Exploring the Structural Performance and Passenger Experience of Mumbai Metro Line 5’s 65-Metre Steel Span
A Milestone in Urban Rail Infrastructure
It was early morning at Anjurphata, Bhiwandi, when the first light glinted off the newly installed 65m Open Web Girder (OWG), suspended above the busy Vasai-Diva railway line. For the engineers and construction teams who had spent months meticulously planning, welding, and coordinating every movement, this moment was the culmination of precision, patience, and teamwork. The structure represents more than steel and concrete, it embodies the collective effort of labourers braving the elements, engineers calculating every bolt, and designers envisioning a structure that balances functionality with urban aesthetics.
Weighing 456 metric tonnes, the OWG connects two pivotal piers, forming a crucial segment of the elevated viaduct. This steel span is a testament to advanced engineering and a symbol of the city’s commitment to modern, reliable urban transport.
The Story Behind the Installation
On the day of installation, the scene resembled a carefully choreographed symphony of engineering precision. The massive steel girder, prefabricated off-site, was transported to Anjurphata and lifted into place using Strand Jacks. Workers guided the structure with care as it hovered above the active railway line. Tiny adjustments using Hillman Rollers ensured perfect alignment with the piers, while spotters monitored every joint and bolt. Engineers coordinated in real-time, verifying clearances and load distribution, ensuring safety without interrupting train operations. For a few tense hours, the OWG appeared to float above the tracks — a striking testament to teamwork, planning, and the remarkable capabilities of steel.
Engineering Excellence: Structural Performance
Fabricated by Eurocoustic Products in Daman, the OWG’s open web design not only provides visual appeal but also reduces weight, making it ideal for urban settings with tight space and load constraints. Over 30,000 High Strength Friction Grip (HSFG) bolts secure the structure, ensuring long-term stability and durability. The installation was coordinated during a designated railway block to minimise disruption, reflecting careful planning and respect for the city’s daily pulse. The span is engineered to withstand dynamic loads, wind forces, and vibrations, demonstrating how modern steel design balances strength, efficiency, and aesthetics.
Enhancing Passenger Experience
For commuters, the bridge is a promise realised: smoother, faster, and safer travel across the 24.9 km Thane-Kalyan corridor. Its elevated design allows uninterrupted road and railway operations below, reducing congestion and travel times. Every beam, bolt, and rivet contributes not only to structural stability but also to a reliable, comfortable commuting experience, highlighting how infrastructure design directly impacts daily life.
Innovation and Modular Construction
One of the standout aspects of the OWG is its modular, prefabricated construction. Large steel segments were assembled off-site and transported carefully to the installation site, reducing on-site work and minimising risks. This approach also accelerated project timelines and ensured precision in alignment, a critical requirement for spans over active railways. By combining advanced fabrication techniques with innovative installation methods, the project showcases how modular steel construction is shaping the future of urban transit.
Sustainability and Urban Integration
Beyond performance and safety, the bridge demonstrates sensitivity to its urban environment. Its open web design reduces material usage while providing visual lightness, allowing the structure to blend into the surrounding landscape. Strategic placement above active transport lines minimises disruption, while its robust steel ensures durability and longevity, reducing maintenance needs over time. The project highlights how well-engineered steel infrastructure can harmonise functionality, aesthetics, and environmental considerations.
Looking Ahead: The Role of Steel in Modern Infrastructure
Behind each girder lies a story of human endeavour, precision engineering, and careful planning. Structures like this illustrate the pivotal role of steel in shaping resilient, long-lasting urban infrastructure. As cities continue to grow and modernise, advanced steel applications enable longer spans, faster installation, and safer, more efficient networks. This blog is part of an ongoing series on infrastructure developments shaping cities worldwide — stay tuned for the next milestones in urban engineering and transport innovation.
