• Project Name: Installation of India's Heaviest Arch Bridge for Mumbai Coastal Road Project Package - 2

The Mumbai Coastal Road Project aims to enhance connectivity and reduce traffic congestion along Mumbai’s western coastline. This ambitious infrastructure initiative involves constructing multiple bridges, each facing unique challenges due to the dynamic and unpredictable coastal environment.

Freight Wings Pvt Ltd took on the monumental task of installing 8 bridges as part of the Mumbai Coastal Road Package 2 project. This included 2 arch bridges and 6 composite bridges, each weighing up to 2500 metric tonnes and spanning up to 136 meters. The project’s primary goal was to improve Mumbai’s coastal infrastructure, providing crucial connectivity and easing metropolitan traffic congestion.

Scope and Challenges

The project encompassed several critical tasks:

  • Jacking and Lifting: Utilizing hydraulic jack-up cylinders and strand jack tower systems to lift spans weighing up to 2500 MT.
  • Transportation and Loadout: Employing synchronized self-propelled modular transporters (SPMTs) for seamless transportation and loadout operations.
  • Engineering Challenges: Conducting detailed engineering calculations for sea fastening, marine transportation, and ensuring structural integrity during installation.
  • Erection in Open Sea: Implementing the float-over method for erecting bridges in challenging open sea conditions, aligned using hydraulic jacks post-erection.

Innovative Solutions and Methodologies

Freight Wings faced unprecedented challenges, including delays in the supply of fabricated bridges and adverse weather conditions. To mitigate these challenges, innovative solutions were implemented:

  • Float-Over Methodology: Deploying a 110 x 64 x 6-meter barge with a 25,000 DWT capacity for transporting and installing bridge spans. This method was chosen due to shallow drafts and anticipated wave heights of up to 1.5 meters.
  • Two-Body System: Introducing a two-body system to enhance stability during installation, ensuring safety and precision.
  • Leg Mating Units: Utilizing specialized leg mating units for secure positioning of the bridge spans during the float-over installation process.
  • Quick-Lowering Long Stroke Tidal Jacks: Employing high-capacity tidal jacks for rapid adjustments and precise positioning during critical phases of installation.
  • Rapid Ballast Systems: Implementing rapid ballast systems to stabilize the barge and ensure safe operations in varying sea conditions.

Execution and Achievements

The project commenced with the successful installation of the first composite span, despite initial challenges. Freight Wings adapted swiftly to delays by optimizing logistics and operational strategies. The highlight of the project was the flawless installation of the largest arch span, weighing 2400 metric tonnes, achieved through meticulous planning and innovative methodologies.

This landmark achievement marked the debut of the float-over method and leg mating units in India’s offshore construction sector, setting a new benchmark for future projects. The pioneering use of advanced engineering techniques overcame logistical and environmental hurdles, demonstrating significant progress in the country’s infrastructure capabilities.


Freight Wings Pvt Ltd’s successful completion of the arch and composite bridge installation underscores its expertise in handling complex heavy-lift operations. By integrating cutting-edge methodologies and equipment, Freight Wings ensured project success and contributed to advancing India’s infrastructure development landscape. This case study highlights the importance of innovation and meticulous planning in overcoming challenges inherent in large-scale engineering projects.