK Connect, timelapse and 3D videos.”

Elaborating on a couple, she mentions that Rebar Pro is helping the site to manage rebar usage efficiently. “With training, we have achieved 100% implementation by reconciling application and site data and streamlining the processes from store management to rebar receipt, for transparency and efficiency for reinforcement.” ConPro, on the other hand, has significantly reduced wastage, and improved tracking with 100% implementation. “We have reduced concrete consumption from 2.5% to 1.64% and saved crores, while contributing to environmental sustainability,” Mahima adds triumphantly.

Eager to cover more ground in the digital space, Mahima is keen to enhance the integration of data analytics tools for deeper insights into project performance and efficiency. “I believe that we should improve the user interface of our Apps to make them more intuitive and user-​friendly that could further drive technology adoption,” she points out insightfully. “Of course, implementing an advanced predictive analytics tool could significantly enhance project planning and execution by providing real-​time insights and forecasts, enabling proactive decision-​making and resource optimization,” she nods.

L&T has been a great proving ground for Mahima with its unwavering commitment to innovation and excellence, fostering a culture of continuous improvement that empowers employees to lead impactful projects. She has found her seniors guiding and supporting her while her team members are ever ready to adopt, implement, and troubleshoot. “Their collaboration and feedback are invaluable to overcome challenges and achieve project goals,” she notes meaningfully.

A native of Kanpur, Uttar Pradesh and single, Mahima’s family comprises her father, Akshay Kumar; mother Javitri Devi, brother Aditya, and sister Gauri. Her secret to maintaining work–life balance is to spend her free time studying Indian history, cooking, and reading spiritual books. “One of my most memorable moments was a visit to Mahakal, Ujjain, with my family, which was a significant milestone for us,” she recalls happily.