Unique solutions, serious efforts behind the steel structures of the new metro stations

A real milestone was the KÉSZ Csoport subsidiary, KÉSZ Metaltech Kft., to carry out part of the M3 metro renovation. The metro renovation – the general construction of the city centre stations was carried out by SWIETELSKY Magyarország Kft. and KÉSZ Metaltech Kft. worked as a subcontractor for the company – was one of the most ambitious and largest projects in Budapest's transport system. During the project, the employees of the metal structure manufacturing and installation company faced numerous challenges, demonstrating their expertise in all areas, from design and logistics to innovative technical solutions.

The company designed, manufactured and installed a total of 34,933 m² of pavement, more than 7,500 m² of canopy structures and nearly 15,500 m² of suspended ceilings at 9 stations during the renovation of the central section of the M3 metro stations. In total, more than 30 people were involved in production and more than 100 in installation.

For the first time in Hungary - unique cable cladding walls

Two solutions were used for the cable covers at the stations: aluminium foam cable covers made from recycled aluminium in 100%, and uniquely patterned perforated cable covers, which were designed with the help of KÉSZ Csoport's strategic partner, bim.GROUP Kft.. The preparation of these flat tray panels took up to 6-12 months. A good example of the scale of the challenge is the 500 m² cable cover in Nagyvárad Square, which forms a moving hand.

The installation of several types of wall cladding was required to complete the work, which was challenging not only to create a unique appearance, but also to meet the specific characteristics of each station. The stations were all given a distinctive look through the use of uniquely patterned cladding: for example, the graphic element in Kálvin Square, based on the work of Katalin Fábry, is a reworking of Béla Bartók's choral work Cantata Profana.

The maze of irregular polygons - technical solutions for metal suspended ceilings

During the renovation of the middle section of the stations, a total of 7,500 m² of canopies were installed in the track areas. These are designed to drain leachate, so the coating had to be applied with great care during manufacture to ensure that they would last for up to 30-40 years. In addition to these, KÉSZ Metaltech Kft. was responsible for the so-called multilevel suspended ceilings of several stations, whose uniqueness lies not in their construction, but in the way they are used - for example, the ATENA suspended ceiling of the Corvin quarter station with its tracked track was made with the help of HILTI.

In other places, expanded (splayed) suspended ceilings, irregular polygonal ceiling panels, tray wall cladding, extruded ceilings made from extruded aluminium or even perforated ceilings were used, each with its own character. From a supply point of view, one of the biggest challenges was the use of corrugated trapezoidal sheeting, which was used for 7 stations with different arch lengths. From a logistical point of view, the biggest challenge was the metal suspended ceilings, including the trapezoidal sheet metal track-side canopies, which weighed approximately 1.6 tonnes per load.

Biggest challenge: everything at the same time

The reconstruction of the slope shafts and track areas were seen by all as the biggest challenges of the project. During the reconstruction of the slope shafts, the inclined lift, the escalator, the air supply, the mechanical electrics and the cladding had to be installed at the same time, as all the subcontractors were working at the same time. An additional difficulty was that the biggest problems were discovered en route, so it was necessary to react quickly and correct them in parallel with the head renovation. For the project as a whole, their colleagues spent the most specific time in the slope shafts, including night work. In contrast, the aim was to improve the existing conditions of the track areas, which were different in each case, so they had to find different solutions to different problems.

The company's work has contributed to the renovation of Hungary's busiest public transport route, where KÉSZ Metaltech Kft. has taken on a number of engineering challenges on behalf of other Group companies and strategic partners to contribute unique and creative solutions to the renewal of metro stations.