An Architectural Gem Featuring a Dramatic Ceiling made of GFRG

Mumbai’s New T2 Airport Terminal GFRG Ceiling Manufactured by Formglas is an architectural gem featuring a dramatic ceiling. 

The recent inauguration of Mumbai airport’s new state-of-the-art T2 terminal reveals an impressive engineering and architectural achievement. The newly opened Terminal 2 building at the Chhatrapati Shivaji International Airport, designed by the New York office of globally leading architectural firm Skidmore, Owings & Merrill LLP (SOM) and built by India-based conglomerate GVK Power & Infrastructure Ltd. (GVK), features a dramatic, technically complex and aesthetically breathtaking molded coffer ceiling inside the terminal, with integrated columns, as well as a striking retail corridor featuring perforated ceiling petals and skylights, manufactured by Formglas Products Ltd., a leading provider of molded architectural product solutions to projects globally.

“The sheer scale and aesthetic impression of the ceiling and columns is difficult to appreciate unless you stand beneath it,” said John Chettleburgh, President and CEO of Formglas, whose company worked in close collaboration with SOM and GVK throughout the Mumbai new airport project to ensure flawless execution of this impressive and critical design element.

The ceiling structure includes more than 4000 coffers, nearly 100 square feet each, and complex columns over 100 feet high. Formglas leveraged sophisticated 3D and CAD/CAM technology to model and fabricate molds, and glass fiber reinforced gypsum (GFRG) material was used to create the modular ceiling and column components installed on site. Formglas manufactured and supervised the installation of close to 40,000 m2 of material over one year, was responsible for other molded decorative ceiling elements throughout the retail, departure and arrival areas, and supported production of exterior architectural components by supplying molds to another producer on the project. “Taking into account that this is likely the largest installation of GFRG in the world, that it involved exceptional logistical coordination of our two North American factories, and was our first major project in India, we are extremely proud of the achievement,” said Chettleburgh.

The new Mumbai Airport terminal will cater to over 40 million passengers annually and serve as a modern, efficient and vital transportation hub for India and the region. 

The size and scale of the project is difficult to appreciate by photography alone. The components manufactured were unusually large and complex. 

  1. Standard coffers were 9’-2L” x 8’-9W”.

  2. Column shafts were 10’-0”W x 13’-0”L x 26’-0” tall

  3. Column capitals were 22’-0” tall and 111’-0 in diameter, and made up of 320 pieces

  4. The scope of components supplied included:

    • Standard coffers – 3,055

    • Coffer caps – 1,249

    • Capital perimeter parts – 879

    • Capital parts – 5,017

    • Column shafts – 2,470

    • Domes and troughs – 183

    • Perimeter coffers – 326

    • Skylights – 1,969

    • Stair Enclosure components – 158

    • Total parts shipped = over 15,500