Spanning Precision

Introduction: Spanning 21.5 km along the Ganges in Patna, the Ganga Path Project is a game-changing corridor connecting Digha to Didarganj. At its core lies a series of complex composite steel bridges, meticulously fabricated and delivered by Apex Buildsys Ltd. This feature unpacks the precision engineering, logistics, and coordination behind Apex’s delivery of over 8,000 MT of structural steel for one of India’s most ambitious riverfront developments.

Commissioned by Navayuga Engineering Company Ltd., Apex Buildsys took charge of the entire fabrication lifecycle from detailing and mock-up assembly to CJP welding, painting, and transportation. Fabrication drawings were developed based on inputs received from the lead contractor. The steel used for the project comprised E410 BR and E350 BR grades, offering robust strength and compliance with project-specific demands.

Surface treatment was carried out to SA 2.5 blast profile standards, followed by protective coating applications as per IS codes and the approved scheme. The project also included stud welding and Complete Joint Penetration (CJP) welds that underwent 100 per cent ultrasonic testing (UT), reinforcing safety and structural integrity.

FABRICATION COMPLEXITIES

Handling steel girders with such significant physical and structural profiles posed multiple fabrication-level challenges. One such instance occurred during the supply phase for the P140–P141 Bridge, where Apex managed the fabrication and dispatch of a 60 m composite girder with a total weight of 43.2 MT.

• End Diaphragm Box Girder Size: 19.4m (L) × 0.8m (B) × 2.5m (H)
• Weight Distribution: 26.7MT (core) + 8.25MT + 8.25MT (extensions)

The jagged and sinusoidal shapes of the diaphragm aligned with the required pedestal slope added complexity to the fixture setup and required acute accuracy during welding and assembly. Another significant challenge was met during the handling of girders for the Ch.5+400 Bridge with a 50 m span, where a single End Diaphragm Box Girder measured:

• Size: 17.25m (L) × 0.8m (B) × 2.2m (H)
• Weight: 28.4 MT (19.6MT core + 8.8MT extension)

Handling such units involved precise craning sequences using a 50MT truck-mounted crane, phased assembly at the shop level, and alignment checks prior to shipment.

“Every girder fabricated was a mission in precision. The real challenge was not just engineering, but consistency at scale.”

• RAKESH CHOPRA, National Sales Head, Apex Buildsys Ltd.

LAYERED EXECUTION MODEL

To streamline production and minimize site-level complications, Apex implemented a comprehensive three-point supply strategy:

Full-Scale Mock-up Assembly:

Each girder component underwent complete pre-dispatch assembly at the fabrication yard. This step ensured:

• Correct camber arrangement
• Alignment of bolted splices
• Detection and correction of potential fitment issues before shipment

This proactive approach significantly reduced site erection errors and improved schedule adherence.

Quality Through Stage-Wise Inspection & Testing:

Strict quality assurance protocols were embedded into every stage:

• Weld verification, executed by approved and qualified welders
• Jig and fixture alignment, combined with master layout validations
• Match-drilling to ensure splice bolt accuracy

Each CJP weld was subjected to 100 per cent UT testing, supervised by the client representatives from Navayuga Engineering and BRPNNL.

Smart Fabrication Using Advanced Machines:

• Utilisation of CNC and 3D drilling machines ensured high precision and consistent output.
• Nesting software enabled optimal material usage, restricting waste to under 2 per cent.
• Weekly monitoring reports linked workshop and site progress, allowing for real-time updates and course corrections.

TRANSPORTING OVERSIZED GIRDERS

With girders exceeding 17 m in length and up to 43.2 MT in weight, the logistics required military-grade precision. Apex deployed flatbed trailers, truck-mounted cranes, and modular dispatch configurations to safely move the girders from fabrication yards to the riverside site in Patna.

Transport planning involved:

• Multiple route assessments
• Permission coordination for oversized cargo
• Timed dispatches to align with on-site erection windows

Apex’s logistics and fabrication teams worked in tandem through a centralised coordination mechanism, which helped maintain momentum throughout the 21.5 km corridor.

QUALITY AND COORDINATION

In a project of this magnitude, engineering brilliance is only half the equation. Collaborative execution and real-time stakeholder alignment make up the other half. Apex maintained continuous engagement with Navayuga Engineering, resolving design clarifications swiftly and adapting fabrication priorities based on site readiness. Weekly meetings ensured that shop drawings, welding standards, camber corrections, and bolting sequences were aligned with construction priorities.

APEX BUILDSYS AND THE GANGA PATH VISION

The Ganga Path Project is more than a corridor; it is a symbolic step toward urban renewal in eastern India. Apex Buildsys’s role in supplying the backbone of this riverfront vision stands as a testimony to homegrown fabrication expertise, process maturity, and logistical strength. The company’s ability to deliver high-performance composite girders, backed by rigorous quality systems and shop-to-site integration, firmly positions it among India’s most reliable steel fabricators for complex infrastructure projects.

As the Ganga Path opens to the public, the spans beneath it silently tell a story of engineering ambition and the silent resilience of steel.

“The Ganga Path Bridge is a silent icon. Beneath the surface lies months of method, machines, and meticulousness.”

• Editorial Note, SSMB