DFCCIL launched 110.5m Rail flyover girder at JNPT-Nilje section of WDFC
NEW DELHI : Dedicated Freight Corridor Corporation of India Limited (DFCCIL) has successfully installed longest-ever Rail Flyover girder—measuring 110.5 meters and weighing 1500 tonnes—on the Jawaharlal Nehru Port Trust (JNPT-Nilje) section of the Western Dedicated Freight Corridor (WDFC) at Kalamboli. This engineering milestone involved a radial shift of 32 meters over existing Indian Railways tracks and was praised by MD Shri Praveen Kumar.
The open web steel girder spans an impressive 110.5 metres and weighs close to 1,500 tonnes, making it one of the largest components ever launched by DFCCIL for a rail infrastructure project. The installation, a critical feat in precision engineering, involved radial shifting of the mammoth girder across live Indian Railways tracks a manoeuvre that demad expert coordination and the use of cutting-edge heavy-lifting technologies. Engineers executed a 34-metre lateral shift of the girder over active lines, without disrupting regular train movement an achievement that speaks to the growing technical sophistication of India’s freight rail sector.
This milestone reinforces DFCCIL’s mission to transform the country’s freight transport capacity while embedding principles of safety, sustainability, and efficiency into infrastructure development. Once operational, the Kalamboli Rail Flyover will enhance connectivity between JNPT, one of India’s busiest container ports, and the industrial hinterlands in Maharashtra and beyond, streamlining cargo movement and reducing transit time significantly. The Western Dedicated Freight Corridor, spanning over 1,500 kilometres, is one of the two key freight corridors under development, the other being the Eastern corridor. Both projects are designed to decongest India’s overburdened rail network, enabling high-speed freight movement and reducing dependence on road transport. These corridors not only promise significant economic gains but also align with the country’s climate action goals by shifting logistics from carbon-intensive highways to lower-emission rail routes.
Details of the Project:
The girder was installed at Kalamboli, spanning the following sections-
WDFC Mumbai (South) – New Nilje, Thane District
WDFC Mumbai (South) – New JNPT, Raigad District
This bridge is not only DFCCIL’s longest girder but also one of the most technically challenging installations that the organization has to work with till date. The key highlight was a radial shift of 32 meters over operational Indian Railways tracks—executed with accurate alignment and coordination to ensure zero disruption to existing rail services.
Technical Brilliance and Safety Measures:
The completion of this launch was a result of strategic planning, detailed engineering, and the use of top-notch equipment. Engineers had to face multiple constraints including limited space, operational safety, and coordination with Indian Railways. The radial launch of the girder was performed with immense care, requiring synchronous jacking, regular monitoring, and timely operations.
Key technical highlights:
Girder Length: 110.5 meters
Weight: 1500 tonnes
Shift: 32-meter radial displacement
Structure Type: Rail Flyover Girder (RFO)
Corridor: JNPT-Nilje, Western DFC
This structure will facilitate the smooth and grade-separated movement of freight trains, reducing potential conflicts with passenger routes and enhancing the operational efficiency of the DFC network.
Recognition from Leadership:
The milestone event was attended and appreciated by Shri Praveen Kumar, Managing Director, DFCCIL, who applauded the efforts of the engineering teams, contractors, and partner agencies involved in the project.
This launch is a symbol of engineering excellence and teamwork. The successful placement of this girder marks a turning point in DFCCIL’s journey to strengthen India’s freight backbone.
Strategic Importance of the WDFC:
The Western Dedicated Freight Corridor (WDFC) is a vital component of India’s logistics infrastructure strategy. Spanning from Dadri in Uttar Pradesh to JNPT in Maharashtra, the corridor aims to provide high-speed, high-capacity connectivity for freight traffic. The JNPT-Nilje section is especially crucial due to its proximity to India’s largest container port—Jawaharlal Nehru Port Trust (JNPT).
The newly launched flyover will help decongest the busy suburban rail network in Mumbai and allow flawless freight movement from port to hinterland. This is in line with the national goal of minimising logistics costs and enhancing last-mile connectivity for exports and imports.
Conclusion:
The successful launch of DFCCIL’s longest-ever girder at Kalamboli exemplifies the organization’s commitment to innovation and precision. As India accelerates toward transforming its freight infrastructure, such milestones underscore the key role DFCCIL plays in driving large-scale, future-ready transport solutions that support economic growth and global trade efficiency.
