In one of the most complex underground construction projects currently underway in North Africa, BAUER EGYPT S.A.E. is carrying out specialist foundation engineering works for the new Giza Station on Cairo Metro Line 4 — a vital component of Egypt’s expanding urban mobility infrastructure.
Commissioned by Orascom Construction PLC, the local subsidiary of German foundation engineering specialist BAUER Spezialtiefbau GmbH began work in November 2024, with completion targeted for December 2025. The station will eventually extend over an area of approximately 5,543m² and reach a depth of up to 81 metres, making it one of the deepest metro stations in the region.
The foundation scope includes the construction of 209 diaphragm wall panels and 20 barrettes, with a total of approximately 49,000m² of diaphragm walls and 7,400m² of barrettes to be installed. Some of the diaphragm walls reach depths of up to 81 metres and thicknesses of 1.5 metres, while the barrettes – designed to bear loads of up to 3,600 tonnes – are being drilled to depths of 81 and 35 metres, depending on their position within the station structure.
Among the specialist equipment deployed is a BAUER MC 96 duty-cycle crane, which is supporting the demanding excavation and construction processes. Work is taking place in double shifts, six days a week, to meet the tight timeline. As of May 2025, 84 diaphragm wall panels had already been completed.
“At this size and depth, there’s zero tolerance for deviation – every centimetre counts,” explains 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.”
In addition to the significant depth and complexity of the design, site logistics have added another layer of difficulty. Space is extremely limited, with parts of the site still being used by the contractor until November 2025 for backfilling an existing tunnel. This overlapping usage is necessary for the sequential excavation of diaphragm wall boxes three and four within the station.
“The logistics, the depth, and the constant coordination with other trades present daily challenges, but that’s exactly what makes this project so special,” Galal adds.
A further first for Egypt is the use of vertically stacked tunnel boring machines, which are operating one above the other – a novel approach in the region that has required new levels of planning and precision engineering.
Despite the constraints, the project remains on track and represents a major milestone in Cairo’s push to modernise its public transportation network. The completion of the foundation engineering work by the end of 2025 will pave the way for final structural works, ultimately connecting the station to one of the city’s busiest transport corridors.
