Overcoming the impact of the pandemic and other challenges

To contend with lockdowns, supply chain disruptions and manpower shortage caused by the pandemic, the team closed ranks quickly adapting to changing circumstances, taking proactive measures to keep their employees and workers safe by following all the prescribed protocols and the strict UAE regulations.

Managing stakeholders was a major challenge during execution that included regulatory bodies at different geographical locations. “The key was to select the right design and local consultants and manage them effectively to deliver compliant designs meeting both the project and local requirements,” shares Barath, “but it was not entirely a smooth and hurdle-free journey,” he smiles tightly, citing an example of the E611 flyover in Dubai, over the approach rail track to the facility.

Maintaining a constant inflow of material

Procurement Manager, Vinod Choudhary is a relieved and happy man having successfully managed a team comprising people drawn from diverse nationalities, including from China, Syria, Philippines and Lebanon, to source quality goods from 20 different countries and have them delivered to site on time, within the allocated budget. “It called for extensive coordination and constant communication,” he says, “and our procurement strategy was to identify critical long lead packages, evaluate suppliers in advance, prepare SOPs with details of preorder, ordering and post order guidelines that helped our team to work in sync with the project schedule.” In addition, regular monitoring, risk assessment and supporting the supply chain in times of need helped them to overcome the numerous supply chain disruptions. “In fact, periodic reviews and guidance from our senior management at the Kolkata HO were morale boosters for the team,” he adds, with gratitude.

Managing and ensuring a high level of performance and delivery from 250+ subcontractors was a tall order. Vinod attributes their success to effective leadership, timely decision making and constant communication with their senior management. “We successfully managed this complex network of subcontractors to ensure that their work met the expectations of our project management consultants – Egis and Jacobs,” he announces proudly. Their commitment to deliver a project of the highest quality, strict adherence to best practices in project & supply chain management and focus on continuous improvement based on feedback from the consultant/client and L&T senior management stood the team in excellent stead all through the project life cycle.

“The Project, executed as a Joint Venture, required a strategic approach to liquidity management, resource optimization, and cost efficiency,” remarks Akash Jain, Senior Deputy General Manager – Accounts. “As Deputy CFO, I focused on disciplined cash flow management, leveraging surplus funds, securing vendor advantages, and implementing cost-control measures. Rigorous financial oversight, including quarterly audits and seamless coordination with over 650 vendors and subcontractors, ensured operational efficiency and regulatory compliance across UAE and India. This meticulous financial stewardship contributed to a well-governed and successfully executed project.”

Project management tested to the limit

Of the six facilities, the Ghweifat Freight Facility was introduced as a change order to the original scope, that sternly tested the project team’s project management skills. “At the UAE-KSA border, the construction of the facility faced constraints in terms of resource, material, and equipment availability,” mentions Construction Manager, Suneel Kumar S, “however, through meticulous planning, we ensured timely availability of the resources, avoiding typical last-minute hurdles to adhere to the project timeline and deliver as per an extremely demanding schedule.” He looks a happy man.

Unfavourable weather conditions with temperatures in summer soaring to 50*C, humidity levels reaching 90% compounded by frequent sandstorms and remoteness of the site were other challenges that team had to overcome. “There we relied heavily on precast construction,” explains Suneel. “Additionally, we utilized a special concrete mix with an extended initial setting time of up to 8 hours to accommodate to the needs of the site.” Modular Porta-cabin structures minimized extensive on-site work, and all construction activities were scheduled during the day, as obtaining night shift approvals was difficult due to remoteness of the site.

Smooth interfaces speed up delivery

Another key reason for the project’s timely delivery was how interfaces were expertly managed with the systems contractor, whose engineering completion and interface inputs were critical to the design and construction of the facility buildings and infrastructure. The interface team, led by the Interface & Systems Manager, Sutanu Biswas, proactively engaged in technical discussions to define the interfaces and provisions acceptable to both the parties, recording them and proceeding with the designs so that engineering completion was not affected by the Systems contractor.

“Working closely with the construction team, we ensured that those interface provisions were incorporated, inspected and accepted during the construction phase itself, even though the program for installation was by different interfacing contractors,” mentions Sutanu. “This met our customer’s expectations, which resulted in Faster Taking Over, despite longer duration in integration works by the systems contractor,” he smiles.

Sutanu mentions the unique Terminal Operating System (TOS) and Gate Operating System (GOS) solutions that digitalized the entire operations of the rail terminal bringing in efficiency & better visibility. “It is the first of its kind in the region for rail operation,” he remarks proudly.

Risks related to such unique solutions were mitigated through in-depth interface discussions & records with all stakeholders and a robust contract where the supplier was also made accountable and responsible for end-to-end design, interface, implementation and handover.

“The Etihad Rail Freight Facilities Project is a testament to our ability to navigate complexity with precision and agility,” says T Kumaresan, EVP & Head – M&M, all praise for his award-winning team. “Through strategic planning, seamless stakeholder collaboration, and engineering excellence, we have delivered a world-class logistics infrastructure that strengthens UAE’s freight network. This achievement underscores our commitment to innovation, sustainability, and setting new industry benchmarks in large-scale project execution.”

“At the end of the day, despite the challenges, we successfully completed the Etihad Rail Freight Facilities project on time, with Zero Harm and or LTI and within budget,” exults a delighted Barath. “The facilities are also so designed that they are environmentally sustainable, reduces carbon emissions and supports UAE’s commitment to sustainability,” he concludes on a high.