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Indian highway project using automated formwork on complex ‘Missing Link’ bridge

Austria-based formwork specialist Doka is providing engineering and climbing systems for one of India’s most complex highway upgrades: the so-called ‘Missing Link’ project on the Mumbai–Pune Expressway.

Doka formwork solutions are in-used on the nearly-complete "Missing Link" bridge project for India's Mumbai–Pune Expressway. Image: Doka Doka formwork solutions are in-used on the nearly-complete “Missing Link” bridge project for India’s Mumbai–Pune Expressway. Image: Doka

The estimated US$800-billion 13.3km scheme, led by the Maharashtra State Road Development Corporation (MSRDC) and built by Afcons Infrastructure, includes twin eight-lane tunnels and several major bridges to bypass a hazardous road section. It is expected to cut travel time between Mumbai and Pune by about 30 minutes and reduce the route by more than 6km.

At the heart of the project is Viaduct 2, a 650m cable-stayed bridge with four diamond-shaped pylons reaching 182m in height, said to be among the tallest in India. The bridge spans 305m and runs through steep, landslide-prone terrain.

To support construction, Doka is supplying a range of systems including automatic climbing formwork systems SKE50 plus and SKE100 plus, guided climbing formwork system Xclimb 60, and large-area formwork system Top 50. For the geometrically complex pylons, Doka said it developed a custom solution combining Xclimb60 Short Track and SKE100 plus to handle varying inclinations and reduce manual handling on site.

The Missing Link segment is said to be around 95% complete, with an opening possible as soon as this year.

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