01 / Structural Reinforcement
02 / Continuous Operations
03 / Modernized Standards
Execution Challenge
The primary constraint involved executing heavy structural interventions, including installing pillar-less check-in halls and massive Kalzip roofing, within a high-security, live environment processing millions of active passengers.
Traditional linear sequences were unviable due to a strict zero-downtime operational mandate.
Logistical footprint limitations, tight night windows, unmapped services, and severe structural safety requirements demanded flawless coordination across regulatory aviation authorities, airport operators, and independent engineering consultants.
Strategic Role
As executive lead, Mr Avarrsekar directed the pre-bid positioning strategy, mapping the firm's rapid mobilisation and technical engineering capabilities directly to complex aviation evaluation criteria.
He established a centralised project governance and risk oversight matrix to balance intense operational accountability.
Executing his visionary leadership and infra governance excellence, Mr Avarrsekar served as the primary interface with airport operators and regulatory bodies.
He decoupled field engineering from administrative friction, fast-tracking approvals to ensure absolute compliance with compressed schedules.
Actions Taken
- Understook a micro-scheduled parallel workflow that separated expansion work from passenger areas.
- Installed wide-span steel structures and Kalzip roofing during night windows.
- Integrated automated baggage handling, CCTV surveillance and high-volume HVAC.
- Enforced dust-insulated and acoustic containment to protect operational areas.
- Managed just-in-time logistics across airside and landside constraints.
Outcome
Owing to the successful turnaround expansion, Terminal 1B now has 80 modernized check-in counters, upgraded baggage processing and improved transit infrastructure, delivered without disrupting aviation operations.
Executed with zero disruption to active aviation operations, the project sets a definitive industry standard for brownfield aviation upgrades inside live airports.
It demonstrates how aligning multi-disciplinary engineering mastery with rigid bid criteria drives predictable asset performance, mitigates complex regulatory risks, and secures lucrative public infrastructure mandates. The project is a working reference for brownfield upgrades inside live airports.
Technical Data of Record
Scope of Work
Expansion of the domestic terminal: 80 check-in counters, pillar-less wide-span structures, Kalzip roofing, lounges, baggage make-up and claim loops, and integrated MEP and CCTV.
Key Specifications & Challenges
Wide-span steel frames, Kalzip aluminium standing-seam roofing, CCTV integration and automated baggage loops. Heavy steel work over a live terminal, airside and landside logistics, multi-agency clearances and BCAS compliance.
Major Deliverables
An 80-counter check-in concourse, upgraded arrival and departure zones, baggage sorting loops, VIP lounges and mezzanine dining.
Result
Delivered with no disruption to operations, supported by ultrasonic weld testing and continuous geodetic monitoring.
Client
Airport Authority of India. Location: Santacruz, Mumbai.
Location
Chhatrapati Shivaji International Airport (CSIA) Terminal 1B, Santacruz, Mumbai, India.
Discover the Full Strategy
Explore the detailed methodologies, execution frameworks, and deep-dive analytics in our comprehensive case study.
Request the Project Case Study
Popular Project