The Mumbai Metropolitan Region Development Authority (MMRDA) has reached a key construction milestone on the 13.9-km Elevated Eastern Freeway Extension (EFE), beginning the installation of precast segments above the operational Eastern Express Highway.
The first segment, weighing more than 90 tonnes, was erected at Pier P78 near Bhandup Pumping Station using a 115-metre-long mechanised Launching Gantry-01 (LG-01). The operation marks the shift from foundation and substructure works to construction of the elevated corridor’s main superstructure.
The mechanised system is designed to lift, transport and position heavy precast components while reducing the requirement for ground-level support. This is particularly important as construction is taking place above a busy highway that must continue carrying traffic.
Before deployment, the gantry underwent third-party testing to assess its operational readiness.
Following the first launch, LG-01 will progressively install 1,632 precast segments towards Mumbai. The segments will be longitudinally post-tensioned to form complete bridge spans.
A second gantry, LG-02, will work from Vikhroli towards Mumbai, while a Ground Support System will undertake construction between Bhandup and Kanjurmarg towards Thane.
The project incorporates mechanised construction techniques and a combination of large-diameter monopiles and single-pier structures to reduce the construction footprint. The design includes 2,500-mm-diameter monopiles and a single-pier arrangement that removes the need for conventional pile caps.
The elevated corridor will comprise 288 full spans, with a typical span measuring approximately 40 metres and made up of 16 precast segments. Individual segments can weigh up to 106 tonnes, while a complete span can reach around 1,450 tonnes. The deck will be approximately 25 metres wide at the top and seven metres at the bottom.
According to the latest progress figures, 81% of monopile work and 19% of group-pile work have been completed. Pier construction is at 51%, while 33% of pier caps are complete. Of the planned 3,732 precast segments, 135 have been cast so far.
The EFE will connect Anand Nagar in Thane with Chheda Nagar in Ghatkopar. The corridor is intended to provide an additional high-capacity route between Thane and Mumbai and ease pressure on the Eastern Express Highway. Once operational, it is expected to bring travel time between South Mumbai and Thane down to around 20–25 minutes.
Source: Mid-day
