Multi-Modal Logistics Park (MMLP) Master Planning and Infrastructure Optimization

Project:

Multi-Modal Logistics Park (MMLP)

Sector:

Logistics Infrastructure, Railways, Roads & Highways, Integrated Industrial Infrastructure, Warehousing

Services:

Master Planning, Global Benchmarking, Assistance in Surveys and Investigations, Engineering Design, Cost Optimization, Quantity Survey, Design Supervision and Assistance in Site Supervision

Key Outcomes:

• ₹14 crores saved through optimized retaining wall design
• Reduced earthwork quantities and development costs
• 100% increase in warehousing built-up area compared to the original master plan
• Estimated ₹4.8 crores/month additional revenue potential

The Context

A private infrastructure developer involved in logistics and transport infrastructure commissioned the development of a Multi-Modal Logistics Park (MMLP) to support growing freight movement and improve logistics efficiency. The proposed logistics park was intended to handle cargo through both rail and road connectivity while providing large-scale warehousing infrastructure for freight handling and distribution.

Eka Infra was engaged to support the project through master planning, engineering design and traffic assessment. The assignment required addressing site constraints, improving land utilization and developing a credible methodology for estimating cargo traffic associated with the logistics park.

The Challenge(s)

Planning the MMLP involved several technical and commercial challenges related to site conditions, land utilization and traffic estimation.

• Significant variation in natural ground levels
  The project site exhibited considerable variations in terrain. Applying conventional uniform grading would have resulted in large cut-and-fill volumes and substantially higher development costs.
• Boundary wall design implications due to terrain
  The external peripheral access road levels were, at certain points, varying by almost 12m w.r.t the railway corridor within the plan. Uniform formation levels would have required significant boundary cutting along the peripheral external access road. This would have necessitated retaining walls of approximately 8–10 metres in height along parts of the boundary, leading to major structural and cost implications.
• Limited land utilisation in the base master plan
  The base master plan had relatively low land utilisation, particularly for warehousing. As warehousing represents the primary revenue-generating component of the logistics park, this directly affected the project’s long-term commercial potential.
• Absence of Codal guidance for MMLP traffic estimation
  In the master plan, only a small portion of the site caters to rail cargo, while the majority of the land was allocated for warehouses expected to handle cargo arriving via road. However, cargo traffic projection was only available for Rail cargo. Unlike highways or urban roads where established norms exist, there are no standard Codal guidelines for estimating truck movements generated by multimodal logistics hubs due to road cargo. A reliable methodology was therefore required to estimate daily vehicle flows and annual cargo throughput, which are essential for planning the operational efficiency of logistic park, utilities design, parking requirements and internal roadways and gate complex designing as well as docking space requirements for warehouses.

Our Solution

The Eka Infra team adopted a practical, engineering-led planning approach that integrated the site’s natural terrain into the development strategy.

• Terrain-sensitive land grading strategy
  Instead of enforcing uniform grading across the site, the existing contours were studied in detail and incorporated into a dynamic land grading plan. This approach minimized unnecessary cut-and-fill operations and reduced overall earthwork quantities.
• Optimized boundary design
  Integrating the natural terrain into the development strategy significantly influenced the boundary design. By retaining the natural topography and adjusting development levels accordingly, the required boundary retaining wall height was reduced from an estimated 8–10 metres to approximately 3–4 metres, resulting in significant savings in earthwork and structural retaining wall costs.
• Revision of the master plan to improve land utilisation
  The master plan was revisited to improve land productivity. Through improved zoning and spatial optimization, the layout was reworked to maximize usable development parcels while maintaining efficient circulation and operational safety. This resulted in a 100% increase in warehousing built-up area compared to the Authority’s original master plan.
• Hybrid methodology for traffic estimation
  In the absence of Codal provisions for estimating traffic in MMLPs and due to the lack of reliable data for cargo expected via road, a hybrid traffic estimation approach was developed. The methodology combined relevant IRC guidelines with warehouse capacity assessments and cargo throughput modelling. By triangulating these inputs, projections were established for daily vehicle flows and annual cargo throughput, providing a defensible basis for infrastructure planning.

The Impact

• Reduced structural costs through optimized boundary design
  By integrating the natural terrain into the land grading plan, the required boundary retaining wall height was reduced from 8–10 metres to approximately 3–4 metres, resulting in structural savings of around ₹14 crores and simplifying construction along the project boundary.
• Optimized utilities design despite terrain variations
  Incorporating the site’s contours initially complicated the design of gravity-based utilities such as the sewer network and rainwater harvesting system. Early iterations resulted in very deep inspection chambers and collection sumps/tanks. Further design refinement utilized the natural level differences to support gravity flow, resulting in a more practical and financially viable utilities design.
• Improved land utilization and enhanced revenue potential
  The revised master plan significantly increased the warehousing capacity of the logistics park. The additional warehouse space available for leasing is expected to generate an estimated increase of ₹4.8 crores per month in revenue for the client.
• Credible basis for infrastructure planning
  The customized traffic modelling approach provided defensible projections for vehicle movements and cargo throughput, enabling more reliable planning of internal roads, gate complexes, parking areas and warehouse docking infrastructure.