Named the icon of modern India, the Mumbai International Airport is being rebuilt to provide world-class architectural design and futuristic facilities, with Rondo providing both product and technical assistance to three of the six main stages of the development.

Constructing such a huge project is complex, as the airport must continue to run as normal whilst massive developments take place over the 800 hectare site. Rondo has been providing a solid support foundation, using resources from both our International and Australian Technical Services departments.

The South West Pier (Stage 1), is being built by Rachana Arts and is nearing completion. During its 8 month construction period, Rondo provided assistance for the corian cladding to the columns by creating adjustable and concealed fixings that were purposely designed for the hollow section support framing, as well as providing stud and track to support the various cladding materials.

The Skywells Package (Stage 5) of the Mumbai International Airport are located within the ceiling plenum space. Commencement of this stage is about to take place, and will involve Rondo supplying Steel Stud Drywall Framing System with some hollow sections to provide immediate support between the main structural steelwork of the roof.

Around the exterior of the main arrivals/departure building, glass fibre reinforced concrete (GFRC) is to be used as the ceiling and column cladding material. This meant Rondo needed to provide a custom ceiling design that could support the GFRC and Bullnose Exterior Ceiling Panels using Rondo Steel Stud and Track components, and prefabricated hollow section trusses.

Before approval of this design took place, Rondo’s Technical Representatives worked to fabricate a half scale mock up of the bullnose facade section, which allowed a simulation of the actual construction methods to be employed on site.

The lifting frame, truss and GFRC support members were all designed in-house with Rondo Australia engineers running a two dimensional structural model of the frame using specialist design software. This provided Rondo India Engineers with the design loads required to enable checking of the proposed framing sections.

In addition to the technical support, Rondo Technical Representatives have been and will continue to attend weekly site meetings to track the progress of the airport and assist contractors until completion.

Once complete, the airport will allow for 40 million passengers per year, which will handle up to 1 million metric tonnes of cargo per annum, and boast 188 check in counters, over 20,000m2 of commercial space (retail, F&B outlets, lounges and travel services), 66 passenger boarding bridges and 5000 car parking spaces.