Adani Power vs the Clock: How a Crazy 5-Day Deadline Redefined Fire Safety in Mumbai
When uninterrupted electricity for millions collides with strict government fire regulations, failure is not an option. At Adani Power’s Array Colony facility in Mumbai, a high-stakes safety challenge demanded an unconventional solution and flawless execution under extreme time pressure.
This is the story of how a critical power transformer received a four-hour fire-rated safety barrier in just five days, rewriting expectations for urban power infrastructure projects.
Why This Project Mattered
The transformer at Adani Power Array Colony supplies electricity to a significant portion of Mumbai and is located close to residential buildings. Government safety authorities mandated a four-hour fire-resistant enclosure to mitigate risks associated with potential transformer fires.
Unlike standard residential projects that require a two-hour fire rating, this installation was subject to a higher compliance threshold, with only a five-day shutdown window permitted for execution.
The Impossible Constraints
- Mandatory four-hour fire resistance requirement
- Maximum transformer shutdown period of five days
- Wall height requirement of approximately 28 feet
- Zero tolerance for extended power outages
Traditional construction methods such as 230 mm thick brick walls with cement plaster were evaluated but rejected due to extended construction timelines exceeding ten days.
The Bold Solution: Rising EPS Cement Sandwich Panels
To overcome these constraints, the project team adopted Rising EPS (Expanded Polystyrene) sandwich panels engineered for fire-rated applications and rapid installation.
- Panel thickness: 120 mm
- Panel height: up to 28 feet
- Prefabricated for precision and speed
These panels provided a lightweight yet robust solution, enabling fast on-site assembly while maintaining strict safety compliance.
Fire Rating Validation Under Pressure
Fire safety compliance was validated through a live fire test conducted on the 120 mm Rising EPS panels within a two-day timeframe.
The panels exceeded the four-hour fire rating requirement, confirming their suitability for protecting critical power infrastructure.
Execution at Full Speed
Following validation, fabrication and installation commenced immediately. Prefabricated components minimized on-site work and eliminated delays caused by conventional curing and construction processes.
The complete installation was finished in four days, well within the permitted shutdown window.
The Result: Safety Without Sacrifice
- Full compliance with four-hour fire safety regulations
- Transformer downtime strictly controlled
- Continuous power supply maintained for surrounding areas
- Proven alternative to traditional masonry construction
Implications for Future Power Infrastructure
This project demonstrates that engineered, prefabricated fire protection systems can successfully replace slow conventional construction in time-critical environments.
For substations and transformers located in dense urban areas, this approach establishes a new benchmark for speed, safety, and operational continuity.
Conclusion
Adani Power’s Array Colony project highlights how innovative construction methods and decisive engineering can overcome extreme regulatory and operational constraints. When timelines are non-negotiable, engineered solutions become essential.