Mumbai Metro Line 5: 65-Metre Open Web Girder Launched Over Vasai-Diva Railway Line

In a significant engineering achievement, the Mumbai Metro Line 5 (Thane–Bhiwandi) project has successfully completed the launch of a 65-meter-long Open Web Girder (OWG), weighing 456 metric tons, across the Central Railway’s Vasai-Diva line at Anjurphata, Bhiwandi. This marks a major milestone in the development of the elevated viaduct between Metro piers P328 and P329.

The challenging operation required meticulous planning and seamless coordination between the Mumbai Metropolitan Region Development Authority (MMRDA), Central Railway, and Traffic Police. The girder spans a complex multi-level site: the busy Thane-Bhiwandi Road at ground level, the Vasai-Diva railway line at the first level, and the Metro viaduct 20 meters above.

मुंबई मेट्रो लाईन- ५ च्या कामाचा ऐतिहासिक टप्पा पूर्ण!

मुंबई महानगर प्रदेश विकास प्राधिकरणाने ठाणे–भिवंडी–कल्याण या मुंबई मेट्रो लाईन ५ च्या (पहिला टप्पा) अंतर्गत मध्य रेल्वेच्या वसई-दिवा मार्गावर अंजुरफाटा, भिवंडी येथे ६५ मीटर लांबीचा "ओपन वेब गर्डर (OWG)" यशस्वीरित्या… pic.twitter.com/bO4seomMRZ

— MMRDA (@MMRDAOfficial) April 15, 2025

The first phase saw 44 meters of the OWG pulled into place, followed by final positioning of the complete 65-meter structure. The girder crosses the Central Railway’s Thane-Bhiwandi Subway, located between Kharbav and Bhiwandi stations.

Constructing over a live railway line and congested urban roadway demanded innovative engineering solutions. Construction occurred near a narrow railway underpass, amid live train operations and heavy road traffic. The OWG was launched at a height of 21 meters, requiring temporary enabling structures made from 400 metric tons of structural steel.

Assembled in segments using cranes (250 MT to 800 MT) the Girder was pulled into place over temporary supports using 40 Hillman rollers and 4 strand jacks powered by hydraulic packs.

According to MMRDA, Timely approvals were secured from Central Railway for designs and launch plans. Traffic diversions and railway power blocks were managed efficiently, with cooperation from DFCCIL, Central Railway, and Metro Line 5 agencies.

The work is being executed in eight planned power blocks provided by Central Railway.