• Project Name: Loadout of Multiple OSDs for Mumbai Trans Harbour Link Project

The Mumbai Trans Harbour Link (MTHL) is a flagship infrastructure project designed to enhance connectivity between Mumbai and Navi Mumbai, significantly reducing travel time and bolstering economic integration. Spanning 22 kilometers, this sea bridge is one of India’s longest, incorporating an ambitious design to withstand harsh marine conditions and heavy traffic. Freight Wings was entrusted with the critical task of handling 32 Orthotropic Steel Decks (OSDs) for the MTHL project due to our proven expertise in handling large-scale, complex infrastructure projects.

Project Summary

Freight Wings undertook the comprehensive transportation and installation of 32 OSDs, each weighing between 650 MT to 2683 MT and extending up to 180 meters in length. This project was located at Karanja Port, Navi Mumbai. The scope of work included detailed transportation, loadout, and lifting engineering services, and supplying advanced systems to ensure the safe and efficient handling of these substantial components.

Scope of Work:

Engineering and Planning

Freight Wings conducted comprehensive engineering and planning to ensure successful project execution. This involved detailed structural analysis and loadout planning to handle the massive weight and dimensions of the OSDs. Key considerations included:

  • Load Distribution: Ensuring even load distribution on the jacks and SPMTs.
  • Stability Analysis: Assessing the stability of OSDs during jacking, transportation, and loadout operations.
  • Safety Measures: Implementing robust safety protocols to prevent accidents and damage to the structures.


Jacking of OSDs

The initial phase involved jacking up the OSDs to a height of 8 meters using Mega Jacks with capacities ranging from 200 MT to 900 MT in various combinations. This step was crucial for aligning the decks with the SPMTs for smooth maneuvering.

  • Equipment Used: Mega Jacks with capacities from 200 MT to 900 MT.
  • Procedure:
    1. Positioning the jacks under the designated jacking points of the OSD.
    2. Synchronizing the jacks to lift the OSD uniformly.
    3. Monitoring the jacking process to ensure stability and alignment.


Transportation of OSDs

The transportation phase involved moving the OSDs from the fabrication yard to the loadout site using 94 SPMT axle lines.

  • Equipment Used: 94 Self-Propelled Modular Transporter (SPMT) axle lines.
  • Procedure:
    1. Preparing the route and ensuring it could handle the weight and dimensions of the OSDs.
    2. Carefully maneuvering the SPMTs to transport the OSDs.


Loadout Operations

The final phase was the loadout of the OSDs onto transport vessels, involving precise coordination and specialized equipment.

  • Equipment Used: SPMTs, ballast pumps, mooring winches, and ballast monitoring systems.
  • Procedure:
    1. Positioning the OSD barge at the loadout jetty.
    2. Using ballast systems to adjust the vessel’s draft and ensure stability during the loadout.
    3. Securing the barge using mooring winches.
    4. Continuously monitoring the ballast levels and structural integrity of the vessel during the loadout.


Deck Equipment Supply

To facilitate the loadout operations, Freight Wings supplied essential deck equipment including:

  • Ballast Pumps: To manage the vessel’s stability by adjusting the ballast water levels.
  • Mooring Winches: To secure the OSDs onto the transport vessels.
  • Ballast Monitoring Systems: To provide real-time data on the vessel’s ballast conditions, ensuring a safe and balanced loadout process.



Freight Wings overcame several challenges during the project:

  1. Heavy Weight and Large Dimensions: Handling OSDs weighing up to 2683 MT and lengths up to 180 meters required precise engineering and robust equipment.
  2. Stability During Jacking: Ensuring stability during the jacking process to avoid accidents and structural damage.
  3. Safe Transportation: Navigating the transport route with large and heavy loads.
  4. Loadout Precision: Coordinating the loadout process to ensure the OSDs were securely placed on the barge without any mishaps.


Freight Wings implemented several innovative solutions to address these challenges:

  1. Advanced Engineering Analysis: Conducted detailed structural and stability analysis to plan the jacking, transportation, and loadout processes.
  2. State-of-the-Art Equipment: Utilized Mega Jacks with capacities from 200 MT to 900 MT and 94 SPMT axle lines capable of handling the heavy loads and large dimensions of the OSDs.
  3. Route Planning and Preparation: Undertook meticulous route planning and preparation to ensure safe transportation.
  4. Skilled Personnel: Deployed experienced engineers and technicians to oversee each phase of the project, ensuring precision and safety.


The successful loadout of the OSDs for the Mumbai Trans Harbour Link project at Karanja Port demonstrates Freight Wings’ capability to handle complex and large-scale transportation and installation projects. Through meticulous planning, advanced engineering, and the use of state-of-the-art equipment, Freight Wings ensured the safe and efficient execution of the project, contributing significantly to the progress of the MTHL initiative.