Infrastructure – Second Bullet Train Mountain Tunnel Nears Breakthrough in Palghar
Infrastructure- A significant construction milestone is expected on Tuesday in Maharashtra’s Palghar district, where the second mountain tunnel for the Mumbai-Ahmedabad Bullet Train project is set to achieve a major breakthrough. The tunnel, measuring 454 metres in length and 14.4 metres in width, has been designed to carry both up and down rail tracks for the high-speed corridor.
Second Tunnel Breakthrough in a Month
This development marks the second successful tunnel breakthrough in Palghar within January. Earlier this month, engineers completed excavation work on Mountain Tunnel-5 near Safale, reinforcing the project’s steady pace in the region. The latest structure, known as Mountain Tunnel-6, has been excavated simultaneously from both ends and is scheduled to connect fully later today.
Construction teams completed the excavation process in approximately 12 months, reflecting careful planning and continuous monitoring in challenging terrain. Once completed, the tunnel will play a key role in ensuring uninterrupted high-speed rail connectivity through the hilly stretches of northern Maharashtra.
Advanced Excavation Method Used
The tunnel has been constructed using the New Austrian Tunnelling Method, a controlled drill-and-blast technique widely used in complex geological environments. This method is particularly suited to regions with uneven rock formations, where tunnel boring machines cannot be deployed efficiently.
Unlike heavy mechanised approaches, this technique allows engineers to respond in real time to changing ground conditions. Structural reinforcement is carried out progressively using shotcrete, rock bolts and lattice girders, enabling both flexibility and safety during excavation.
Strong Focus on Worker Safety
Ensuring the safety of personnel has remained a priority throughout construction. A combination of geotechnical instruments and real-time monitoring systems has been used to track ground movement and tunnel stability. Fire safety protocols, adequate ventilation systems and a regulated access framework have also been implemented to reduce risks during underground operations.
Project officials have stated that these measures have helped maintain consistent progress without compromising on safety standards, even in areas with difficult rock profiles.
Broader Construction Progress in Maharashtra
Beyond tunnel construction, work on the high-speed rail corridor is progressing rapidly across Maharashtra. The project’s longest river bridge, being built over the Vaitarna River, has reached the pier construction stage. Foundation work is also ongoing across other major rivers, including the Ulhas and Jagnisarkhya.
All four planned stations within the state are currently under construction, while the 21-kilometre underground stretch between Bandra Kurla Complex and Shilphata continues to advance. This section includes long-span steel bridges at several crossings over national and state highways.
At present, seven mountain tunnels are under construction in Palghar district, forming a critical part of the alignment through the Western Ghats region.
Status of Individual Mountain Tunnels
According to the latest progress update, Mountain Tunnel-1 spans 0.820 kilometres and has achieved 16 percent completion. Tunnel-2, with a length of 0.228 kilometres, remains in the preparatory phase. Tunnel-3 stretches 1.403 kilometres and is 41 percent complete, while Tunnel-4, measuring 1.260 kilometres, has reached 32 percent progress.
Tunnel-5, at 1.480 kilometres, stands 57 percent complete and achieved its breakthrough earlier this month. Tunnel-6, currently 47 percent complete, is scheduled for breakthrough today. Tunnel-7, measuring 0.417 kilometres, has progressed to 29 percent completion.
Overall Project Status
The Mumbai-Ahmedabad High-Speed Rail project spans approximately 508 kilometres, with 352 kilometres passing through Gujarat and Dadra and Nagar Haveli, and 156 kilometres located in Maharashtra. As of January 27, 2026, around 334 kilometres of viaducts have been completed, along with 17 river bridges and 12 major crossings over highways, rail lines and other infrastructure.
Track laying and electrification work is advancing rapidly in Gujarat, indicating steady progress toward operational readiness in phases.