The Mumbai-Pune Expressway, a vital artery connecting two of India’s major cities, is undergoing a significant upgrade with the construction of the 13.3 km ‘Missing Link’. This ambitious undertaking, spearheaded by the Maharashtra State Road Development Corporation (MSRDC), is being constructed by Afcons Infrastructure Ltd, which is executing Package-II.
The project aims to improve connectivity by reducing travel distance by over 6 km and travel time by approximately 30 minutes. Doka plays a pivotal role here, providing its expertise and innovative systems for the construction of the complex cable-stayed bridge.
Bridging the gap
The Missing Link is designed to bypass the Khandala Ghat section of the existing expressway, notorious for its hairpin bends and susceptibility to landslides. The project includes two, eight-lane twin tunnels, viaducts and a series of bridges, including a 650-m-long cable-stayed bridge with four diamond-shaped pylons, each 181.77 m high – making it one of the tallest in India.
This cable-stayed bridge is designed to navigate steep slopes and hazardous sections of the existing expressway, transforming the 19-km stretch from the Khopoli Exit to the Sinhagad Institute into a ‘zero-fatality corridor.’
Complex structures
The diamond-shaped pylon, with its complex geometry and inclinations in different directions, presented a unique challenge. Doka devised a tailored solution combining the Xclimb 60 Short Track and Automatic climbing formwork SKE100 plus systems. This innovative approach allows for the efficient and precise execution of the construction process, addressing both the simpler and more intricate sections of the pylon.
The Automatic climbing formwork SKE50 plus and SKE100 plus, Guided climbing formwork Xclimb 60, along with the Large-area formwork Top 50, ensure rapid and safe construction progress, while minimising manual handling, thereby reducing risks for on-site crews and accelerating construction timelines.
By collaborating closely with Afcons, and leveraging its engineering expertise, Doka is contributing to the successful completion of this vital infrastructure project, which will significantly enhance connectivity and safety on the Mumbai-Pune Expressway.
All images: Doka
