PREFAB structures has been widely used for construction of industrial buildings due to its many advantages over conventional structures like speed, cost, versatility and superior quality. This project is to extend the concept of PREFAB in construction of crossover bridges in cities. The advantages are manifold. The project is to design and build a scale model prototype of a flyover using PREFAB structures that will be manufactured in a factory and assembled part by part. The design of the crossover bridge has been done with the assistance of town planners, architects and experts in civil engineering, metallurgy, and surface treatment. The PREFAB design has been analyzed for stability and durability using ANSYS software and compliance with existing bridge building standards. To bring authenticity to the project, the TIDEL park- Indira Nagar junction at Adyar, Chennai, has been taken as a case study, where the need for such a flyover is acutely felt. This project offers a design for a flyover, built by PREFAB structures that will ensure smooth flow of traffic on all sides. This PREFAB flyover can be manufactured in individual components in shop floor with highest quality standards and erected at site with little or no diversion of existing traffic. While the conventional flyover would cost approximately Rs.100 crores and 2 years to complete, the PREFAB design can be completed in 2 months and within Rs. 20 crores. This project demonstrates the feasibility and highlights the economic advantages of adapting PREFAB concept in fabrication of steel crossover bridges in lieu of conventional civil construction. The project has identified and selected the steel, design the fabrication of individual units, vibration dampers, anti skid coating for surface, grouting procedures and surface finishing of the PREFAB structures. The sequence of erection has also been detailed. © 2017 Elsevier B.V., All rights reserved.