Metro expansion in Cairo: Bauer executes specialist foundation engineering works for Giza station

• Construction of 209 diaphragm wall panels and 20 barrettes for the new metro station
• BAUER MC 96 duty-cycle crane in operation
• Tight site conditions and a strict schedule

Cairo, Egypt – In the heart of Egypt’s bustling capital, where ancient monuments meet modern mobility, one of the region’s most technically demanding infrastructure projects is underway: the new Giza Station on Cairo Metro Line 4. With a planned depth of up to 81 m, it will be one of the deepest metro stations in North Africa. As part of the initial construction phase, Orascom Construction PLC has commissioned BAUER EGYPT S.A.E., the local subsidiary of BAUER Spezialtiefbau GmbH, to carry out the specialist foundation engineering measures. Work began in November 2024 and is scheduled for completion by December 2025.

Approx. 49,000 m² of diaphragm walls and 7,400 m² barrettes

Two special foundation techniques are being used for the new station in the Giza district of Cairo: in addition to 81 m deep diaphragm walls with a thickness of 1.5 m and 47 m deep diaphragm walls with a thickness of 1.2 m, 81 m and 35 m deep barrettes with the same dimensions are also installed. The barrettes are designed to transfer loads of up to 3,600 t into the subsoil. Amongst others, a BAUER MC 96 duty-cycle crane is in use for the construction work, which is executed and in double shifts, six days a week. As of May 2025, 84 panels of the total 209 diaphragm wall panels have already been completed. Once work is complete, the station will cover a total area of approx. 5,543 m². “At this size and depth, there’s zero tolerance for deviation – every centimeter counts,” says Karim Galal, Project Manager at Bauer Egypt. “The BAUER Construction Process provides us with a clear structure and guidance. It ensures that everyone involved in the project works to the same standards and helps us achieve our goals on time.”

Limited space, technical challenges

Building the Giza Station requires not only precision at great depth, but also an exceptional level of logistical coordination. Certain areas of the construction site will continue to be used by the contractor until November 2025 for backfilling an existing tunnel. This is necessary so that the diaphragm walls boxes three and four in the main station can be excavated. The construction work will be carried out in several phases. “We’re working under highly unusual conditions with extremely tight space and immense time pressure,” Galal explains. Another unique aspect: the tunnel boring machines are operating one above the other – a first in Egypt, placing new demands on planners and contractors alike.

“The logistics, the depth, and the constant coordination with other trades present daily challenges, but that’s exactly what makes this project so special,” emphasizes the project manager. The specialist foundation engineering works are expected to be completed by the end of 2025 – a key milestone on the path toward modern urban infrastructure in Cairo.