Stainless Solutions for Bridges: Ensuring 100-Year Durability
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Stainless Solutions to make your bridges last 100+ years

Case Study on Stainless Steel Foot Over Bridge in
Bhayandar Railway Station, Mumbai division, Western Railway, INDIA

Introduction

Stainless steel foot over bridges have become essential for pedestrian safety in congested urban areas. In India, where the population density is high, stainless foot over bridges have become a popular solution due to their durability, strength, and resistance to corrosion. This case study examines the benefits and drawbacks of using stainless steel foot over bridges in India, focusing on constructing one such bridge at Bhayandar Railway Station in Mumbai.

Bhayandar Railway Station

Bhayandar Railway Station is an important transit hub located in the Mumbai Division of the Western Railway. It serves the rapidly growing residential and commercial hub of Bhayandar in the Thane district of Maharashtra. Its well-connected transport network makes the station crucial for thousands of daily commuters and travellers.

Foot Over Bridge - Jindal Stainless

Stainless steel is the ideal material for foot over bridges (FOBs) in railway stations in India for several reasons:

Durability

Durability: Stainless steel is strong and can withstand harsh weather conditions and heavy foot traffic.

Corrosion resistance

Corrosion resistance: Stainless steel is highly resistant to corrosion, even in humid and polluted environments.

Low maintenance

Low maintenance: Stainless steel FOBs require little to no upkeep, saving time and money in the long run.

Aesthetics

Aesthetics: Stainless steel's sleek and modern appearance enhances the look of railway stations and creates a positive impression for travellers and commuters.

Cost-effective

Cost-effective: Stainless Steel is a cost-effective option compared to other materials, despite its long-lasting benefits.

A Symbol of Innovation & Progress:

Mumbai's First Stainless Steel Footover Bridge | Jindal Stainless

Project Details

The Bhayandar foot over bridge project in Maharashtra revolutionizes pedestrian movement around the Bhayandar Railway Station. Jindal Stainless Limited, a renowned Indian supplier of top-quality stainless steel products, provided the stainless steel used in the construction. A steadfast commitment to durability, longevity, and commuter safety is evident by employing stainless steel in this project.

ProjectBhayandar FOB, Western Railway
ContractorSai Projects Mumbai Pvt Ltd., Mumbai
FabricatorSai Projects Mumbai Pvt Ltd., Mumbai
Stainless Steel SupplierJindal Stainless Ltd.

The stainless steel used in the project

The Bhayandar foot over bridge project utilized high-quality stainless steel, specifically IRS350CR grade, known for its excellent corrosion resistance and durability. The project used HRAP plates and sheets ranging from 60mm to 40mm thickness applied to the girders, columns, and hollow sections of the bridge. A total of 170 metric tonnes of stainless steel ensures the strength and stability of the bridge for years to come.

GradeProductApplicationQuantity(MT)
IRS350CRHRAP Plates/Sheets (6mm to 40mm thickness)Griders/Columns/Hollow Sections170

Working with Research Designs and Standards Organisation (RDSO) to create a customized grade of stainless steel for bridge application:

Jindal Stainless set up a war room to solve challenges posed by Indian Railways. The challenges were to find or create the right grade of stainless steel for this application, incorporate this grade into the Policy Manual of RDSO for a pilot study, and finalize specifications and drawings as a benchmark for other bridge constructions. The project used the IRS350CR grade of stainless steel adhering to Design Life and Techno-Economics criteria stated by Indian Railways for bridges with a lifespan of over 100 years.

Jindal Stainless worked closely with RDSO and other reputed institutes to create and validate the IRS350CR grade of stainless steel for bridge application, ensuring that it met the safety and durability requirements of Indian Railways. The Jindal Stainless team also provided on-ground training and support to the workforce involved in constructing the bridge and developed vendor partners who could supply welding consumables and fasteners that met the project's technical requirements.

Through these efforts, the Bhayandar foot over bridge project was successfully completed using high-quality stainless steel, ensuring the safety and comfort of thousands of commuters who use the bridge daily.

Partner Testimonials

“I am proud to be handling the first stainless steel bridge project in India. It is not only a milestone for Sai projects but for the entire construction industry. In the course of the construction of this bridge, we realized that stainless steel is much easier than we had anticipated initially. Thanks to the hand-holding of Jindal Stainless, our team is much better equipped to manage modern materials and equipment.“

- Mr Sunil Kodani, Managing Director, Sai Projects

“The requirement of this stainless steel FOB at Bhayandar Station has been very stringent. Keeping this in mind, we had to customize and process it at our Palghar workshop under the guidance of Jindal Stainless. We abided by the quality procedures mentioned and defined by Jindal Stainless which mainly included storage, handling and fabrication of the girders. Looking at the bridge standing tall today makes me proud and I can easily say all the efforts were worth its while.”

- Mr Sanjay Kodnani, Executive Officer, Sai Projects

Partner Testimonials

“Welding plays a vital role in all kinds of infrastructure projects. Today, we are happy to say that on the basis of technical evaluation and trials, our samples were tested and approved for the construction of this stainless steel foot over bridge at Bhayandar, This is a project of national importance and we are proud to be associated with this.“

- Mr VR Mulye, Vice President, Marketing, Premier Industrial Corporation Limited

“When Jindal Stainless approached us to develop a special grade of fasteners that will go into the stainless steel foot over bridge in Mumbai, we found the opportunity truly exciting though slightly challenging. The special grade desired by Jindal Stainless required special skills and knowledge. APL and Jindal Stainless worked hand in hand and collaborated on knowledge that resulted in the development of APL special-grade fasteners and are now part of India’s first stainless steel foot over-bridge.”

- Mr Vineet Agarwal, Director, Agarwal Fastener Private Limited

More details about IRS350CR grade of Stainless Steel

IRS350CR is a highly prized grade of stainless steel known for its excellent corrosion resistance, durability, toughness, strength, and elasticity. It's a high-chromium, low-nickel austenitic stainless steel that is cost-effective compared to other high-nickel grades. It's non-magnetic, resistant to stress corrosion cracking, and ideal for use in harsh environments where corrosion is a concern. Its high chromium content provides excellent resistance to corrosion and oxidation, while its good mechanical properties make it an ideal choice for girders, columns, and hollow sections. Its cost-effectiveness compared to other high-nickel grades adds to its popularity. With similar chemical composition as shown in below table, Jindal Stainless has also developed IRS450CR with yield strength of 450 MPa, which can result in higher weight savings in infrastructure applications.

Chemical Composition and Mechanical Properties:

Chemical Composition:

C%Mn%Si%S%P%Ni%Cr%Mo%N%
0.03 max1.5 max1.0 max0.01 max0.04 max1.50 max10.5-12.50.1-0.750.03 max

Mechanical Properties:

0.2%Y.S. (MPa), Min.U.T.S (MPa), Min.%El, (50 mm G.L.) Min.Charpy Impact Test (V Notch) Joules, min (at RT)
4505501827

RT- Room temperature (25 ± 2°C)

IRS350CR grade of Stainless Steel

The Bigger Picture - Infrastructure projects and Stainless Steel

The Bhayandar foot over bridge project showcases how stainless steel can create durable and visually appealing infrastructure in India. The harsh coastal environment makes stainless steel an ideal choice due to its low maintenance and long-lasting qualities. The success of this project was possible through the collaboration between industry leaders like Jindal Stainless Limited and experienced contractors like Sai Projects Mumbai Private Limited. With more such projects in the pipeline, stainless steel's use in infrastructure projects in India will continue to grow and contribute to the country's development.

IRS350CR grade of Stainless Steel
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