Engineering a New Standard in Metro Maintenance

Supporting Metro Maintenance Through Engineering Innovation:

As India's urban rail networks continue to expand, the need for advanced, reliable and efficient depot maintenance infrastructure has become increasingly important. Supporting modern metro operations requires more than conventional workshop equipment; it demands integrated engineering solutions capable of handling complex maintenance requirements with precision, safety and operational flexibility. At Mumbai's Aarey Depot, this vision took shape through the successful installation of an integrated workshop maintenance solution from CMCO, under its Pfaff brand. Bringing together Synchronized Underfloor Lifting System “Pit Jacks”, Synchronized Mobile Jacks, and a Bogie Turntable, the project represents a significant milestone in India's metro maintenance infrastructure. Designed for eight-car metro trainsets, the customized solution incorporates synchronized lifting technology with a total lifting capacity of 384 tonnes.

The installation also marks a new chapter in Pfaff's engagement with Mumbai Metro, reinforcing CMCO's commitment to delivering globally inspired, locally customized engineering solutions.

The Challenge: Rethinking Conventional Depot Maintenance:

Efficient maintenance infrastructure plays a critical role in ensuring the reliability and availability of metro rolling stock. Traditional maintenance arrangements at Indian Metro Depot involved large, individual pit configurations that presented practical challenges for servicing and maintenance activities. The existing approach highlighted the need for a more streamlined workshop environment capable of supporting multiple maintenance operations through an integrated infrastructure. The requirement extended beyond the installation of individual lifting systems. Mumbai Metro envisioned a comprehensive maintenance solution that would improve workshop functionality, accommodate eight-car trainsets and support evolving operational and maintenance requirements.

The Solution: Three Critical Depot Maintenance Equipment, One Brand:

CMCO India, through its Pfaff brand, delivered a customized combination of three essential depot maintenance systems, designed to support the maintenance and servicing requirements of Mumbai Metro's eight-car rolling stock.

Underfloor Lifting System (Pit Jacks):

Underfloor Lifting System (Pit Jack) in Aarey Depot Mumbai represents a first-of-its-kind project in India. At the heart of the project is the tunnel-based Pit Jack System, inspired by the Vienna Metro's maintenance infrastructure. The system introduces an advanced approach to underfloor lifting systems, supporting maintenance access and controlled lifting operations while addressing the limitations associated with conventional individual pit arrangements.

Mobile Jack System

The Mobile Jack System provides synchronized lifting capabilities for metro trainsets, supporting maintenance activities that require controlled and coordinated lifting operations. Engineered for the depot's specific rolling stock configuration, the system forms an important part of the workshop's maintenance infrastructure.

Bogie Turntable

Complementing the lifting systems, the Bogie Turntable facilitates the positioning and movement of bogies within the workshop environment, supporting the depot's maintenance workflow.

Together, these three systems establish an complete depot maintenance equipment solution tailored to Mumbai Metro's operational vision. With a combined synchronized lifting capacity of 384 ton, the project demonstrates the scale and engineering complexity involved in supporting modern eight-car metro trainsets.

Engineering Under Pressure: Delivering Installation Excellence:

Executing a project of this scale required close coordination, technical expertise and adaptability throughout the installation and commissioning process. The project team encountered several technical and non-technical challenges during execution, requiring effective on-site problem-solving and coordination to maintain progress.

Despite these complexities, the Mobile Jack installation and commissioning were successfully completed within just 10 days. This achievement reflects the team's ability to respond to site-specific challenges while maintaining focus on the project's operational requirements.

A significant milestone was achieved during the commissioning of the Pit Jack System. As part of the commissioning process, the system successfully completed a 48-hour continuous holding test with an eight-car metro trainset at Aarey Depot. The successful test demonstrated the system's ability to sustain the required load under the specified test conditions, providing an important validation milestone before operational use. The project also received highly positive customer feedback, reflecting satisfaction with the solution and its execution.

The Outcome:

The solution delivers several important operational advantages:

- The First Step: Marked the first footprint in Mumbai metro rail corporations which helped us to establish our wings across all the Metro and Railway depots in Mumbai

- Customized engineering: Equipment designed around the specific requirements of eight-car metro trainsets and the depot's maintenance infrastructure.

- Modern maintenance architecture: A tunnel-based Pit Jack arrangement inspired by international metro engineering practices.

Building on a Legacy, Accelerating India's Rail Maintenance Transformation:

Pfaff's association with India's metro maintenance sector extends back more than two decades, with the brand among the early providers of advanced workshop lifting technologies for Indian metro depots. Following a period of limited project participation between 2002 and 2022, the brand has significantly expanded its presence in the Indian market. From a small number of projects over two decades, Pfaff's portfolio has grown to more than 20 projects between 2022 and 2026, reflecting renewed market engagement and growing demand for specialized rail maintenance solutions. What began with a focus on underfloor lifting systems has evolved into a broader portfolio of depot workshop equipment, including Mobile Jacks, Pit Jacks, Drop Pit Tables, Bogie and Locomotive Turntables, Bogie Manipulators and Bogie Transporters. This growth is supported by a dedicated engineering team, an expanding partner network and a continued commitment to quality, reliability and customer experience.

Moving Forward: Engineering Confidence in Every Lift:

With every successful installation, CMCO India’s Pfaff team continue to strengthen their contribution to India's modern rail maintenance infrastructure — delivering engineering solutions built around precision, reliability and the needs of tomorrow's mobility networks.