JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 22

civil engineering

The largest indian GRP infrastructure project
Ercon Composites, a leading Indian pultruder, recently completed the largest project of its kind in the world.
ted by 117 concrete piers. The railway company wanted an inspection platform on each pier to inspect the bearings. Most of the piers being inside the sea, building the RCC inspection platforms was next to impossible and uneconomical as it required shuttering and concreting/ casting on each pier in the centre of the sea. Using metal was not advisable for this offshore structure due to the corrosive salty winds and water sprays. Moreover, metal being heavy, the installation would have been a tough job. Ercon Composites was approached to advise on the feasibility of making the complete structural platform in GRP. The company took up the challenge and prepared a feasibility report, which was examined by the main contractor in charge of the construction, AFCONS, who accepted the concept. But convincing the railway company to accept the concept was a challenge since no similar work had been conducted anywhere in the world in the past. A detailed calculation was done and a prototype was developed and tested at Ercon’s works. Finally, RVNL accepted the proposal.

A project completed quickly and efficiently
The job was awarded to Ercon Composites and the project had to be completed before the start of the rainy season. It was carefully planned and completed well within the time schedule, just within 7 months. The complete platform was built from pultruded composites. Specially-designed cantilever beams were used instead of GRP braced brackets since headroom space was a constraint specified by RVNL. All the components were pre-designed and pultruded in specific lengths to

By

Mukesh Maheshwari Managing Director Ercon Composites

F

or this project, Ercon supplied 117 structural platforms entirely prefabricated in-house. Several platform designs and sizes were installed under its supervision on a very difficult site on a sea bridge at Kochi, Kerala. The platforms consisted of glass reinforced plastics (GRP) I-sections, channels, angles, cage ladders, gratings and handrails. Almost 90 metric tons of GRP structural profiles were pultruded for the project. The company fabricated them to the minutest detail, even the smallest parts including stainless steel bolts and nuts. The complete design, validation and prototyping work was carried out inhouse.

A 4-km-long bridge
The RVNL bridge is supporAt almost 6 km length, RVNL’s Vallarpadam over-the-sea railway bridge is the largest in India

22 jec composites magazine / No71 March 2012



JEC COMPOSITES MAGAZINE - Issue #71 - March 2012

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #71 - March 2012

Cover
Edito
Point of view: FRP Composites is a key growth industry for the UK
Contents
Agenda of Events
Index
COMPANY & BUSINESS
- In Brief
- Japan > Banpo, serious advantages for the future
- Aerospace > Paul G. Allen wants to revolutionize space travel
APPLICATIONS
- Emergency > Composites to the aid of populations
- Civil engineering > The largest Indian GRP infrastructure projetc
- Sports and leisure > First small watercraft that is compostable at end of life
MARKET
- Human ressources > Quality engineer: ensuring compliance with customer needs
- Bioplastics > Global bioplastics demand forecasts
- Natural fibre > Composite-dedicated natural fibres in France and Europe
SPECIAL JEC EUROPE 2012
- UK, country of honour
- Conferences > 4th International Composites Summit: Composites for mass production
- Awards > JEC Innovation Award Program 2012
- lnnovations
- United States
RESEARCH & DEVELOPMENT
- Failure > Composites failure criteria estimation of A- and Bbasis allowables
- Thin-ply laminates > Structural integrity of thinply laminates
- Bi-angle NCF > Giving more freedom to composite designer through advanced NCF reinforcements
- Fabrics > Novel +a/-b Spread Tow fabrics for the production of tubular items
- Biocomposites > Technical flax & polyamide 11: performance with renewable ressources
TECHNOLOGY & INNOVATIONS
- CFRP > From carbon fibre to carbon-fibre-reinforced thermoplastics
- Design tools > Free design tools with unmatched easy, speed and sophistication
- LFTPC > Thermoplastic Composite structural innovative assemblies for the automotive industry
- Automotive > Sustainable and environmentally friendly technologies for the automotive sector
In the world
Special JEC Asia
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - Cover
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 2
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - Edito
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - Point of view: FRP Composites is a key growth industry for the UK
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 5
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - Contents
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 7
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - Index
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - In Brief
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 11
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Japan > Banpo, serious advantages for the future
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 13
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Aerospace > Paul G. Allen wants to revolutionize space travel
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 15
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 16
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 17
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 18
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Emergency > Composites to the aid of populations
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 20
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 21
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Civil engineering > The largest Indian GRP infrastructure projetc
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 23
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Sports and leisure > First small watercraft that is compostable at end of life
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 25
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Human ressources > Quality engineer: ensuring compliance with customer needs
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 27
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Bioplastics > Global bioplastics demand forecasts
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 29
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 30
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Natural fibre > Composite-dedicated natural fibres in France and Europe
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 32
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 33
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - UK, country of honour
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 35
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Conferences > 4th International Composites Summit: Composites for mass production
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 37
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 38
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JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 44
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 45
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Awards > JEC Innovation Award Program 2012
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 47
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 48
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JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 52
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - lnnovations
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 54
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 55
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JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - United States
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 79
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JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 86
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Failure > Composites failure criteria estimation of A- and Bbasis allowables
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 88
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 89
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 90
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Thin-ply laminates > Structural integrity of thinply laminates
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 92
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Bi-angle NCF > Giving more freedom to composite designer through advanced NCF reinforcements
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 94
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Fabrics > Novel +a/-b Spread Tow fabrics for the production of tubular items
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 96
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 97
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Biocomposites > Technical flax & polyamide 11: performance with renewable ressources
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 99
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 100
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - CFRP > From carbon fibre to carbon-fibre-reinforced thermoplastics
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 102
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 103
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Design tools > Free design tools with unmatched easy, speed and sophistication
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 105
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 106
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - LFTPC > Thermoplastic Composite structural innovative assemblies for the automotive industry
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 108
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 109
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - - Automotive > Sustainable and environmentally friendly technologies for the automotive sector
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 111
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 112
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 113
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 114
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - In the world
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - Special JEC Asia
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 117
JEC COMPOSITES MAGAZINE - Issue #71 - March 2012 - 118
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