Bandra-Woril sea link set new trends in construction methodology, completes 15 years of existence

Today (June 30) marks the 15th anniversary of the Bandra-Worli Sea Link, with its opening to traffic on this day in 2009. The west island freeway, a crucial component of the city's transport infrastructure, has been completed recently with the inauguration of the coastal road. The sea link forming its northernmost tip was taken up for construction in the year 2000.
Officials from the Maharashtra State Road Development Corporation led by Shri Nitin Gadkari, the then Minister of Public Works, prepared the plan of the sea link with a vision to create a landmark structure that would enhance Mumbai’s western skyline.The result was a magnificent cable-stayed bridge spanning Mahim Bay, featuring a single 128-metre-high ‘Namaste-shaped’ pylon supporting a 500-meter-long span.
The Bandra-Worli Sea Link project, overseen by some of the world’s most respected international bridge experts, set new trends in construction methodology. It introduced several pioneering techniques to enrich India's infrastructure landscape. Notably, large-diameter pile foundations were employed for the first time in the country, supporting the bridge's piers. The superstructure of bridge carrying twin four lane carriageways comprised 50-metre-long spans of the bridge, made by piecing together of pre-cast segments each weighing approximately 3 metric tons. These segments were cast onshore, transported by large barges, and lifted into place and assembled using gigantic launching trusses. Notably, concrete of M60 grade was used throughout, making this the first bridge using such high-performance concrete in India.
Construction innovations extended beyond the structural components. The application of an asphaltic wearing coat using polymer-modified bitumen provided a smooth, pothole-free surface for comfortable driving—a defining feature of a good bridge. Similarly, a protocol for fixing expansion joints enabled jerk-free travel over them. Innovations dotted project's logistics also. The deployment of the massive Asian Hercules barge crane facilitated the relocation of the launching trusses over the 500-metre span at the cable-stayed bridge section. This intricate operation, avoiding a six-month delay from dismantling and reassembling the trusses, involved demanding utmost precision in execution. The project achieved a zero-fatality record despite its immense scale, underscoring robust safety protocols and meticulous planning.
A crucial lesson learned from the Bandra-Worli Sea Link project for all engineers was the paramount importance of aesthetics. This included achieving perfect geometry and immaculate finishes on concrete surfaces, beside other details. The towers of the bridge, for instance, feature grooves designed to enhance their visual appeal. These aesthetic requirements were achieved by compliance to exacting standards set forth by the London based designer Mr. S. Srinivasan credited with designing some of the world’s most beautiful bridges.
Construction of the Bandra-Worli Sea Link faced initial delays starting from the early 2000s due to a contractual dispute over seaward shift of the alignment and the addition of another cable-stayed bridge on the Worli side; changes which accommodated the concerns raised by local fishermen. The resolution of these issues in the international FIDIC-based contract, could take place only by the end of 2003. The sea link, including two cable stayed bridges, was completed and commissioned for traffic in June 2009, notwithstanding that all marine construction work had to stop for four months of monsoon every year.
The design and supervision of the sea link project was overseen by reputed international experts. Nevertheless, the construction involved a significant workforce comprising young engineers from various parts of India. This provided them with valuable training in executing a large marine project, equipping them with skills necessary for handling complex infrastructure projects. This benefit accruing from the project, often overlooked, was underscored by most visitors to the project insisting to meet and personally congratulate these young engineers, recognising their involvement and contribution.
An unforgettable anecdote from the sea link’s history is when officials of the Maharashtra State Road Development Corporation (MSRDC) were approached by officials from Mahanagar Telephone Nigam Limited (MTNL), immediately after completion of the link, seeking permission to replace the traditional picture of the Gateway of India on the cover of their directory with a picture of the newly opened sea link. This request symbolized the recognition of the sea link as a modern emblem of the city.
Over the past 15 years, the Bandra-Worli Sea Link has not only eased traffic congestion but also emerged as an iconic symbol of Mumbai's modern infrastructure. Its imposing silhouette against the city's skyline continues to inspire and enthrall us.
(Sharad Sabnis, former chief engineer of MSRDC, was the chief engineer of the Bandra-Worli Sea Link work)