Astral Aquasafe Powers Rainwater Management at Bengaluru Airport T2

When Bengaluru’s monsoons hit with over 100mm of rainfall in a single day, the city’s infrastructure is put to the test. Heavy rain causes water to quickly accumulate at low-lying points across the city. As it begins to drain toward designated channels, the water surges toward critical areas, posing a threat to overwhelm drainage systems. At Kempegowda International Airport, this relentless flow puts vital operations at risk, with water pooling across runways and terminals. With over 25,000 daily passengers relying on smooth operations, even a slight disruption can have cascading effects on the airport’s functions.

Astral Pipes enabled Bengaluru Airport to maintain 24/7 flight operations during monsoons. By eliminating the risk of weather-related disruptions, we ensured that thousands of passengers continued their journeys smoothly, even through India’s heaviest rainfall seasons, keeping the nation’s busiest travel hub running seamlessly when it mattered most.

The Challenge: Managing Bengaluru T2’s High-Volume Rainwater Drainage Needs

Bengaluru is known for its heavy monsoon seasons, with average annual rainfall around 850mm, over half falling between June and September. This creates significant challenges for infrastructure projects like Bengaluru’s T2, which must withstand large-scale water accumulation without disrupting airport operations or passenger comfort. We tackled these challenges:

• Operational Requirements Drainage and Water Management: Designing an effective drainage system capable of managing high volumes of seasonal rainfall, ensuring proper water diversion, and collecting rainwater for reuse without affecting airport operations.
• Waterlogging Prevention: Preventing waterlogging to avoid disruptions to airport traffic, infrastructure damage and safety risks, especially in high-traffic areas like aircraft movements and passenger boarding.
• Operational Continuity: Maintaining uninterrupted operations while handling high-volume water flow challenges, with zero waterlogging incidents that could hinder ground operations or disrupt daily airport functions.
• Cost-Effective and Sustainable Solution: Developing a system that minimises long-term operational costs while aligning with the terminal’s environmentally-conscious design and maintaining optimal performance.
• Compliance with Aviation Standards: Meeting stringent performance, reliability, and regulatory standards necessary for aviation infrastructure.
• Technical Constraints Complex Site Layout: T2’s intricate layout required precision and careful planning for seamless integration with the airport’s design.
• Tight Project Timelines: Rapid deployment of the rainwater management system was essential to meet the airport’s phased construction schedule, particularly with delays caused by the global pandemic.
• High-Pressure Performance: The system had to sustain high pressure for continuous water flow throughout the terminal, addressing heavy rainfall without failure.
• Regulatory Compliance: Compliance with IS: 4985 and IS: 7834 standards for pressure pipes and fabricated fittings was a strict requirement for safety and regulatory alignment.

Astral’s Solution: The Aquasafe uPVC System

To address these challenges, we deployed our Aquasafe uPVC system, a solution known for high performance, durability, and the ability to meet stringent industry standards.

Product Specification

• System: Aquasafe uPVC Pressure Pipes (compliant with IS: 4985)
• Fittings: IS: 7834 Fabricated Fittings
• Scale: 1,119 pipes installed across 6,714 meters of pipeline network

We chose the Aquasafe uPVC system for its structural integrity and operational benefits:

• Structural Integrity: High-strength uPVC material withstands significant external loads under high pressure and extreme weather conditions.
• Corrosion Resistance: Made with lead-free composition, the system resists rust and corrosion, delivering long-lasting, low-maintenance infrastructure.
• Installation Efficiency: Lightweight design enabled quick and precise installation, important for adhering to tight project timelines.
• Standards Compliance: Full adherence to IS: 4985 and IS: 7834 specifications guaranteed regulatory compliance, making it suitable for high-demand environments like international airports.

Solution Implementation: Coordinated Execution Under Tight Timelines

Astral’s project execution team worked closely with on-site engineers to deploy the Aquasafe system smoothly. The installation process was rigorous, involving several stages of quality checks and performance testing. Throughout the project, our team followed clear timelines and collaborated with the construction team to handle complex logistical challenges posed by the terminal’s intricate design.

Performance Outcomes: A Success Story of Operational Efficiency

The rainwater management system is now fully operational and has significantly enhanced Bengaluru T2’s functionality. With a 6.7-kilometre pipeline network, the Aquasafe system routes rainwater away from terminal infrastructure, eliminating waterlogging incidents. Since activation, the system has operated flawlessly, protecting airport infrastructure during high rainfall periods.

Operational Benefits

• Zero Waterlogging Incidents: The Aquasafe uPVC has effectively prevented waterlogging across the terminal, maintaining smooth operations during seasonal rainfall.
• Sustained Efficiency: The system continues to support operational needs, demonstrating durability and performance that match the airport’s growing capacity.
• Future-Ready Design: The system’s scalable design handles the airport’s expanding infrastructure and operational requirements.

Quality Assurance and Performance Testing

Each installation phase was backed by stringent quality assurance protocols, confirming every pipe and fitting met the highest standards. All incoming uPVC pipes and fittings were inspected for compliance with IS: 4985 and IS: 7834 standards, with dimensional checks, batch traceability and visual inspections conducted on-site.

Installation was supervised by certified Astral technicians and jointing was verified using laser alignment tools to guarantee correct slopes for gravity drainage. Our team conducted performance tests to validate system integrity and efficiency before network activation. Simulated rainfall tests confirmed the system’s ability to handle peak monsoon flows, while discharge points and sumps were monitored for efficient water routing and zero pooling.

Strategic Impact: Reinforcing Astral’s Role in High-Stakes Projects

This successful deployment of the Aquasafe uPVC system at Bengaluru T2 demonstrates Astral’s ability to deliver world-class infrastructure solutions for such infrastructure projects. By addressing complex challenges head-on, Astral Pipes has solidified its position as a trusted partner in large-scale applications across aviation, industrial and commercial infrastructure sectors.

The Aquasafe system has proven its worth as a dependable, high-performance solution, maintaining seamless operation of one of India’s most significant transportation hubs while contributing to the airport’s sustainable development goals.