Flexible solutions for the Mumbai Metro

Large cycles formed with the MBS wall formwork

Data & Facts

  • Project
    • Siddhivinayak metro station, Mumbai (IND)
  • Principal
    • Mumbai Metro Corporation Limited (MMRCL)
  • Engineering Company
    • MAPLE GC
  • Contractor
    • CEC-ITD Cem TPL Joint Venture
  • MEVA systems
    • MBS wall formwork
  • Engineering and support
    • MEVA Formwork Systems Pvt. Ltd., Navi Mumbai, India

Efficient implementation for rapid ­construction progress

Traffic and public transport are an ongoing issue in expanding megacities around the world. On their daily journey to work people often have to travel long distances, and those who drive themselves regularly have to contend with traffic jams. Expanding public transport promises to improve this situation. In the megacity of Mumbai with more than 15 million inhabitants the existing network is thus being extended.

To a large extent, the new metro lines are being built below existing roads. The stations are being built 20 metres below the surface. Nine out of the 26 stations planned are not, however, located under existing roads. Some are even situated in the immediate vicinity of culturally significant buildings such as the large Siddhivinayak temple.

Strictest safety requirements
On the south side of the city the construction company CEC-ITD Cem TPL is working on one of the new metro stations. The proximity to the temple, which is over 200 years old, means that the work is subject to a number of constraints to ensure that the temple is not damaged in the process. 

Watertight outer walls
After successful completion of the excavation phase and corresponding work on the tunnels, watertight outer walls were poured with the help of MEVA’s formwork experts. One way to do this is to screw tie rods into the water stop from each side. The water stop is then left in the wall as a irrecoverable internal part after pouring. When using the water stop, two short anchor sleeves and four cones for plastic tube are also required in order to seal the tie hole (see figure below).

Efficient implementation for rapid ­construction progress
Use was made of the smart MBS wall formwork, which can be precisely adapted to suit the building layout and the fresh-concrete pressure by positioning the girders and tie locations as required. For this project the lightweight K6 aluminium beams were delivered to the construction site just in time together with the 3S shuttering panels. They were assembled by the team from CEC-ITD Cem TPL supported by MEVA formwork engineer Sarfaraz Solkar. The direct customer support on the spot provided by MEVA guarantees efficient and rapid construction progress in the long term.

Advantage through flexible adaptation
The track bed in the newly built subway station is on the third basement level. Here, the first watertight concrete walls with a thickness of up to 1 m were poured over a length of 220 m. With 7.20 m, the third basement level is high enough to allow trains to enter and leave the station. With 6 m and 4.80 m, the floors above are lower and serve as the station concourse and arrivals level for the passengers. Using the flexible MBS wall formwork offers a significant advantage during the construction work. “Having set up the MBS for a pouring height of 7.20 m in the lower basement level, it can be simply shortened for the subsequent storeys,” explains Mahesh Dhanawade, the MEVA engineer responsible for the planning. “This enables us to offer the customer a clear advantage with our formwork system.”