TEAM BIAL, BEATING ALL ODDS TO
THE FINISH LINE!

“Things, however, were dramatically different to start with for us,” comments Shivaraj. “As a team we have had to go through a lot. Ours is really a story of struggle and triumph, overcoming disruptions to bring to reality what is conceived as an ‘airport terminal inside a garden’.”

Green Terminal – an integration of natural elements

Pivoted on the concept of ‘a terminal in a garden’, the architecture of Terminal 2 integrates several natural elements such as clay, bricks, bamboo, rattan, and extensive landscape. A lagoon with a big artificial forest belt around it, a multimodal transport hub, including the Metro, provisions for solar panels on the roof, artificial waterfalls, elevated walkways, and green seating areas are among its standout features.

“There are several firsts,” remarks Anne like conducting an Integrated Test and having simulation labs at site for testing, simulating the IT systems, BHS HLC and LLC (high- and low level controls), combined wash & dry faucets in rest rooms with ADA compliance, LOD 400 (clash free shop drawings developed in BIM 360 Cloud) & Cobie (asset management system integrated with BIM platform). “We conducted Virtual FATs (factory acceptance tests) along with the customer for both imported and indigenous equipment and our MEP systems have been installed with complete mechanization (duct lifters, pipe lifters, etc.) with prefabrications to expedite process and progress,” he says, proud of his
team’s efforts.

“In the initial phase of the project, we completed all the RCC works for the terminal as per the project milestones,” shares S Kaliyan ‐ Head Construction (Terminal), with a sense of purpose. Post COVID, the team faced the challenge of mobilizing workmen and vendors to execute the finishing works for which they rigorously followed up and
re‐mobilized the entire workforce. “We realigned our strategy and prepared a detailed plan for 750+ Back of House Rooms which were required for the operations team. In addition, we created a separate team to focus on the passenger movement areas” informs Kaliyan. “Detailed interface plan with all trades were prepared and works were monitored daily to complete all the rooms and passenger movement areas.”

The elevated corridor with the Departure Forecourt and the road network, were logistically constrained in all sides with the MMTH, metro tunnel, lagoon, air-side boundary, and the CUP building. “The elevated corridor consists of Void Form Slabs, PT Slabs, a signature bridge (connecting the existing Terminal 1 to the main exit road),” informs Pranab Krishna De ‐ Head Construction (Elevated Corridor, Forecourt & At-Grade Roadworks). The bridge bearings of this elevated network (of varying load bearing capacity), had to be tested 100% as a stringent quality assurance measure by EDRC as against one of each type as per codal provision prior to installation. “With very few test facilities available in the country to test such higher capacity bearings, we proactively engaged with stakeholders, identified the facility, and ensured that the bearing testing was not an impediment to site progress and completed the bridge as per the project timelines.” Pranab’s triumphant expression says it all. “The signature bridge was the project’s first major milestone (related to operation readiness) to be completed, that was inaugurated on April 25^th, 2022, in the presence of our senior management and BIAL senior management,” he adds proudly.

“Executing about 1.35 lakh sqm of granite flooring and cladding selected from various quarries from across India was a huge task,” remarks Anil Dureja, Head ‐ Special Finishes. “Right from selecting the stone blocks in the quarry, processing the stone slabs, till delivery at site was monitored by our people placed at every location to track the supply chain, which is key to delivering such massive expanse of natural stone flooring and cladding.”

“While COVID 19 certainly caused enormous disruptions to progress, we from the Admin team, have done all that it takes to ensure that the impact was lessened,” recalls N. Sridhar, Head ‐ Finance, Accounts & Administration. “Be it liaising with the Railway Ministry to allocate dedicated trains for workmen to travel to Bengaluru, obtaining special approvals from the Health Minister of Karnataka to reduce the quarantine period for workmen who tested negative in Rapid Antigen Tests, and more.”

All lifts including the critical ones, using 60 T crane over the RCC slab at 12 m levels, were carried out in consultation with the CMPC Department. MEWP – mobile elevated working platforms – have been used extensively instead of scaffoldings, another unique safety feature while 110v hand-held power tools make operations safer for workmen. Roof works, a critical activity was completed efficiently and safely.

No compromise on Quality

The Terminal 2 is spread over about 20 acres of footprint area with a basement and 4 upper levels which will typically take a person about 3 days to visit every nook and corner of the terminal in detail. For former Quality Head,
V. Yegappan, who retired recently, the project was his best shot in terms of quality adherence. Not only did the project win the internal rolling B&F Quality Trophy in 2019-20 but has also consistently won the client’s appreciation, which was no mean achievement, he grins. “We achieved many exciting milestones simply because we didn’t quit when faced with challenges and worked together as a team to give the best output.”

