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Mumbai Metro - Bandra Kurla Complex (BKC) station, Mumbai, India

PERI has delivered around 480 tonnes of formwork and scaffolding material to the client’s construction site in addition to providing comprehensive on-site support.
On account of the subterranean position up against the ground earth, it was not possible to use end-to-end formwork ties when concreting the retaining walls. For this reason, a single-sided formwork solution was required.
The columns were formed in a straightforward manner without any special-purpose components thanks to the integrated perforated strips on the LIWA Panel Formwork.
The single-sided formwork solution consisting of the SCS Climbing System and the LIWA Panel Formwork made it possible to form the 24-m-long and 4.5-m-high concreting sections in only one cast.
With the aid of the SCS Climbing System for non-tied wall formwork, it was possible to transfer the loads resulting from the fresh concrete pressure of the second concreting section through climbing ties and into the previous concreting section via the brackets.
The 750-mm and 1,200-mm-thick slabs with drop panels were cast effortlessly with the aid of the PERI UP Flex Shoring Tower Plus and TABLE MODULE VT Slab Table.
VT20 Alpha 3S Formwork Girders were used to support the slab formwork. These stand out due to their particularly high cost-effectiveness
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Project data

Location: Mumbai, India

  • Supporting the construction of the underground station Bandra Kurla Complex (BKC), which forms part of the new rapid transit system in Mumbai, India
  • The BKC, which is scheduled for completion in 2020, will be an important hub in the Mumbai Metro – and will also be the largest underground station in Asia
  • All in all, the BKC is 475 m long and 30 m wide and comprises two subterranean levels
  • Both of the 8.40-m-high and 5.50-m-high levels end with a 750-mm-thick slab and a 1,200-m-thick roof plate

Requirements

  • Provision of complex spectrum of coordinated formwork and scaffolding solutions
  • Use of end-to-end tie rods not possible on account of subterranean position up against the ground earth
  • 24.00-m-long and 4.50-m-high concreting sections that need to be formed in a single operation
  • Installation of complex 750-mm-thick and 1,200-mm-thick ceiling slabs at heights of 8.40 m and 5.50 m respectively
  • Adherence to demanding construction schedule spanning only 14 months

Customer

J. Kumar Infraprojects Limited

Customer's benefit

  • Comprehensive PERI solution using perfectly coordinated formwork and scaffolding material from a single source
  • 24.00-m-long and 4.50-m-high concreting sections formed in only a single cast, thus ensuring adherence to the stipulated cycle time of 25 to 30 days
  • Reduction in personnel requirements due to use of LIWA system formwork, resulting in cost savings
  • Optimum transfer of loads and height-adaptable table support through use of the modular shoring solution PERI UP Flex Shoring Tower Plus
  • Time savings thanks to the pre-assembled TABLE MODULE VT slab tables on site, which were quickly ready for use to meet the tight schedule
  • Construction site personnel trained and assisted on a continuous basis by on-site PERI support staff
A portrait of Somesh Pandey, Project Head, J. Kumar Infraprojects Limited
Somesh Pandey
Project Head

Bandra-Kurla Complex (BKC) is Asia’s largest metro station. We were looking for formwork material for a complete solution. Furthermore, we had to ensure that the strict project timeline with a pour to pour cycle time of 25 to 30 days could be met. With PERI’s formwork solution, we achieved our planned cycle time. Compared to conventional formwork systems, we also needed less manpower on site to execute such a large scale project. Along with the good quality of the material it was a great co-operation with the PERI designers and site engineers throughout the project.

PERI solution

  • SCS Climbing System used in combination with the LIWA Panel Formwork as a formwork solution for the retaining walls with single-sided application
  • Quick and simple column concreting procedure using LIWA Panel Formwork – with no special-purpose components
  • PERI UP Flex Shoring Tower Plus used to support the slab formwork
  • 750-mm-thick and 1,200-mm-thick ceiling slabs formed using TABLE MODULE VT Slab Table combined with VT 20K Formwork Girders
  • Support provided on site by PERI design and construction engineers to ensure adherence to the demanding construction schedule

PERI systems in use