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Mumbai, Indias commercial metropolis and one of the most densely populated cities in the world, is changing. A new and fast connection expressway is being built between Mumbai and Pune, greatly improving the safety and comfort of commuters “ and cutting travel times by 45 minutes.

The Mumbai-Pune Expressway will create a reliable shortcut for the existing road, helping commuters to avoid traffic congestion and delays, the result of a rapidly expanding urban population and monsoon weather conditions. Shotcreting will play an integral role in forming and strengthening the hanging and side walls of the tunnel excavations, and Atlas Copcos electric E-Air compressor has been chosen as the ideal partner for this confined subterranean task.

RVR Projects, a local construction specialist, is one of two contractors working on the expressway, with the task of shotcreting the tunnel excavations. Shotcreting is being used to strengthen the tunnel while leaving the structure of the rocks intact, and is generally the preferred method of stabilisation and aesthetics in the construction of tunnels. It allows structural engineers to flexibly adapt the thickness of the concrete being sprayed, offers higher concrete adhesion, and enables concrete to be applied at high elevations.

Maximum shotcreting quality

Within the tunnels of the expressway, the sprayed concrete process must adhere to stringent quality requirements. The RVR projects team opted to use two of its 13 Atlas Copco E-Air compressors, influenced by the machines ability to maintain a consistent supply of clean, quality air. The state-of-the-art, zero-emission electric compressors produce a reliable supply of oil-free, dry air “ also ideal for maintaining sufficient nozzle velocity for all aspects of the shotcreting work.

The E-Air compressors are fitted with Atlas Copcos innovative PACE technology, which increases the machines Free Air Delivery (FAD) as the pressure is reducing. They offer a distinct competitive advantage when the nominal FAD is not enough “ due to a leakage or bigger nozzle, for example “ as the extra FAD increase by PACE will optimize the shotcrete application. The PACE system influences the productivity, speed, efficiency (through less material being wasted), and quality of shotcrete.

Game-changing performance

RVR projects require a compressor that can provide exceptional maximum working pressure for its shotcrete application. Material moving inside the hose of the shotcrete machinery causes friction, meaning that a higher pressure is needed to push the materials through the hose. Thanks to the on-site E-Airs PACE technology, the RVR team can flexibly adjust the required pressure to maximise the efficiency of the process.

The E-Air electric compressors also significantly reduce the operational costs for RVR projects, thanks to their VSD motor. The power limitation function allows the compressor to operate shotcrete machinery at a low power grid “ a true game-changer when it comes to performance, even in the toughest conditions. The highly efficient, ultra-clean E-Air is the perfect match for the dusty, muddy, and very hot conditions of the underground expressway, where temperatures rise to a sweltering 45 degrees Celsius. The machines will continue to work 24/7 to keep the shotcrete process running continuously, delivering maximum performance.

Road to net zero

Atlas Copco is committed to being at the forefront of change in offering sustainable solutions for shotcreting applications. It has developed a portfolio of solutions that target net zero goals while delivering better efficiency and contributing to a lower total cost of ownership than traditional alternatives. Atlas Copco Portable Air has taken an innovative step towards decarbonisation by offering sustainably driven electric compressors, without compromising on performance.

To learn more about electric compressors from Atlas Copco, visit website https://www.atlascopco.com/en-in