Around 13,000 MT of structural steel having AESS (Architecturally Exposed Structural Steel) was fabricated externally and brought to site with two dedicated QA/ QC Engineers deployed at factory for strict inspection & adherence.

“Another big challenge was casting the circular columns of 1.2 & 1.8 m diameter of 12 m height in a single pour without intermediate lifts,” shares PL Alagappan – Head-Formwork, with the hint of a frown. “By devising a proper methodology and through our dedicated team, we cast 400 plus columns in a single lift that saved us time and cost. Generally, we construct such long columns in multiple lifts.”

Digital Transformation through BIM, COBie

“Being the country’s first project to integrate a full BIM lifecycle for the entire project cycle meant that we had to hand hold the teams through the process as our vendors were used to 2D,” shares Narin Gobindranath, Design Head.

The BIAL project site looks like a giant pitstop with every person playing a key role. Senior Principal Architect, Nandedkar Suchita walks energetically and points at the granite flooring and says, “All the dry lay inspections of granites have been carried out by me personally day in and day out to meticulously ensure that the extensive granite flooring at various levels of the terminal are of the best quality and aesthetics.”

“My team has done an excellent job against all odds,” says Shivaraj proudly. And as they march closer to the finish line together, of late he has been asking them only one thing, “How is the josh?” “High Sir”, they roar in unison.

A MATTER OF PRESTIGE!

Spread over 32 acres with 5 Buildings & 15 Towers, 3571 flats with each tower having 2 to 3 Basements + Ground Floor +30 Floors, the Prestige Jindal City residential project paints a majestic picture in the dense residential area of Bengaluru. For Project Director, K Ravichandran and team, it was time to celebrate, entering the last leg of completing a project which was initially marred by several disruptions. As the team cheered in tailormade sherwanis made for the occasion, Ravichandran remarks, “the timely completion and commendable progress of the project are only because the team stood by each other undeterred by challenges. An indication of the quality of our work, is that we have bagged more high value projects from Prestige.”

Every challenge is an opportunity to excel

Located in a residential area, the team only had a restricted 7 am ‐ 7 pm window for construction activities during which they had to complete 500 ‐ 750 cum of concrete in 12 hours and maintain equipment at the highest levels of efficiency and availability, with zero breakdowns. Elaborating, Head Finishing- A Subramanian shares, “Our challenges were not to create any noise after 7 pm and take extreme care to minimize dust by using vacuum grinding machines, and sprinkling water around the clock. I am equally thrilled that we have been able to maintain the highest levels of quality and consistency even while working with multiple agencies and workmen.”

“During the second wave of COVID, the team faced challenges for the transit of workmen from their habitat to site due to the stringent guidelines announced by the State Governments,” informs Vegu Sreenivas, Head Accounts, “but we managed with impeccable co-ordination and strictly following all SOPs.”

Some of the team’s prime challenges were to sustain the increasing prices of transportation despite the spike in fuel prices, steel prices and all consumables, retain and timely re-mobilize vendors and sub-contractors for all the activities.

“With stringent planning at task level, active resource mobilization, workmen and P&M allocation, and strict monitoring of site progress, we achieved several milestones, well ahead of time,” happily grins
Head ‐ Planning, Ms. V Ramani.

Another huge challenge for M. Sivanthilingam, Head Structure, “was to complete the 19 Lakh sq ft of non-tower area structure with almost 9 ancillary building structures of STP, UG Sump, DG rooms at the 3rd & 2nd basement levels.” he huffs with relief. “The IPS flooring for the 3 basements was a tall ask with the logistics of pump placing, transit miller movement with all finishing works and ground works progressing in tandem. But here we are today, all set to handover the project,” he says with a quick smile.

“I am proud that the team effectively implemented QMS systems and digital checklists at site. We have received several accolades from the client and recently, we were awarded the best high-rise structure from the American Concrete Institute which was only possible because the team had a common vision and worked in tandem with each other,” states Manikandan P – Head Quality.

Ravichandran or “Captain” as the team affectionately calls him looks proudly as they rally around each other in easy camaraderie, knowing that in a few weeks, they will congratulate each other on their latest triumph and move on to other projects to do what they do best – changing cityscapes together!